Modular Fuel Rail Assembly with Adjustable Brackets
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Solution Overview
Problem
Existing fuel rail assemblies for combustion engines are not easily adaptable to different engine shapes and dimensions, leading to increased development costs and time.
Innovation Solution
A fuel rail assembly with a modular design featuring axially and rotatably movable connecting elements and laterally adjustable bracket elements, secured by filler material joints, allowing for flexible positioning and attachment to various engine configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed rigid fuel rail assembly design is used, then structural stability is maintained, but adaptability to different engine shapes and dimensions deteriorates
Solution Approach 1:
The fuel rail assembly is divided into modular components: a base element with fixation brackets and at least one detachable pipe element that can be connected via coupling elements. This segmentation allows different pipe configurations to be attached to the same base element, enabling adaptation to various engine shapes without redesigning the entire assembly.
Solution Approach 2:
The base element is designed as a universal component that can accommodate multiple different pipe element configurations through standardized coupling mechanisms. The same base element with its fixation brackets can serve multiple engine types by simply changing the pipe elements, achieving multi-functionality and broad adaptability.
2Adaptability or versatility
If custom fuel rail assemblies are designed for each engine type, then perfect fit and performance are achieved, but development costs and time increase
Solution Approach 1:
The base element is pre-configured with fixation brackets and coupling elements during manufacturing, preparing it in advance for various pipe configurations. This preliminary preparation allows rapid assembly and adaptation to different engine types without requiring time-consuming custom design and manufacturing for each application.
Solution Approach 2:
The system transitions from static, engine-specific designs to a dynamic, reconfigurable architecture where pipe elements can be detached and reattached. This dynamic capability enables the same base element to be quickly adapted to different engine configurations, significantly reducing development time across multiple engine types.
3Adaptability or versatility
If multiple separate fuel rail designs are manufactured for different engines, then optimal performance for each engine is achieved, but manufacturing costs increase
Solution Approach 1:
Multiple engine-specific fuel rail designs are merged into a single universal base element design that incorporates standardized coupling mechanisms. Instead of manufacturing separate complete assemblies for each engine type, the same base element is produced in volume, and only the pipe elements vary, significantly reducing manufacturing complexity and cost.
Solution Approach 2:
The system maintains adaptability to different engine configurations by changing only the pipe element parameters (length, orientation, connection points) while keeping the base element parameters constant. This selective parameter change approach allows cost-effective mass production of the standardized base element while still achieving engine-specific optimization through pipe configuration variations.
Data Source
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AI summary
A fuel rail assembly (20) with a fuel delivery pipe unit to be hydraulically coupled to an elongated tubular fuel rail (4) is disclosed. The pipe unit comprises an injector cup (3), a pipe (2), and a fixation unit for fixing the fuel delivery pipe unit to the combustion engine. The fixation unit comprises a connecting element (6) being axially and rotatably movable with respect to the pipe (2) and the injector cup (3), the connecting element (6) being fixedly connected to a predetermined pipe unit portion by a first filler material joint, and a bracket element (1) being laterally movable with respect to the connecting element (6) for adjusting its radial distance from the pipe (2) and the injector cup (3), the bracket element (1) being fixedly connected to a predetermined connecting element portion by a second filler material joint. Further, a method for manufacturing the same is disclosed.