High-Pressure Fuel Pump Flange Welding With Spatter-Containment Recess
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Solution Overview
Problem
Existing high-pressure fuel pumps face issues during the welding process, where the welding bead can come into contact with the cold housing wall, leading to weld spatter and potential damage to the pump components, and there is a need for an efficient and cost-effective welding method that prevents undesired pressure buildup.
Innovation Solution
The high-pressure fuel pump design incorporates a receiving space wider than the weld bead, an annular space created by a circumferential groove, and an opening to prevent contact with the pump housing, along with capacitor discharge welding to concentrate energy efficiently and prevent heat dissipation, ensuring optimal connection without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding is used to connect the fastening flange to the pump housing, then the connection strength is improved, but weld spatter damages the pump housing and fastening flange
Solution Approach 1:
The welding area is segmented into a recess that isolates the weld bead from the external environment. This recess creates a protected zone where the welding process occurs, preventing spatter from reaching and damaging the pump housing and fastening flange surfaces.
Solution Approach 2:
The recess acts as an intermediary structure between the welding process and the components being protected. It serves as a barrier that contains the harmful welding byproducts while allowing the welding process to proceed effectively.
2Productivity
If capacitor discharge welding is used to reduce welding time and cost, then productivity and economy are improved, but heat concentration may cause localized overheating
Solution Approach 1:
The recess provides a thermal buffer zone that absorbs and dissipates the concentrated heat from capacitor discharge welding. By positioning the weld bead within this recess, the heat is contained and distributed more effectively, preventing damage to surrounding components while maintaining the high-speed welding process.
3Object-affected harmful factors
If the receiving space is made wider than the weld bead, then protection from weld spatter is improved, but the device complexity increases
Solution Approach 1:
The recess is integrated into the existing pump housing structure, combining the protective function with the housing design itself. This merging approach adds minimal complexity while effectively preventing weld spatter damage.
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 effectively prevents weld spatter and ensures a strong, efficient connection between the pump housing and fastening flange, maintaining component integrity and reducing assembly complexity while maintaining high welding efficiency.
Implementation Method 1
In capacitor discharge welding, the energy required for welding is switched from previously charged capacitors to a welding transformer via a thyristor. The loading times are in the range between 0.5 s and 2 s, the welding times between 3 and 10 ms. At the same time, the effective resistance applied during welding preparation causes the temperature at the welding point to rise at a very high rate.
Implementation Method 2
it is prevented during the welding process that the welding bead emerging at the edge of the welding area comes into contact with its free surface with the cold housing wall, for example the pump housing or the fastening flange. This in turn prevents weld spatter from forming which can damage the pump housing and/or the mounting flange and/or the weld area
Data Source
Figure 1
Figure 2~4
AI summary
The invention relates to a high-pressure fuel pump (10) for a fuel injection system of an internal combustion engine, comprising a pump housing (12) and at least one fastening flange (32), wherein the fastening flange (32) is fixed to the pump housing (12) by a welding (34), and wherein the welding (34) has one weld region and at least one weld bead (40) arranged laterally from the weld region (34). It is proposed that the weld bead (40) is arranged in a receiving space (46) formed between the pump housing (12) and the fastening flange (32).