Fuel Injector Duct Structure Alignment Mechanism

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Solution Overview

Problem

The existing fuel injector and duct assembly in internal combustion engines requires cumbersome and time-consuming replacement processes, involving skilled labor and significant machine downtime due to the need for manual alignment and decoupling of cylinder heads, which increases operational costs and reduces productivity.

Innovation Solution

A fuel injector assembly with an insert and duct structure that includes a through-hole in the cylinder head, allowing for easier installation and alignment of the fuel injector and ducts, utilizing a press-fitting or threaded coupling mechanism, and featuring alignment protuberances and grooves for precise rotational alignment, reducing the need for skilled labor and intricate tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual alignment and decoupling of cylinder head is used for fuel injector replacement, then precise alignment of ducts relative to orifice can be achieved, but the replacement process becomes time-consuming and requires skilled labor

Engineering Contradiction:

Improvealignment precisionVSAvoidreplacement time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The duct structure is pre-formed with integral attachment features (such as ribs, tabs, or molded-in connectors) that align with corresponding features on the fuel injector assembly. This preliminary integration of alignment features into the mold eliminates the need for manual alignment during replacement, allowing the duct to be quickly attached to the pre-assembled fuel injector unit while maintaining precise orientation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

An intermediate alignment mechanism (such as a alignment pin, guide feature, or pre-assembled bracket) is introduced between the duct and fuel injector components. This intermediary element facilitates automatic or simplified alignment during installation, reducing the skill level required and time needed for replacement while ensuring accurate positioning of the duct relative to the fuel injector orifice.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If manual alignment and decoupling of cylinder head is used for duct replacement, then precise alignment of ducts relative to fuel injector orifice can be achieved, but the process becomes laborious and increases operational cost

Engineering Contradiction:

Improvealignment precisionVSAvoidease of replacement

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of repair

If decoupling of cylinder head from cylinder block is used for fuel injector replacement, then access to fuel injector and ducts is achieved, but machine downtime increases significantly

Engineering Contradiction:

ImproveaccessibilityVSAvoidmachine downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The fuel injector assembly is segmented into removable components (fuel injector, duct structure, and insert) that can be accessed and replaced independently. The duct structure with integral attachment features is designed to be detachable from the cylinder head insert, allowing the duct to be replaced without removing the entire fuel injector assembly or decoupling the cylinder head from the cylinder block, thereby minimizing machine downtime.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The duct structure is extracted as a separate, easily removable component from the assembly. By designing the duct with integral attachment features that connect to the insert rather than being permanently bonded to the cylinder head, the duct can be quickly removed and replaced without requiring disassembly of the cylinder head-cylinder block assembly, significantly reducing machine downtime while maintaining proper alignment through the insert's guide features.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If skilled labor is used for manual alignment and replacement, then accurate installation of fuel injector and ducts is achieved, but operational cost increases

Engineering Contradiction:

Improveinstallation accuracyVSAvoidoperational cost

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10711752B2Fuel injector assembly having duct structure

Publication Date: 2020.07.14 CATERPILLAR INC

AI summary

A fuel injector assembly for an engine. The engine includes a cylinder head defining a through-hole. The fuel injector assembly includes an insert, having a first end and a second end, configured to be received within the through-hole and coupled to the cylinder head. The insert defines a bore extending from the first end to the second end. The fuel injector assembly further includes a fuel injector including a plurality of orifices, received within the bore of the insert; and a duct structure including a plurality of ducts, coupled to the insert such that the plurality of ducts align with the plurality of orifices to at least partially receive one or more fuel jets from the plurality of orifices of the fuel injector.