Fuel Injector Nozzle Radial Orientation via Spline Alignment
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Solution Overview
Problem
Existing fuel injectors face challenges in automatically aligning nozzle spray holes relative to the fuel injector body and combustion chamber, requiring large fixtures and cameras, which are time-consuming, costly, and unsuitable for high-volume production.
Innovation Solution
The fuel injector design incorporates a body with alignment features, a nozzle with corresponding alignment features, and a clocking ring with splines that mate with the body and nozzle alignment features to automatically align the nozzle holes in a desired orientation relative to the body and combustion chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment methods using fixtures and cameras are used, then spray hole orientation can be controlled, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The nozzle and body are equipped with self-aligning features (alignment features on the nozzle and corresponding features on the body) that automatically orient the spray holes correctly during assembly, eliminating the need for external fixtures and cameras. The component's own structure performs the alignment function that previously required separate equipment.
Solution Approach 2:
Alignment features act as intermediary elements between the nozzle and body, providing a mechanical interface that ensures correct orientation. These features mediate the connection between components, transferring the alignment function from external measurement equipment to the assembly structure itself.
2Manufacturing precision
If conventional alignment methods using fixtures and cameras are used, then spray hole orientation can be controlled, but the manufacturing cost increases
Solution Approach 1:
The alignment function is integrated into the nozzle and body structures themselves through self-aligning features, eliminating the need for expensive external alignment equipment. The components align themselves during assembly, reducing manufacturing costs while maintaining precision.
Solution Approach 2:
The alignment function is extracted from the assembly process equipment and embedded directly into the component design. By taking the alignment capability out of external fixtures and cameras and putting it into the nozzle and body structures, the patent eliminates expensive equipment requirements.
3Manufacturing precision
If conventional alignment methods are used, then spray hole orientation can be achieved, but the process is not suitable for high-volume production
Solution Approach 1:
The self-aligning features enable rapid assembly without time-consuming measurement and adjustment steps. Components automatically orient correctly upon engagement, allowing high-speed assembly lines to maintain precision while increasing production volume.
Solution Approach 2:
The alignment features are pre-configured into the nozzle and body during manufacturing, so that when assembly occurs, the correct orientation is already built-in. This preliminary preparation of alignment capabilities eliminates the need for time-consuming on-site alignment procedures.
Data Source
AI summary
The present disclosure provides a fuel injector, comprising: a body including a plurality of body alignment features; a nozzle including a plurality of nozzle alignment features and a plurality of nozzle holes for injecting fuel; and a plurality of alignment guides configured to mate with the plurality of body alignment features and the plurality of nozzle alignment features to align the nozzle with the body such that the plurality of nozzle holes is in a desired orientation relative to the body.