Fuel Injector Connecting Element with Integrated Flow Fuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In high-pressure common rail systems of piston engines, a malfunctioning fuel injector can cause constant leakage, leading to engine cylinder damage and external fuel leaks due to continuous connection with the fuel rail, where small damages can result in significant fuel loss.
Innovation Solution
A connecting element with a flow fuse integrated into the fuel pipe, which prevents fuel supply to a fuel injector if its valve needle is stuck open, comprising a connecting block, fuel pipe, and a flow fuse mechanism that limits fuel flow to a malfunctioning injector, reducing the risk of leakage and the number of system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel injectors are continuously connected to the fuel rail in a common rail system, then fuel supply to all injectors is ensured, but a malfunctioning injector can cause constant leakage and damage
Solution Approach 1:
The patent segments the fuel supply system by introducing individual flow fuses for each fuel injector line. Each flow fuse acts as an independent safety device that can close off a specific malfunctioning injector line without affecting other injectors. This segmentation allows the system to maintain fuel supply reliability to functioning injectors while isolating harmful leakage from malfunctioning ones.
Solution Approach 2:
The flow fuse serves as an intermediary safety device between the fuel rail and the fuel injector. It monitors the fuel flow and automatically closes when detecting abnormal conditions (such as a stuck-open valve needle). This intermediary component protects the system by intercepting and stopping harmful fuel leakage before it reaches the cylinder or surroundings.
2Reliability
If multiple separate components are used in the fuel injection system, then functionality is ensured, but the number of parts increases and space requirements grow
Solution Approach 1:
The patent merges the flow fuse directly into the fuel pipe structure, creating an integrated component rather than a separate assembly. The flow fuse is formed as an integral part of the fuel pipe, eliminating the need for additional connection elements and reducing the overall number of parts. This merging maintains the safety functionality while simplifying the device structure and reducing space requirements around cylinder heads.
3Ease of operation
If multiple connections are made between fuel injection system parts, then functionality is achieved, but the risk of leakages increases
Solution Approach 1:
By integrating the flow fuse into the fuel pipe as a single-piece component, the patent eliminates additional connection points between separate parts. The merged structure removes potential leakage sites that would exist at connection interfaces between multiple components, thereby reducing the overall leakage risk while maintaining full system functionality.
Data Source
Figure 1
Figure 2
AI summary
The connecting element (10) for connecting a fuel injector (3) of a piston engine (1) to a fuel rail (4) comprises a connecting block (11) for receiving fuel from a fuel rail (4), and a fuel pipe (12) that is attached to the connecting block (11) for supplying fuel to a fuel injector (3), the connecting block (11) being provided with a fuel inlet (13) for receiving fuel from the fuel rail (4) and with a fuel outlet (14) that is connected to the fuel pipe (12). The fuel pipe (12) is provided with a flow fuse (15) for preventing fuel supply to a leaking fuel injector (3).