Intake Assembly Fuel Rail Segmentation for Engine Mixing
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Solution Overview
Problem
Existing intake manifold assemblies for internal combustion engines face challenges in assembly complexity, space requirements, and inefficient air-fuel mixing, particularly when using gaseous fuels like hydrogen.
Innovation Solution
The proposed intake assembly features a modular design with a fuel rail mounted to the first plenum of the intake manifold, allowing for preassembly of the fuel rail and fuel injectors, which simplifies assembly and improves access for maintenance. Additionally, the intake runners include protrusions with fuel orifices to enhance air-fuel mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the fuel rail is integrated with the intake manifold as a single assembly, then the structural integrity is improved, but the assembly complexity and difficulty of maintenance increase
Solution Approach 1:
The fuel rail assembly is segmented into a separate removable unit that can be detached from the intake manifold. This allows the fuel rail to be serviced independently without dismantling the entire intake manifold, reducing assembly complexity and maintenance difficulty while maintaining structural integrity when connected.
Solution Approach 2:
The fuel rail is pre-assembled with fuel injectors as a complete unit before being mounted to the intake manifold. This preliminary assembly simplifies the overall installation process and allows for easier replacement of the entire fuel delivery system as a single module.
2Volume of moving object
If the fuel rail is positioned close to the cylinder head for compactness, then the space requirements are reduced, but the accessibility for maintenance and inspection deteriorates
Solution Approach 1:
By segmenting the fuel rail as a separate removable unit from the intake manifold, the design allows the fuel rail to be positioned optimally for both compactness and accessibility. The removable nature enables easy access for maintenance while allowing compact integration when assembled.
Solution Approach 2:
The fuel rail assembly is designed with dynamic accessibility - while positioned for compact integration during operation, it can be easily removed and repositioned during maintenance. This dynamic capability allows the system to switch between compact operational configuration and accessible maintenance configuration.
3Ease of manufacture
If fuel is injected into the intake runner for port fuel injection, then the fuel-air mixing is improved, but the mixing efficiency is insufficient for optimal combustion
Solution Approach 1:
Turbulence promoters with curved or spherical surface features are installed in the intake runners to create turbulent flow patterns. This curvature-induced turbulence enhances the mixing of fuel and air, improving combustion efficiency while maintaining the simplicity of port fuel injection implementation.
Solution Approach 2:
The turbulence promoters create mechanical disturbances and vibrations in the airflow within the intake runners. This mechanical vibration of the air-fuel mixture enhances mixing efficiency by creating eddies and turbulent patterns that thoroughly blend fuel and air before combustion.
4Device complexity
If a common fuel rail supplies multiple fuel injectors, then the fuel distribution system is simplified, but the assembly and maintenance difficulty increases
Solution Approach 1:
The fuel rail and fuel injectors are segmented into a separate removable assembly that functions as a complete unit. This segmentation maintains the simplicity of the common fuel rail design for fuel distribution while enabling easy removal and replacement of the entire fuel delivery assembly for maintenance, reducing repair difficulty.
Data Source
AI summary
An intake assembly for an internal combustion engine, includes an intake manifold including a first plenum and a plurality of intake runners, the first plenum including an air supply inlet, the intake runners configured to be couplable to a cylinder head of the engine for supplying an air-fuel mixture thereto, the intake manifold configured such that, in use, air is supplied from the air supply inlet to the intake runners via the first plenum; a plurality of fuel injectors, each arranged to inject a fuel into one of the intake runners; and a fuel rail coupled to the plurality of fuel injectors, the fuel rail including a fuel supply inlet, and configured to supply fuel from the fuel supply inlet to the plurality of fuel injectors, in use. The fuel rail is mounted to the first plenum.