Fuel Injector Stator Positioning Feature Prevents Angular Misalignment

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Solution Overview

Problem

The existing fuel injector assembly process lacks a reliable mechanism to ensure correct angular positioning of electrical terminals relative to connector pins, leading to potential incorrect connections and defective electrical contacts.

Innovation Solution

A positioning feature comprising a first member with a transverse front face and axially extending lateral faces, and a second member with notches, is integrated with the stator assembly to prevent incorrect angular orientation and ensure correct engagement of terminals with connector pins, thereby facilitating a secure electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If no positioning feature is provided, then the assembly process is simpler, but incorrect angular positioning of terminals relative to pins occurs leading to defective electrical contacts

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A positioning feature comprising a first member with a transverse front face and axially extending lateral faces, and a second member with notches, is introduced as an intermediary element. This positioning feature acts as a mediator between the stator assembly and connector, ensuring correct angular orientation and preventing incorrect positioning during assembly, thereby guaranteeing reliable electrical contact between terminals and pins.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The positioning feature is integrally moulded with the stator assembly, allowing the stator assembly to self-position correctly during assembly without requiring external positioning tools or complex alignment procedures. The geometric features (front face, lateral faces, notches) enable self-guidance and self-correction of angular orientation during the insertion process.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If a positioning feature is added, then correct angular positioning is ensured, but the manufacturing complexity increases

Engineering Contradiction:

Improveangular positioning precisionVSAvoidassembly manufacturing ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The positioning feature is integrally moulded with the stator assembly in a single manufacturing process. The first member and second member are combined into one integrated component that is moulded together with the stator assembly body, eliminating the need for separate manufacturing steps and reducing assembly complexity while maintaining high angular positioning precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The positioning feature employs asymmetric geometric elements including a transverse front face with specific length smaller than the inter-pins distance, axially extending lateral faces, and notches positioned at specific locations. These asymmetric features provide unique angular orientation guidance that prevents incorrect positioning while being straightforward to manufacture through integral moulding.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentEP3529484B1Stator assembly of a fuel injector with a position feature

Publication Date: 2022.02.23 DELPHI TECH IP LTD

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AI summary

A positioning feature (44) comprises a first member (46) so that in an embodiment where the pins of a connector (38) are perpendicular to a main axis (X1), an incorrect angular orientation is prevented by said positioning feature (44) that would contact one of the pins and, a correct angular orientation is assured by the engagement of a first member (46) between the pins.