High-Pressure Pump Suction Valve Inserts to Prevent Armature Impact
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Solution Overview
Problem
High-pressure pumps in fuel injection systems face component failure and leaks due to high impulse forces between magnet armature and pole core, which are made of materials with good magnetic properties but low strength, leading to reliability issues and potential loss of function.
Innovation Solution
The design incorporates a pole core insert with a second flange and a magnet armature insert that protrudes, avoiding magnetic adhesive forces and using materials with higher strength, along with a second compression spring arrangement to reduce damage and enhance rigidity, thereby preventing component collisions and increasing the pump's reliability and service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the magnet armature and pole core are made of materials with good magnetic properties, then the magnetic force is optimized, but the strength is low leading to component failure under high impulse forces
Solution Approach 1:
The patent applies composite material construction by combining soft magnetic materials (for magnetic properties) with hard protective coatings or surface treatments (for strength and wear resistance). The magnet armature and pole core use layered or coated structures where the base material provides magnetic functionality while the protective layer provides mechanical strength and impulse resistance.
2Ease of operation
If the magnet armature and pole core collide to close the working air gap, then the valve operation is achieved, but high impulse forces cause damage to component connections and seals
Solution Approach 1:
The patent implements cushioning elements or damping structures between the magnet armature and pole core, or in the mounting connections, to absorb and reduce the impulse forces generated during collision. This beforehand cushioning protects component connections and seals from damage while allowing the valve operation to function properly.
3Force
If magnetic adhesive forces occur between the pole core and magnet armature, then the components stick together, but this causes reliability issues in continuous operation
Solution Approach 1:
The patent extracts or removes the problematic magnetic adhesive forces by introducing non-magnetic spacers, separators, or protective layers between the pole core and magnet armature surfaces that would otherwise adhere to each other. This extraction of the harmful adhesive effect allows continuous operation without sticking issues while maintaining necessary magnetic forces for valve actuation.
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 design enhances the wear resistance and reliability of the valve and pump by reducing magnetic adhesive forces, preventing component failures, and optimizing magnetic force, leading to energy savings and cost reductions.
Implementation Method 1
The magnet armature and a pole core are part of an electromagnetic actuator, which also includes a magnetic coil. When the magnet coil is energized, a magnetic field is formed, causing the magnet armature to move relative to the magnet coil against the spring force of a second compression spring in order to close a working air gap between the magnet armature and the pole core.
Implementation Method 2
The valve has a valve element which can be moved between an open position and a closed position and which is acted upon in the closing direction by the spring force of a first compression spring.
Data Source
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AI summary
The invention relates to a valve, in particular a suction valve, in a high-pressure pump of a fuel injection system, in particular a common rail injection system, comprising a magnet actuator (22) which has a magnet coil (6), a magnet armature (10) that moves in a stroke-like manner, and a pole core (20), wherein the magnet armature (10) and the pole core (20) together limit a working air gap (28), and the magnet armature (10) can at least indirectly contact the pole core (20), wherein the valve also has a valve element (14) which can be moved between an open position and a closed position, and which is at least indirectly in mechanical contact with the magnet armature (10). According to the present invention, a separate magnet armature insert (8) arranged in the magnet armature (10) and/or a separate pole core insert (24) arranged in the pole core (20) is provided in the contact area of the magnet armature (10) on the pole core (20), in order to achieve a separation of the mechanical and magnetic forces. The invention also relates to a high-pressure pump with a suction valve of this type.