Nested Check Ducted Fuel Injector Alignment
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Solution Overview
Problem
Current ducted fuel injection systems in internal combustion engines face challenges in effectively managing combustion to reduce particulate matter and NOx emissions, as they often rely on rotating checks that can disrupt the alignment of spray orifices and transfer passages, affecting fuel-air mixing and emission control.
Innovation Solution
A nested-check ducted fuel injector with a non-rotating outer check is introduced, featuring spray orifices arranged in two sets with transfer passages and spray ducts, where the outer check is fixed in angular orientation to maintain alignment, and inner and outer checks are movable to control fuel flow and injection patterns, ensuring efficient fuel distribution and mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rotating checks are used in ducted fuel injection systems, then fuel flow control is achieved, but alignment between transfer passages and spray orifices is disrupted, affecting fuel-air mixing
Solution Approach 1:
The check mechanism is segmented into an outer check and an inner check that operate independently. The outer check remains stationary to maintain alignment between transfer passages and spray orifices, while the inner check rotates to control fuel flow. This segmentation allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The inner check acts as an intermediary between the fuel supply and the spray orifices. It controls fuel flow through rotation while the outer check provides a stable structural framework that maintains the alignment of transfer passages with spray orifices, preventing direct disruption of the alignment by the rotating inner check.
2Productivity
If rotating checks are used to control fuel injection, then fuel delivery is regulated, but emission control effectiveness is reduced due to misalignment
Solution Approach 1:
By segmenting the check system into stationary outer check and rotating inner check, the invention maintains proper alignment of fuel delivery paths while still enabling regulated fuel injection. This ensures optimal fuel-air mixing for reduced emissions while maintaining fuel delivery control capability.
Solution Approach 2:
Instead of having the check rotate to maintain alignment (conventional approach), the invention inverts the approach by keeping the check stationary and using a separate rotating component (inner check) for flow control. This inversion preserves alignment while enabling regulation.
3Device complexity
If a single check is used for fuel injection control, then device complexity is reduced, but precision in controlling fuel injection patterns is limited
Solution Approach 1:
The check mechanism is divided into an outer check for structural support and alignment, and an inner check for precise fuel flow control. This segmentation allows the inner check to be optimized for precision control of injection patterns while the outer check maintains the necessary structural framework.
Solution Approach 2:
The inner check is nested within the outer check, with the inner check having a smaller diameter and being positioned coaxially within the outer check. This nested arrangement allows the smaller inner check to provide precise control for specific injection patterns while the larger outer check provides overall structural support and alignment.
Data Source
AI summary
A fuel injector includes an injector housing having a nozzle assembly with a nozzle piece, and a nested check assembly of an outer check and an inner check. Spray orifices are formed in the nozzle piece in a first orifice set equipped with a first spray duct set and a second orifice set equipped with a second spray duct set. The inner check can be opened to spray fuel from the first orifice set and the outer check can be opened to spray fuel from both the first orifice set and the second orifice set. The outer check is non-rotating while the inner check can be permitted to rotate during service. Spray ducts associated with the first orifice set may have a different duct length and duct inside diameter than spray ducts associated with the second orifice set. The first orifice set may include lower-flow spray orifices and the second orifice set may include higher-flow spray orifices. Related methodology is also disclosed.