High-Pressure Pump Flange Design for Fuel Systems
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Solution Overview
Problem
High-pressure fuel pumps for internal combustion engines face mechanical stress, vibration, and material deformation due to welded connections, which are costly and prone to thermal changes and dirt contamination, limiting flexibility in assembly and increasing material waste.
Innovation Solution
A two-piece flange design with a groove-like receiving area on the housing, held by caulking or pressing, eliminates the need for welded connections, allowing for flexible assembly, reduced material usage, and cost-effective production with different materials, and minimizes deformation and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded connection is used to attach the flange to the housing, then the connection strength is improved, but thermal deformation and material structural changes occur
Solution Approach 1:
The patent replaces the welded (thermal) connection system with a mechanical connection system using a press-fit interface. The flange is inserted into a recess in the housing with interference fit, creating a mechanically strong connection without thermal input. This substitution eliminates thermal deformation while maintaining connection strength through precise mechanical geometry and material elasticity.
2Reliability
If a welded connection is used to attach the flange to the housing, then the connection reliability is improved, but contamination from welding spatter and smoke occurs
Solution Approach 1:
The patent replaces the welding process with a mechanical press-fit connection. The flange is pressed into the housing recess under controlled mechanical force, creating a reliable connection without producing welding spatter, smoke, or other contaminants. The connection reliability is achieved through precise dimensional tolerances and interference fit design rather than thermal bonding.
3Strength
If a one-piece flange design is used, then the structural integrity is improved, but material waste increases due to stamping limitations
Solution Approach 1:
The patent divides the flange into multiple separate stamped components that are then assembled together using the press-fit connection method. This segmentation allows each component to be optimally shaped from stamped material with minimal waste, while the assembled structure maintains sufficient structural integrity for the application. The modular approach enables better material utilization during the stamping process.
4Stability of the object's composition
If additional connecting elements like pins are used to attach flange parts, then the connection stability is improved, but the positioning accuracy requirements and assembly complexity increase
Solution Approach 1:
The patent merges the connection function into the flange-housing interface itself through the press-fit design. The flange directly engages with the housing recess through interference fit, eliminating the need for separate connecting elements like pins. This integration maintains connection stability while significantly reducing assembly complexity and positioning accuracy requirements, as the press-fit interface self-aligns during installation.
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 solution reduces material waste, simplifies assembly, lowers production costs, and avoids thermal deformation and contamination, while enabling the use of less expensive materials for the flange, enhancing the structural integrity and corrosion resistance of the high-pressure pump.
Implementation Method 1
a material of the housing being caulked in the recesses
Implementation Method 2
the flange parts are held on the housing by a caulking connection and/or a press connection
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
The invention relates to a high-pressure pump (10), in particular a plug-in pump, for a fuel system for an internal combustion engine, wherein the high-pressure pump (10) comprises a housing (14) and a flange (16) that is rigidly arranged on the housing (14). According to the invention, the flange (16) is constructed of at least two parts. The high-pressure pump (10) is thereby provided with a groove-like receiving area (18), in which a radially inward region of the flange parts (16a, 16b) is accommodated. The flange parts (16a, 16b) are held on the housing (14) by means of a caulked joint and/or a press connection.