Rail Fastening Sleeve via Bolt Welding for Weight Reduction
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Solution Overview
Problem
High-pressure fuel accumulator components, such as those in common-rail fuel injection systems, face challenges due to their high weight and material usage resulting from forging technology, leading to increased costs.
Innovation Solution
A method involving a base body with a longitudinal cavity and fastening flange, where a bolt is inserted into a through-bore with opposite openings, forming a secure and lightweight fastening sleeve through material connection, such as welding, allowing for optimized weight and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening elements are formed integrally with the base body using forging technology, then strength and reliability are improved, but weight and material usage increase significantly
Solution Approach 1:
The fastening element is divided into two separate parts: the base body and the insert element. The insert element is inserted into a bore of the base body and secured through material connection (welding), eliminating the need for integral forging while maintaining structural integrity and strength under high pressure conditions.
2Reliability
If fastening elements are formed integrally with the base body, then reliability is improved, but production costs increase due to high material usage
Solution Approach 1:
The fastening system is segmented into a base body with a bore and a separate insert element. This allows optimization of material usage by only providing material where structurally necessary, while the insert element can be precisely sized and shaped to meet functional requirements without excess material.
Solution Approach 2:
The design changes from integral construction to a modular assembly with controlled material connection. The material connection (welding) parameters are optimized to provide sufficient strength and reliability while using minimal material for the connection zone, reducing overall material consumption.
3Strength
If wall thicknesses are increased for integral fastening elements, then strength is improved, but weight and costs increase
Solution Approach 1:
The fastening function is segmented from the base body structure. The insert element provides the necessary strength and wall thickness locally where needed for fastening, while the base body can maintain thinner walls elsewhere, reducing overall weight while preserving structural integrity.
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 reduces material usage and production costs while providing a secure, lightweight, and durable connection suitable for high-pressure applications, enhancing the component's performance and efficiency.
Implementation Method 1
materially connecting the bolt inserted in the through hole to the mounting flange
Data Source
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AI summary
The present invention relates to a method for producing an internally pressurized component (1), having the steps of: providing a main body (2) with a longitudinal cavity (3) and with an attachment flange (6) for attachment of the internally pressurized component (1), providing a bolt (80), introducing a through-bore (7) that extends longitudinally through the attachment flange (6) and has two opposite openings (70, 71) with respect to the longitudinal axis (L7), inserting the bolt (80) into the through-bore (7) such that the bolt (80) is arranged flush with the attachment flange (6) on the side of one of the openings (70) and extends from this opening (70) through the through-bore (7) and through the other opening (71) in order to project from the attachment flange (6), materially bonding the bolt (80) to the attachment flange (6), and introducing a longitudinal bore (81) into the bolt (80) to form an attachment sleeve (8). The invention also relates to a corresponding internally pressurized component (1).