Reciprocating Pump Injector with Magnetic Actuation
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Solution Overview
Problem
Conventional fuel injection systems for internal combustion engines are complex and costly due to the separation of fuel pumps and injectors, which increases the number of components and manufacturing costs.
Innovation Solution
A fuel injector with an integrated reciprocating piston pump that includes a magnetic actuation assembly, allowing the piston to move and pressurize fuel within a pumping chamber, eliminating the need for a separate fuel pump and pressure regulator, and featuring a solenoid actuator assembly with a fixed stator and movable armature to manage fuel flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a separate fuel pump and injector are used, then fuel delivery function is achieved, but system complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the fuel pump and injector into a single integrated unit. The pump chamber and injector share a common body structure, with the piston directly actuating the injector needle through magnetic coupling. This merging eliminates separate fuel pump and injector components, reducing system complexity while maintaining reliable fuel delivery through the integrated design.
Solution Approach 2:
The integrated fuel pump/injector unit performs multiple functions within a single device: it pumps fuel from the inlet, pressurizes it in the pump chamber, and delivers it through the injector nozzle. The magnetic actuation system simultaneously controls both the piston motion for pumping and the needle valve for injection, achieving multi-functionality that reduces component count while ensuring reliable operation.
2Ease of manufacture
If a separate fuel pump is used, then fuel pressurization is achieved, but manufacturing cost increases
Solution Approach 1:
The patent integrates the fuel pressurization function directly into the injector body, eliminating the need for a separate fuel pump. The piston within the integrated unit creates pressure in the pump chamber by reciprocating motion, and this pressurized fuel is directly delivered through the injector. This merging reduces manufacturing cost by eliminating separate pump components while achieving the required fuel pressure through the integrated pressurization mechanism.
3Ease of operation
If conventional solenoid actuation is used, then needle movement is achieved, but force consistency varies through travel
Solution Approach 1:
The patent replaces the conventional solenoid actuation system with a magnetic actuation system that uses magnetic coupling between the piston and needle. This substitution provides more consistent force throughout the needle's travel range because the magnetic field strength remains relatively constant compared to the varying electromagnetic force in conventional solenoids. The magnetic actuation system directly couples the piston motion to needle motion, eliminating the need for complex calibration while maintaining consistent actuation force.
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 simplifies the fuel injection system by reducing the number of components, lowers manufacturing costs, and ensures consistent fuel flow and ease of calibration, while also allowing for high-temperature operation and efficient atomization of fuel.
Implementation Method 1
a magnetic actuation assembly supported by the housing and coupled to the piston, the magnetic actuation assembly configured to translate the piston
Implementation Method 2
The solenoid actuator assembly includes a fixed stator, a coil, and a movable armature configured to move toward a first end of the fixed stator in response to the coil being energized
Implementation Method 3
The magnetic flux through the radial gap may increase as the axial gap is reduced. The magnetic actuation assembly may provide a substantially constant force through its intended range of travel
Implementation Method 4
The movable armature is configured to move relative to the fixed stator to reduce the axial gap and to increase a magnetic flux through the radial gap such that a total axial force acting on the movable armature is substantially constant
Implementation Method 5
a piston received in the sleeve and slidable between a first position and a second position
Implementation Method 6
a piston configured to pressurize the fuel entering the pumping chamber
Implementation Method 7
an inlet valve through which fuel passes to enter the pumping chamber. The fuel injector may include an inlet check valve and outlet check valve
Implementation Method 8
The outlet nozzle may include a thin plate with an indent to support the outlet check valve spring and one or more orifices to atomize fuel
Implementation Method 9
The magnetic actuator assembly includes a magnetic flux path that passes substantially between the movable armature and the fixed stator via a radial gap and an axial gap
Implementation Method 10
The magnetic flux through the radial gap may increase as the axial gap is reduced
Data Source
AI summary
A reciprocating piston pump includes a pumping chamber, an inlet valve through which fuel passes to enter the pumping chamber, a piston configured to pressurize the fuel entering the pumping chamber, an outlet valve through which the pressurized fuel passes to exit the pumping chamber, and a solenoid actuator assembly coupled to the piston. The solenoid actuator assembly includes a fixed stator, a coil, and a movable armature. The movable armature is configured to move toward a first end of the fixed stator in response to the coil being energized.