Fuel Pump Coil Assembly for Low-Noise Electromagnetic Valves
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Solution Overview
Problem
Conventional high-pressure fuel pumps for direct injection engines require additional components and assembly steps, increasing costs and potentially causing operation sound issues due to the protruding fixed core.
Innovation Solution
A fuel pump design featuring a coil, magnetic core, yoke, cover portion, and molded portion that reduces assembly steps and minimizes operation sound by integrating components and improving magnetic circuit efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixing pin is used to hold the cover portion, then the cover portion is securely fixed, but the number of components and assembly steps increases
Solution Approach 1:
The fixed core is designed to protrude from the cover portion, integrating the fixing function into the cover portion itself. This eliminates the need for a separate fixing pin, reducing the number of components and assembly steps while maintaining secure fixation of the cover portion.
Solution Approach 2:
The fixed core serves multiple functions: it provides magnetic flux path continuity and simultaneously acts as a fixing element for the cover portion. This multi-functionality reduces the need for separate components, addressing both reliability and device complexity.
2Reliability
If the fixed core protrudes from the cover portion, then the magnetic circuit is completed, but operation sound increases
Solution Approach 1:
A damping member is introduced as an intermediary between the protruding fixed core and the pressurizing chamber. This damping member absorbs vibrations and reduces operation sound while allowing the fixed core to maintain its protruding position for magnetic circuit completion.
3Ease of manufacture
If separate components are used for assembly, then manufacturing flexibility is maintained, but assembly steps and cost increase
Solution Approach 1:
The fixed core is integrated with the cover portion, reducing the number of separate components. This integration simplifies assembly procedures and reduces assembly steps, thereby improving productivity while maintaining manufacturing flexibility through the modular electromagnetic drive device 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 design reduces the number of assembly steps and suppresses operation sound, enhancing the fuel pump's efficiency and cost-effectiveness.
Implementation Method 1
a coil 3g; a magnetic core 3e that is arranged on a side opposite to a pressurizing chamber with respect to a movable core 3h and attracts the movable core 3h when the coil 3g is energized
Data Source
AI summary
A coil component of an electromagnetic valve is made compact to achieve both low cost and improvement in sound vibration performance. Therefore, a high-pressure fuel pump of the present invention includes: a coil 3g; a magnetic core 3e that is arranged on a side opposite to a pressurizing chamber 11 with respect to a movable core 3h and attracts the movable core 3h when the coil 3g is energized; a yoke 3q arranged on a radially outer side of the coil 3g; a cover portion 3r that covers the coil 3g from an axially outer side; and a molded portion 17 that covers a radially outer side of the yoke 3q and an axially outer side of the cover portion 3r.