Plastic Fuel Distributor Integrating Sensor for Natural Gas Injection
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Solution Overview
Problem
The existing fuel distributor systems for natural gas injection in internal combustion engines are uneconomical to produce, especially for large volumes, and require additional production steps due to the need for separate sensors and connecting elements, which can lead to sealing issues and increased costs.
Innovation Solution
A fuel distributor system where the sensor is integrated into the base body of a plastic distributor pipe, eliminating the need for separate sensor connections and reducing the number of components, with outlets designed as cups for easy assembly and reduced material usage, allowing for efficient distribution of compressed natural gas to fuel injectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fuel distributor is made from aluminum or stainless steel, then strength and durability are improved, but production cost increases and manufacturing becomes uneconomical for large volumes
Solution Approach 1:
The patent changes the material parameter from metal (aluminum or stainless steel) to plastic, fundamentally altering the material properties to achieve both cost reduction and improved manufacturability for large volumes while maintaining sufficient strength for the application
Solution Approach 2:
The patent adopts plastic material which is cheaper and more economical for mass production, accepting that the material may have shorter service life or lower strength compared to metal, but achieving overall system economy through reduced production costs
2Measurement precision
If separate sensors and connecting elements are mounted on the fuel rail, then measurement functionality is achieved, but production complexity increases and additional work steps are required
Solution Approach 1:
The patent merges the sensor and connecting elements directly into the fuel distributor body, eliminating separate mounting steps and reducing production complexity while maintaining the measurement functionality through integrated pressure and temperature sensors
Solution Approach 2:
The fuel distributor is designed to perform multiple functions simultaneously: fuel distribution, pressure measurement, temperature measurement, and sensor connection, all integrated into a single component that reduces overall system complexity
3Ease of operation
If separate components are used for sensor connection, then assembly flexibility is maintained, but sealing reliability decreases due to additional sealing points that may leak
Solution Approach 1:
The patent integrates the sensor connection directly into the fuel distributor body, eliminating separate connection components and their associated sealing points, thereby improving sealing reliability while maintaining assembly flexibility through the integrated design
4Adaptability or versatility
If multiple separate components are used in the fuel distributor system, then functional requirements are met, but the number of production work steps increases
Solution Approach 1:
The patent combines multiple functional components (fuel distribution channels, sensor mounting, connecting elements) into a single integrated fuel distributor body, dramatically reducing the number of production work steps and improving productivity while maintaining all required functional capabilities
Solution Approach 2:
The integrated fuel distributor performs multiple functions simultaneously - distributing fuel to injectors, measuring pressure, measuring temperature, and providing sensor connections - all within a single component that streamlines production
Data Source
Figure 1
AI summary
The invention relates to a fuel distributor (2), which is used to distribute natural gas to a plurality of fuel injection valves (3, 4). A main body (5), in which a fuel chamber (9) is provided, and a plurality of cups (11, 12), by means of which the fuel can be conducted from the fuel chamber (9) to the fuel injection valves (3, 4), are provided. In addition, the fuel distributor (2) comprises a sensor (7) having a sensor connection (8), wherein the sensor connection (8) of the sensor (7) is integrated in the main body (5). The invention further relates to a fuel injection system (1) having such a fuel distributor (2).