Hydrogen Engine Central Rail Air Distributor Integration

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Solution Overview

Problem

Internal combustion engines with intake manifold injection face challenges due to the large number of pipes required between the central rail and injectors, increasing costs and maintenance, and the need for easy interchangeability of injectors while maintaining electrical isolation from the fuel area.

Innovation Solution

The central rail is mounted directly or in close proximity to the air distributor, potentially as a combined integral component, with integrated connections and injectors partially or fully integrated into the rail, reducing the need for external pipes and allowing for easier maintenance and electrical separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a common central rail is used for all combustion chambers, then the fuel supply system is simplified, but the number of piping between the central rail and respective injectors increases

Engineering Contradiction:

Improvefuel supply system complexityVSAvoidnumber of pipes

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

The patent combines the central rail with the air distributor into an integrated component structure. The central rail is mounted directly on the air distributor with integrated connection points, eliminating the need for separate external piping between the rail and injectors. This merging of components directly reduces the quantity of pipes while maintaining the simplified fuel supply system architecture.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If the central rail is positioned away from the air distributor, then installation flexibility is improved, but the number of external pipes increases and pressure losses increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidpressure losses

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The central rail is integrated with the air distributor structure, positioning the fuel supply component directly at the point of injection. This eliminates long external pipes and reduces pressure losses through minimized flow paths, while the integrated design maintains installation flexibility through standardized mounting interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes the three-dimensional space within and around the air distributor to position the central rail optimally. By mounting the rail directly on the air distributor housing and utilizing internal cavities and passage openings, the system achieves compact spatial arrangement that minimizes pipe length without compromising installation flexibility.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If injectors are fully integrated into the central rail, then electrical isolation from fuel area is improved, but accessibility for maintenance deteriorates

Engineering Contradiction:

Improveelectrical isolationVSAvoidinjector accessibility

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The injector assembly is segmented into distinct functional zones: the electrical control components are positioned outside the fuel-containing central rail, while the injection nozzle and fuel delivery components are integrated within the rail. This segmentation achieves electrical isolation for reliability while maintaining accessibility of the electrical portions for maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The central rail structure itself acts as an intermediary barrier that provides electrical isolation between the fuel injection components and external electrical systems. The rail housing and integrated connections create a physical and electrical boundary that protects sensitive electrical components while allowing controlled access through standardized interfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If multiple separate components are used for central rail and air distributor, then manufacturing flexibility is improved, but assembly complexity and installation space increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The central rail and air distributor are merged into an integrated component assembly where the rail is mounted directly on the distributor housing. This integration reduces assembly complexity by eliminating separate mounting operations and reduces installation space by consolidating functions into a single compact unit, while still allowing flexible manufacturing of the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11920545B2Internal combustion engine with intake manifold injection, in particular hydrogen combustion engine with intake injection

Publication Date: 2024.03.05 LIEBHERR MACHINES BULLE

AI summary

An internal combustion engine has an intake manifold injection, at least two combustion chambers, at least one central rail for supplying fuel for the intake manifold injection, and at least one air distributor for supplying air to the individual combustion chambers. The central rail is attached to the air distributor, or the central rail and the air distributor are formed as an integral component.