Fuel Injector Flow Control System with Segmented Valve Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flow control systems for fuel injectors in internal combustion engines face challenges in minimizing internal leakage and shortening response times while being cost-efficient, especially in high-pressure diesel fuel injection systems where complexity and cost are concerns.
Innovation Solution
A flow control system comprising an inlet channel, outlet channel, return channel, fuel outlet chamber, and a moveable nozzle control member biased by a resilient member, with a valve member that selectively opens and closes a flow passage between the fuel control chamber and return channel, utilizing a hydraulic restrictor to manage pressure and reduce leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a 3-way control valve is used to minimize internal leakage and shorten response times, then injection precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The control valve is divided into two separate functions: a main valve for primary fuel flow control and a shuttle valve for precise injection termination. This segmentation allows each valve to be optimized for its specific function, achieving high injection precision while using simpler, more cost-effective valve designs compared to a complex 3-way control valve
Solution Approach 2:
The shuttle valve acts as an intermediary component that controls the pilot pressure to the main valve. By using the shuttle valve to mediate the control of fuel flow termination, the system achieves precise injection control without requiring a complex 3-way valve design, thus reducing overall device complexity while maintaining manufacturing precision
2Loss of energy
If a 3-way control valve is used to minimize internal leakage, then fuel efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The fuel flow control is segmented into main valve for bulk flow control and shuttle valve for precise termination. This allows each component to be manufactured using standard, cost-effective processes while achieving the low internal leakage performance that would otherwise require expensive specialized 3-way control valves
Solution Approach 2:
The design uses simpler, more readily manufacturable valve components that can be produced at lower cost through conventional manufacturing processes, rather than requiring expensive specialized equipment needed for 3-way control valves, while still achieving the necessary fuel efficiency through proper functional design
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
The system achieves efficient fuel injection with minimized internal leakage and shortened response times in a cost-effective manner, suitable for various fuels including diesel and DME, by using a simplified configuration that limits fluid leakage and enhances controllability.
Implementation Method 1
a first resilient means (16) configured to force said control valve member (6) towards the seat (7) so as to close the control valve (40)
Implementation Method 2
utilizing a hydraulic restrictor to manage pressure and reduce leakage
Implementation Method 3
a fuel outlet chamber for receiving the pressurized fuel from the inlet channel, a nozzle control member arranged in the fuel outlet chamber and configured to be moveable for selectively allowing the pressurized fuel to flow into the outlet channel
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to a flow control system (1) for a fuel injector of an internal combustion engine, comprising: - an inlet channel (2) for receiving a pressurized fuel, - an outlet channel (15) for letting out the pressurized fuel, - a return channel (4) for returning part of the pressurized fuel to a low-pressure system (5) having a lower pressure than the pressurized fuel in the inlet channel when in use, - a fuel outlet chamber (17) for receiving the pressurized fluid from the inlet channel, - a nozzle control member (9) arranged in the fuel outlet chamber and configured to be moveable for selectively allowing the pressurized fuel to flow into the outlet channel, - a biasing member (25) biasing the nozzle control member towards a closed position in which the pressurized fuel is prevented from being allowed into the outlet channel, - a moveable member (7), whereby at least the moveable member and the nozzle control member define a fuel control chamber (12), the fuel control chamber being configured such that a pressure therein biases the nozzle control member towards its closed position, - a valve member (6) configured to be moveable for selectively opening and closing a flow passage (26) between the fuel control chamber and the return channel, wherein the moveable member is configured to be moveable towards and away from the nozzle control member and to raise pressure in the fuel control chamber when moved towards the nozzle control member, and wherein the valve member is biased towards the moveable member for closing the flow passage and for moving the moveable member towards the nozzle control member, wherein the flow control system further comprises a fuel connection (23) between the inlet channel and the fuel control chamber for pressurizing the fuel control chamber.