Laser Match Honing for Injector Needle Tolerance
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Solution Overview
Problem
The existing manufacturing processes for mechanically matching components, such as fuel injector needles and bodies, face challenges in achieving precise fit tolerances, leading to increased material and inventory costs due to the need for grading and potential manufacturing tolerances exceeding requirements.
Innovation Solution
A laser match honing system utilizing an ultrashort pulse femtosecond laser to precisely adjust the dimensions of injector needles based on measurements from the injector bodies, eliminating the need for grading steps and reducing inventory by directly matching the components' tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grading steps are carried out to ensure fit tolerance, then manufacturing precision is improved, but device complexity and inventory costs increase
Solution Approach 1:
The system performs preliminary measurement of the first component's matching portion before processing the second component. This allows the dimension of the second component to be adjusted based on actual measurements, eliminating the need for post-manufacturing grading and reducing inventory complexity
Solution Approach 2:
The patent replaces traditional mechanical grading and sorting systems with an automated measurement and adaptive processing system. The measuring gauge and controller automatically determine the required adjustments, substituting manual or mechanical grading processes
2Ease of manufacture
If traditional grinding processes are used, then manufacturing capability is maintained, but surface precision and heat-affected zones worsen
Solution Approach 1:
The patent substitutes traditional mechanical grinding with laser beam processing. The laser beam removes material through ablation rather than mechanical contact, achieving superior surface precision without the heat-affected zones characteristic of conventional thermal or mechanical processes
Solution Approach 2:
The system changes the processing parameter from mechanical force and heat to focused laser energy. By controlling laser pulse duration and intensity, the process achieves precise material removal with minimal thermal influence, improving surface quality
3Manufacturing precision
If match grinding process is adopted, then fit tolerance is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The system implements a continuous process where measurement and laser processing occur in sequence without interruption. The measuring gauge immediately feeds data to the controller, which directly guides the laser processing, eliminating idle time between measurement and adjustment
Solution Approach 2:
The system creates a digital copy of the first component's dimensions through measurement, then uses this information to guide the processing of the second component. This information copying enables direct adaptive processing without repeated measurement cycles
4Manufacturing precision
If ultrashort pulse lasers are used, then surface precision is improved, but material removal rate may decrease
Solution Approach 1:
The system uses periodic ultrashort pulse laser bursts to remove material. By delivering energy in discrete pulses rather than continuous beam, the process allows heat dissipation between pulses, preventing melt accumulation while maintaining high precision and enabling controlled material removal rates
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 precise matching of components, reduces material and inventory costs, and eliminates the inefficiencies of traditional grinding processes, while maintaining high surface precision and avoiding heat-affected zones.
Implementation Method 1
ultrashort pulse lasers of femtosecond level have been used for laser ablation. As an example, Titansaphir-laser is used in cold material ablation, in which the removed material is transformed directly from solid state into gas state. No heat affected zone is found in the material near the ablation area.
Implementation Method 2
Titansaphir-laser is used in cold material ablation, in which the removed material is transformed directly from solid state into gas state. No heat affected zone is found in the material near the ablation area.
Implementation Method 3
The inner diameter is pneumatically measured. Based on the measurement, the outer diameter of a matching valve needle is adaptively ground.
Data Source
Figure 1~2
Figure 3
AI summary
A laser match honing system and method are provided for processing one of a pair of mechanically matching components (1, 2) having matching portions (12, 22, 16, 26) that will be fitted with each other. A dimension of the matching portion (12, 16) of the first component (1) is measured and is then used for calculating the desired dimension of the corresponding matching portion (22, 26) of the second component (2). An actual dimension of the matching portion (22, 26) of the second component (2) is also measured. Then, the matching portion (22, 26) of the second component (2) is honed by laser beam in the condition that the actual dimension is not equal to the desired dimension.