Fuel Injector Counterbore Insert for Remanufacturing
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Solution Overview
Problem
Fuel injector bodies with injection rate shaping orifices often suffer from erosion or damage due to valve impacts and cavitation, leading to dimensional changes that result in performance detriments, necessitating costly replacement or modification.
Innovation Solution
A method and apparatus involving a fuel injector assembly with a counterbore design and an insert that can be press-fitted into the fuel injector body to modify or replace the injection rate shaping orifice, maintaining specific minimum distances to ensure proper geometry and function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuel injector body is replaced when the injection rate shaping orifice becomes damaged, then the performance is restored, but the cost and time increase
Solution Approach 1:
The fuel injector body is segmented into modular components: a reusable outer body and a replaceable inner insert containing the injection rate shaping orifice. This allows only the damaged insert to be replaced rather than the entire injector body, reducing replacement time and cost while restoring performance.
Solution Approach 2:
The damaged injection rate shaping orifice is extracted from the fuel injector body by removing the insert. The insert can then be replaced with a new or refurbished insert, avoiding the need to replace the entire fuel injector body and reducing waste.
2Reliability
If the fuel injector body is replaced when the injection rate shaping orifice becomes damaged, then the performance is restored, but the cost increases
Solution Approach 1:
By segmenting the fuel injector body into a reusable outer body and a replaceable insert, the cost of replacement is reduced to only the insert rather than the entire injector body, making the system more economical.
Solution Approach 2:
Instead of discarding the entire fuel injector body when the orifice is damaged, only the insert is discarded or refurbished while the outer body is recovered and reused, reducing material waste and replacement costs.
3Loss of energy
If the original geometry of the injection rate shaping orifice is altered to improve performance, then fuel economy and emissions are improved, but the complexity of modification increases
Solution Approach 1:
The insert is designed as a separate modular component that can be easily replaced with different geometries to optimize fuel economy and emissions without modifying the complex outer body structure.
Solution Approach 2:
Different insert geometries with varying parameters (orifice size, shape, positioning) can be implemented by simply replacing the insert, allowing optimization of fuel economy and emissions without increasing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and economic remanufacturing or refurbishment of fuel injector bodies, allowing for adjustments to improve fuel economy and reduce emissions without the need for full replacement, thereby extending the life of the injector and optimizing performance.
Implementation Method 1
an insert that includes geometry that is at least partially complimentarily configured to match the geometry of the counterbore is press fit into the counterbore
Data Source
AI summary
An insert for use with a fuel injector comprises a shaft including a substantially cylindrical configuration defining a shaft cylindrical axis, a shaft radial direction, and a shaft diameter; and a head including a substantially cylindrical configuration defining a head cylindrical axis, a head radial direction, and a head diameter. The shaft and head may be attached to each other, the shaft cylindrical axis and the head cylindrical axis may be parallel to each other, the head diameter may be greater than the shaft diameter, and the shaft cylindrical axis may be spaced away from the head cylindrical axis.