High-Pressure Pump Housing Segmentation for Weight Reduction
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Solution Overview
Problem
High-pressure pumps have complex and heavy housings due to the need for sufficient thickness to discharge high-pressure fuel, leading to increased weight and manufacturing complexity.
Innovation Solution
A high-pressure pump design featuring a housing composed of independently formed lower and upper housings, along with a cup-shaped cover, which simplifies the configuration and reduces weight by not directly receiving fuel pressure, allowing for thinner and more lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing is made with sufficient thickness to discharge high-pressure fuel, then the discharge capability is improved, but the weight and structural complexity of the housing increase
Solution Approach 1:
The housing is divided into multiple independent segments (lower housing, upper housing, and cover) that can be manufactured separately and assembled together. This segmentation allows each part to be optimized independently, reducing the overall weight and complexity while maintaining the necessary pressure containment capabilities through strategic thickening only where required.
2Reliability
If the housing is made with sufficient thickness to discharge high-pressure fuel, then the discharge capability is improved, but the structural complexity of the housing increases
Solution Approach 1:
The housing is divided into multiple independent segments (lower housing, upper housing, and cover) that can be manufactured separately and assembled together. This segmentation allows each part to be optimized independently, reducing the overall weight and complexity while maintaining the necessary pressure containment capabilities through strategic thickening only where required.
3Weight of stationary object
If the upper housing and cover are made thin to reduce weight, then the weight is reduced, but the ability to withstand fuel pressure may be compromised
Solution Approach 1:
Different parts of the housing have different wall thicknesses optimized for their specific functions. The upper housing and cover are made thin where they do not directly receive fuel pressure, while the lower housing and cylinder maintain sufficient thickness to withstand high fuel pressure. This local differentiation of quality allows weight reduction without compromising structural integrity.
Solution Approach 2:
The cylinder acts as an intermediary component that directly receives and contains the high-pressure fuel, isolating the upper housing and cover from direct pressure exposure. This intermediary structure allows the upper components to be made lighter while the pressure-containing functions are handled by the specifically designed lower housing and cylinder.
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 simplifies the housing configuration, reduces weight, and maintains high-pressure fuel discharge efficiency while enhancing rust resistance and manufacturing cost-effectiveness.
Implementation Method 1
a plunger (51) which is supported by the cylinder (13) in such a manner as to reciprocate in its axial direction
Implementation Method 2
When the plunger (51) is moved upward, the fuel in the pressurization chamber (14) is pressurized
Implementation Method 3
The suction valve includes: a suction valve member (74) which closes and opens the suction passage
Implementation Method 4
The discharge valve includes a discharge valve member (94) and a discharge valve body (93) against which the discharge valve member abuts
Data Source
AI summary
A high-pressure pump is comprised of a lower housing, an upper housing and a cover, which are formed independently from each other. Thereby, shapes of the above can be simplified. Although the cylinder and the plunger receive a fuel pressure during a pressurization stroke, the upper housing and the cover do not receive fuel pressure directly from a pressurization chamber. Therefore, the upper housing and the cover can be made thin and light as much as possible.