Fuel Injector Connector Rotation for Serviceable Rail Removal
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Solution Overview
Problem
Direct injection internal combustion engines face challenges in servicing due to rigidly mounted fuel injectors, which require partial engine disassembly and can lead to component stress and failure from torque, causing increased maintenance costs and potential damage.
Innovation Solution
A fuel system component design where the injector connector and terminal are rotated to allow the fuel rail with attached injectors to be removed as a unit without disassembly, and a clip holder and clip plate system secures the injector tip to reduce torsional force, with bolts aligned for easier installation and reduced pressure on the injector body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuel injector is rigidly attached to the fuel rail, then the fuel injector remains stable during operation, but the fuel rail with attached injectors cannot be removed without partial engine disassembly
Solution Approach 1:
The fuel injector system is divided into separable components: the fuel injector body remains rigidly mounted to the fuel rail for operational stability, while the connector assembly (including terminal and harness interface) is made detachable. This allows the fuel injector to be securely fixed during operation yet easily removed for servicing by disconnecting only the connector portion.
2Ease of operation
If the bracket attachment is offset from the injector axis, then the connector can be positioned for harness connection, but torque is created on the fuel injector causing stress and potential failure
Solution Approach 1:
The connector assembly is designed to accommodate misalignment between the fuel injector axis and the bracket attachment point by introducing rotational freedom. The connector can rotate about the injector axis to align with the harness while the bracket remains offset for proper positioning, eliminating torque on the injector body.
3Ease of operation
If the injector connector and terminal extend laterally outwardly from the fuel rail, then the harness can be connected, but interference occurs with other engine components during removal
Solution Approach 1:
The connector assembly is designed with rotational capability, allowing it to dynamically adjust its position. During installation, the connector can be positioned laterally for harness connection. During removal or servicing, the connector can be rotated to a different orientation that clears other engine components, enabling easy removal without interference.
Data Source
AI summary
A fuel system component for a direct injection internal combustion engine. The component includes a fuel rail and a plurality of direct injection fuel injectors which are rigidly attached to the rail. Each fuel injector has an elongated body as well as a harness assembly extending laterally outward from the elongated body. Each injector is attached to the fuel rail such that, when viewed along an axis of the fuel injector body, the fuel rail overlies at least a portion of the injector body and at least a portion of the harness assembly.