Fuel Injection System With Injector Alignment Guides
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Solution Overview
Problem
Existing fuel injection systems face issues such as injector distortion during assembly, pressure loss of fuel, increased number of components, and amplified vibration and noise due to direct connection of the injector to the common rail without a fuel pipe, which complicates the structure and reduces strength.
Innovation Solution
A fuel injection system where the fuel accumulator is supported by a bracket fixed to the cylinder head, with the injector directly connected to the accumulator, using a ladder or grid-shaped bracket to reinforce the fixing structure, reducing the number of components and eliminating the need for a fuel pipe, and incorporating guide members to stabilize the injector's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the injector is directly connected to the common rail without a fuel pipe, then the number of components is reduced and pressure loss is suppressed, but the structure becomes more complex and strength declines due to fixing requirements
Solution Approach 1:
The patent merges the common rail and injector into a single integrated unit where the injector is directly connected to the common rail body. This eliminates the fuel pipe and reduces component count while the integrated structure inherently strengthens the connection, avoiding the need for separate fixing brackets that would add complexity.
2Reliability
If the common rail is fixed to the head cover with mounting portions, then the common rail is securely fixed, but the structure of the common rail becomes more complex and larger
Solution Approach 1:
The mounting portions are integrated into the common rail body as a unified structure rather than separate components. The common rail includes mounting portions that are formed as part of its cylindrical body, allowing secure fixation to the head cover while maintaining a simple, compact overall structure.
3Manufacturing precision
If a dedicated jig or special tool is used to mount the injector, then the injector position is accurately determined, but the number of assembly steps increases and additional tools are required for maintenance
Solution Approach 1:
The common rail is pre-positioned and fixed to the head cover with mounting portions before the injector is installed. This preliminary fixation establishes accurate positioning references that guide the injector installation, eliminating the need for dedicated jigs or special tools while maintaining precise positioning.
4Quantity of substance
If the injector is directly connected to the common rail without fixing brackets, then the number of components is reduced, but vibration and noise become amplified due to reduced structural stability
Solution Approach 1:
The common rail and injector are merged into a rigid integrated structure where the injector is directly connected to the common rail body. This integration creates a stiff, vibration-resistant assembly that reduces noise and vibration without requiring additional brackets or mounting components.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An object of the present invention is to provide a fuel injection system capable of suppressing an occurrence of distortion in an injector during assembly of components. A fuel injection system (3) includes: a bracket (5) which is fixed to a cylinder head (21) of an engine (2); a fuel accumulator (6) which is supported by and fixed to the bracket (5) and which accumulates pressure of fuel supplied from a fuel pump; and an injector (7) which is directly connected to the fuel accumulator (6) and mounted to the cylinder head (21) and which injects the fuel, supplied from the fuel accumulator (6), into a combustion chamber. At least one of the fuel accumulator (6) and the bracket (5) has guide members (64, 513) which guide the injector (7) to a mount position on the cylinder head (21).