Injection Valve Deceleration Device for Wear Reduction
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Solution Overview
Problem
Current fuel injector designs face challenges in achieving precise and reliable operation at high pressures due to hard stops, which lead to hydraulic sticking forces, wear, and difficulties in controlling small fuel quantities, especially with stringent mechatronic requirements and multiple injection strategies.
Innovation Solution
The design incorporates a deceleration device with a high-stiffness spring to eliminate hard stops, uses a permanent magnet for initial armature displacement, and a non-magnetic shell to reduce magnetic flux, combined with a Somaloy U-shaped core for efficient magnetic force transfer and reduced demagnetization, allowing for precise control without chrome plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If hard stops are used to limit armature travel, then the injection valve structure is simple, but hydraulic sticking forces occur and wear increases
Solution Approach 1:
The patent applies beforehand cushioning by introducing a deceleration device with a spring element that gradually reduces the armature's velocity before it reaches the stop position. This cushioning action prevents direct impact and eliminates hydraulic sticking forces, thereby improving operation reliability while maintaining structural simplicity.
2Duration of action of stationary object
If chrome plating is applied to reduce wear, then component durability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for chrome plating by fundamentally removing the cause of wear through the deceleration device. By preventing direct contact between the armature and stop surface, the invention makes protective coatings unnecessary, thereby improving ease of manufacture while maintaining component durability.
3Reliability
If high-stiffness spring deceleration device is used, then wear is reduced, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the spring element to serve multiple functions: it acts as a deceleration mechanism, a cushioning element, and a wear-prevention device simultaneously. This multi-functionality reduces overall device complexity while achieving wear resistance, as one component accomplishes what would otherwise require multiple separate mechanisms.
4Measurement precision
If permanent magnet is used for initial armature displacement, then control precision improves, but manufacturing cost increases
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical positioning mechanisms with a permanent magnet system. The magnetic field provides precise initial armature displacement without requiring intricate mechanical adjustments, thereby improving control precision while simplifying manufacturing and reducing costs.
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 approach ensures stable and repeatable operation with reduced wear, faster demagnetization, and improved multiple injection capabilities, enhancing flow control and spray formation at high pressures without the drawbacks of traditional hard stop designs.
Implementation Method 1
The actuator unit has a permanent magnet arranged in the cavity on a side of the armature remote from the pole piece. The permanent magnet is operable to apply a magnetic force to the armature in the opening direction.
Implementation Method 2
The acceleration device is operable to accelerate the armature by applying a magnetic force to the armature in the opening direction.
Implementation Method 3
The deceleration device comprises a spring. The spring is arranged in the cavity between the armature and the fluid outlet portion. The spring is operable to reduce a speed of the armature prior to the armature impacting onto the acceleration device.
Data Source
Figure 1
Figure 2~4B
Figure 5
AI summary
Injection valve (1) for an automotive engine comprising: - a valve body (14) comprising a cavity (18) and a fluid outlet portion (40), - a valve needle (20) axially movable in the cavity (18), the valve needle (20) preventing a fluid flow through the fluid outlet portion (40) in a closing position and displaceable in an opening direction (62) along a longitudinal axis (60) to other positions for releasing the fluid flow through the fluid outlet portion (40), - an electro-magnetic actuator unit (30) being configured to actuate the valve needle (20), wherein the actuator unit (30) comprises - an armature (32) which is arranged in the cavity (18) and being axially moveable relative to the valve needle (20), the armature (32) being operable to move the valve needle (20), - an acceleration device (50) comprising a pole piece (34) which is arranged in the cavity (18) subsequent to the armature (32) in the opening direction (62), the acceleration device (50) being fixed to the cavity (18) and being operable to move the armature (32) by applying a magnetic force, - a deceleration device (35) being arranged in the cavity (18), the deceleration device (35) being configured to dampen or to avoid an impact of the armature (32) onto the pole piece (34).