Fuel Pump Housing Insert Anodizing Tolerance Control
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Solution Overview
Problem
The existing fuel pump manufacturing process is complex and costly due to surface treatment processes that can damage or coat carbon-containing inserts, leading to disruptive tolerances and increased production costs.
Innovation Solution
The insert is made of electrically non-conductive material, such as phenolic resin, and is fixed in the housing part before surface treatment, allowing only desired components to be treated and reducing assembly complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carbon-containing inserts are used in the housing part, then the fuel pump can be manufactured with conventional materials, but the inserts are destroyed or coated during the anodizing surface treatment process
Solution Approach 1:
The patent changes the material parameter of the insert from carbon-containing material to electrically non-conductive material (such as phenolic resin or plastic). This parameter change makes the insert resistant to damage during the anodizing surface treatment process, as the electrically non-conductive material does not react to the electrical current used in anodizing. The insert maintains its structural integrity and does not get coated, ensuring reliability while still allowing conventional manufacturing processes to be used.
2Reliability
If the insert is assembled after the surface treatment of the housing part, then the insert is protected from surface treatment damage, but the production process becomes very complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by assembling the insert into the housing part before the surface treatment process. The insert is pressed into the housing part prior to anodizing, and because the insert is made of electrically non-conductive material, it automatically protects itself from surface treatment damage without requiring post-treatment assembly. This preliminary assembly simplifies the overall production process by eliminating the need for complex post-surface treatment assembly operations.
3Reliability
If the housing part undergoes surface treatment, then the housing part gains improved corrosion resistance and durability, but tolerances are disrupted and post-treatment of fits is required
Solution Approach 1:
The patent changes the material parameter of the insert to electrically non-conductive material, which has different interaction properties with the surface treatment process compared to carbon-containing materials. This parameter change allows the insert to remain unaffected by the anodizing process, preventing tolerance disruptions. The fit between the insert and housing part maintains its precision without requiring post-treatment adjustments, as the insert does not expand, contract, or get coated during surface treatment.
4Ease of manufacture
If phenolic resin or electrically non-conductive plastic is used for the insert, then production costs are reduced and chemical stability with fuel is achieved, but the insert material selection is limited
Solution Approach 1:
The patent specifies particular material parameters for the insert - electrically non-conductive materials such as phenolic resin or plastic. These material choices provide excellent chemical stability with fuel and resistance to damage during anodizing surface treatment. While the material selection is more specific than conventional carbon-containing materials, the patent maintains versatility by allowing multiple electrically non-conductive material options that all satisfy the key requirements of fuel compatibility and surface treatment resistance.
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 approach results in lower manufacturing tolerances and costs, with improved wear resistance and smooth operation by preventing insert damage during surface treatment, leading to a more cost-effective and efficient fuel pump production.
Implementation Method 1
the housing part is first machined and the surface treated using an electric current
Implementation Method 2
the housing part being made of surface-treated metal
Data Source
Figure 1
Figure 2
AI summary
A fuel pump for delivering fuel has a housing part (8) made from a coated material. An insert (10) made from an electrically non-conductive material, such as for example phenolic resin, is pressed into the housing part (8). The insert (10) which is produced from phenolic resin can be pressed into the housing part (8) before a surface treatment of the housing part (8), since phenolic resin is not electrically conductive. As a result, the fuel pump can be produced particularly inexpensively.