Fuel Injector Outlet Orientation Using a 2D Cell Matrix

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Solution Overview

Problem

The manufacturing process of direct injection fuel injectors is inefficient due to the need for machining features to align the outlet body with the fuel injector body, which increases production time and reduces tool life.

Innovation Solution

A fuel injector design incorporating a 2-dimensional matrix of cells on the outlet body, which serves both as a data storage and orientation feature, allowing for precise alignment with the fuel injector body using a scanner and rotating mechanism during assembly, eliminating the need for additional alignment features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a machined alignment feature is added to the outlet body to ensure proper orientation, then manufacturing precision is improved, but productivity deteriorates due to increased machining time

Engineering Contradiction:
Improveoutlet body orientationVSAvoidmanufacturing speed
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the orientation reference function with the existing data matrix barcode on the outlet body. The data matrix includes specific orientation indicators that serve dual purposes: storing manufacturing data and providing alignment references. This eliminates the need for separate machined alignment features while maintaining precise orientation capability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The data matrix on the outlet body is designed to serve multiple functions simultaneously: it stores manufacturing traceability data, provides orientation information, and serves as an alignment reference during assembly. This multi-functional approach replaces the single-purpose machined alignment feature, improving productivity without sacrificing precision.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Manufacturing precision

If a machined alignment feature is added to the outlet body to ensure proper orientation, then manufacturing precision is improved, but device complexity increases due to additional machining operations

Engineering Contradiction:
Improveoutlet body orientationVSAvoidmanufacturing process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the orientation reference functionality into the existing data matrix structure. The data matrix contains encoded orientation indicators that are read by scanning equipment during assembly, eliminating the need for separate alignment features and reducing manufacturing process complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical machining approach with an optical/electronic solution. Instead of machining physical alignment features, the system uses optical scanning of the data matrix to detect orientation indicators and guide alignment, thereby reducing device complexity associated with machining operations.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the same tool is used to machine both alignment features and other features, then device complexity is reduced, but tool life decreases

Engineering Contradiction:
Improvemachining tool varietyVSAvoidtool life
Core Design Contradiction:
Device complexityVSDuration of action of stationary object

Solution Approach 1:

The patent extracts the alignment function from the mechanical machining domain and places it in the optical/electronic domain through the data matrix. This eliminates the need for specialized alignment machining tools, allowing the use of standard scanning equipment and reducing tool wear issues.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes mechanical machining tools with optical scanning systems for the alignment function. The scanner reads orientation indicators from the data matrix without physical contact, eliminating tool wear and extending the operational life of measurement and alignment equipment.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3536945B1Fuel injector and method of orienting an outlet of the same
Publication Date: 2022.09.14 DELPHI TECH IP LTD
  • EP3536945B1 patent drawingFigure 1
  • EP3536945B1 patent drawingFigure 2
  • EP3536945B1 patent drawingFigure 3

AI summary

A fuel injector (10) includes a fuel inlet (16); a fuel injector body (38); an outlet body (28) having an upstream surface (28a), a downstream surface (28b), and an outlet aperture (28c) fluidly connecting the upstream surface (28a) to the downstream surface (28b); and a valve assembly (22) which controls flow through the outlet aperture (28c). The outlet body (28) includes a 2-dimensional matrix of cells (42) on the downstream surface (28b) and includes a perimeter having a finder pattern (44) and a timing pattern (46) and also includes a field of unpopulated and populated cells (48) within the perimeter which represent bits of data. The 2-dimensional matrix of cells (42) orients the outlet body (28) relative to the fuel injector body (38).