Fuel Injector Intensifier Piston for High Pressure
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Solution Overview
Problem
Current fuel injection systems in diesel engines face challenges in achieving high injection pressures due to physical size constraints and require extensive high-pressure piping, leading to inefficiencies and potential leaks, especially in common rail systems.
Innovation Solution
A compact intensifier piston arrangement is integrated into the fuel injector, featuring a piston member with a longitudinally extending cavity and a counter member, creating a small second work space that increases injection pressure without excessive work fluid pressure, and includes a one-way valve to prevent fuel flow back, minimizing leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a common rail fuel injection system is used to achieve high injection pressures, then injection pressure is improved, but the system requires extensive high-pressure piping which increases device complexity and leakage risk
Solution Approach 1:
The invention extracts the pressure generation function from the external common rail system and relocates it inside the injector body through an intensifier piston arrangement. This eliminates the need for extensive external high-pressure piping by generating the required injection pressure locally within the injector component.
Solution Approach 2:
The intensifier piston arrangement is nested within the injector body structure. The piston member with its cavity and counter member are integrated inside the injector, creating a compact configuration that generates high pressure internally without requiring external high-pressure piping infrastructure.
2Stress or pressure
If an intensifier piston is provided to increase fuel pressure within the injector, then injection pressure is improved, but the physical size of the injector increases which is limited by available space in the cylinder head
Solution Approach 1:
The intensifier piston arrangement is nested within the injector body, with the piston member having a cavity that contains the counter member. This nested configuration allows the pressure generation mechanism to be integrated inside the existing injector volume without significantly increasing the external dimensions of the injector component.
Solution Approach 2:
The invention utilizes the longitudinal dimension of the injector body by creating a cavity within the piston member that extends in the longitudinal direction. This allows the intensifier piston arrangement to be accommodated within the existing injector length, effectively using available space in the cylinder head without increasing the overall injector footprint.
3Stress or pressure
If continuous pressure is maintained in the common rail system, then injection pressure is improved, but fuel leakage into the combustion chamber increases in case of nozzle malfunction
Solution Approach 1:
The intensifier piston operates periodically, generating high pressure only during the injection stroke when fuel needs to be injected. During non-injection periods, the pressure in the fuel supply system is reduced to a lower level. This periodic pressure application eliminates the need for continuous high pressure in the common rail system, thereby reducing fuel leakage risk during malfunction while maintaining adequate injection pressure when needed.
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
This design allows for high injection pressures up to 300 MPa while maintaining low external fuel duct pressures, reducing the risk of leakage and optimizing fuel injection performance within the limited engine space.
Implementation Method 1
an intensifier piston arrangement comprising a piston space and a piston member therein having a first area which is arranged to be effected by a work fluid
Implementation Method 2
The capability of increasing pressure is limited considerably by the physical size of the injector
Implementation Method 3
includes a one-way valve to prevent fuel flow back, minimizing leakage risks
Data Source
AI summary
The invention relates to a fuel injection arrangement for piston engine comprising at least one fuel injector by means of which fuel may be injected into a combustion chamber of the engine, the fuel injector comprising at least one fuel injection valve arranged to meter the fuel into the combustion chamber, the fuel injection arrangement further comprising an intensifier piston arrangement comprising a piston space and a piston member therein having a first area which is arranged to be effected by a work fluid and which first area at least partially borders a first work space of the intensifier piston arrangement; and the piston member having a second area which at least partially borders a second work space of the intensifier piston arrangement, the second work space being arranged in flow connection with the at least one injection valve of the injector. The intensifier piston arrangement comprises a counter member and the piston member is provided with a longitudinally extending cavity providing a space into which the counter member is arranged to extend at least partly, and the second area is at least partly defined at least partly by the piston member and the counter member.