Fuel Injector Coupling With Adjustable Distance Element
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Solution Overview
Problem
Existing fuel injector systems face challenges in achieving precise and reliable coupling with the cylinder head of internal combustion engines, requiring complex manufacturing processes and potentially leading to suboptimal fuel dosing and noise issues during operation.
Innovation Solution
A fuel injector system utilizing a ring element with a spherical surface and adjustable distance elements made of robust plastics like polyphenylene sulfide, polybutylene terephthalate, or polyethylene terephthalate, along with a retaining element for precise alignment and easy disassembly, allowing for simple production and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fuel injector is coupled to the cylinder head with precise alignment requirements, then the fuel dosing accuracy is improved, but the assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The patent introduces a coupling element as an intermediary component between the fuel injector and the cylinder head. This coupling element includes a retaining element that engages with a retaining bore in the cylinder head and a distance element that positions the fuel injector at a precise axial distance. By using this intermediate coupling mechanism, the patent achieves precise coupling alignment while simplifying the overall assembly process, as the coupling element can be pre-assembled and then installed as a single unit.
Solution Approach 2:
The coupling system is segmented into distinct functional components: a retaining element for mechanical engagement and positioning, and a distance element for axial spacing. This segmentation allows each component to be manufactured and adjusted independently, facilitating precise coupling while maintaining simple assembly procedures.
2Reliability
If the fuel injector is firmly fixed to the cylinder head, then the coupling reliability is improved, but the serviceability and ease of disassembly deteriorate
Solution Approach 1:
The coupling element serves as a removable intermediary between the fuel injector and the cylinder head. The retaining element can be disengaged from the retaining bore to allow easy removal of the fuel injector for service or replacement. When properly engaged, this same coupling element provides reliable and secure fixation during operation, thus achieving both reliability and serviceability.
Solution Approach 2:
The coupling system transitions from a static permanent fixation to a dynamic reversible connection. The retaining element can be easily engaged and disengaged from the retaining bore, allowing the fuel injector to be firmly fixed during operation but readily removable when service is needed, thus balancing reliability with ease of repair.
3Adaptability or versatility
If distance elements with different axial extensions are used for leveling, then the adjustability is improved, but the inventory complexity increases
Solution Approach 1:
The distance element's axial extension parameter can be varied to achieve different leveling positions. By designing the distance element with adjustable thickness or providing a selection of standardized thicknesses, the system achieves versatile leveling capability while controlling inventory complexity through parameter standardization.
4Object-affected harmful factors
If a plastic material is used for the distance element, then the noise and adhesion are reduced, but the mechanical strength may be compromised
Solution Approach 1:
The distance element is made from robust engineering plastics such as polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), or polyethylene terephthalate (PET). These materials provide a composite solution that combines the noise reduction and low adhesion properties of plastic with sufficient mechanical strength for the application. The selected plastics maintain dimensional stability and structural integrity while providing the desired low-friction, low-noise characteristics.
Data Source
Figure 1~2
Figure 3
AI summary
Fuel injector (18) including a central longitudinal axis (L) and being operable to be arranged in a cylinder head (14) of a combustion engine (22). The fuel injector (18) has an injector body (26) and an adjustment device (30). The adjustment device (30) comprises a ring element (32) being designed to be arranged in a recess (15) of a cylinder head (14) between the injector body (26) and the cylinder head (14) to align the fuel injector (18) relative to the recess (15) in radial direction, and a distance element (34). The distance element (34) is designed to be arranged in the recess (15) between the ring element (32) and the cylinder head (14) to level the fuel injector (18) relative to the cylinder head (14) in axial direction. Fuel-injection system with a cylinder head (14) and a fuel injector (18).