Electromagnetic Suction Valve Assembly for Tolerance-Independent Gap Control
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Solution Overview
Problem
Existing high-pressure fuel supply pumps with electromagnetic suction valves face challenges in securing a consistent gap between components due to integration tolerance variations, requiring complex assembly processes and shim adjustments.
Innovation Solution
The design incorporates an anchor assembly with a press-fitting mechanism between the anchor and suction valve components, allowing for a controlled gap formation when the valve is closed, independent of individual component tolerances, using a magnetic attraction force to adjust the valve's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dimensional tolerance related to the gap is reduced to secure the gap between components, then the gap can be secured, but the manufacturing complexity and assembly process become more complex due to integration of tolerance variations
Solution Approach 1:
The patent introduces a press-fitting portion as an intermediary element between the first and second anchor assembly components. This press-fitting portion acts as a mediator that absorbs tolerance variations and ensures the gap is maintained without requiring complex assembly processes or tight tolerances on all components. The press-fitting connection provides a controlled interface that manages dimensional variations systematically.
Solution Approach 2:
The patent changes the parameter of the press-fitting length to a specific value that ensures the gap is secured. By optimizing this dimensional parameter, the system achieves reliable gap maintenance without requiring reduced tolerances on multiple components. The press-fitting length is designed to compensate for tolerance variations in other parts of the assembly.
2Reliability
If the number of components related to the gap is large, then the gap can be secured through multiple components, but the integration of tolerance variations makes it impossible to secure the gap without additional assembly steps
Solution Approach 1:
The anchor assembly is segmented into multiple components (first anchor assembly component, second anchor assembly component, and press-fitting portion) that are assembled together. This segmentation allows each component to be manufactured independently with standard tolerances, while the overall assembly achieves the required gap security through the coordinated design of these segments.
Solution Approach 2:
The press-fitting portion serves as an intermediary component that facilitates the connection between anchor assembly components while managing tolerance accumulation. This intermediary element enables straightforward assembly without requiring complex measurement and adjustment procedures, thus maintaining both reliability and productivity.
3Manufacturing precision
If complex assembly processes including measurement and shim selection are implemented, then the gap can be secured, but the assembly time and production cost increase
Solution Approach 1:
The press-fitting portion is designed to automatically ensure the correct gap dimension through its own dimensional design and press-fitting connection. The component structure itself provides the necessary gap control without requiring external measurement tools, shim selection, or adjustment procedures during assembly. The design is self-contained and self-regulating regarding gap maintenance.
Solution Approach 2:
The patent optimizes the press-fitting length parameter to a specific value that inherently ensures the gap is secured. This parameter optimization eliminates the need for complex assembly procedures including measurement and shim selection, thereby reducing assembly time while maintaining manufacturing precision.
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 solution ensures reliable gap formation between the suction valve and anchor assembly, enhancing valve responsiveness and discharge performance while simplifying assembly by eliminating the need for precise tolerance matching and shim selection.
Implementation Method 1
an electromagnetic coil 52 and a magnetic core 33 between which a magnetic attraction force acts
Data Source
AI summary
An object of the present invention is to secure a gap between a component on a suction valve side and a component on an anchor side when a valve is closed, regardless of an integration tolerance of a plurality of components, and to be able to reliably close the valve. In an electromagnetic valve mechanism 300 including an anchor assembly 36 and a magnetic core 33 between which a magnetic attraction force acts, and a suction valve 30 configured to be able to come into and out of contact with the anchor assembly 36, the anchor assembly 36 includes a first anchor assembly component 36a having a facing surface 36ab that faces the magnetic core 33, a second anchor assembly component 36b configured integrally with the first anchor assembly component 36a, and a press-fitting portion 36c that fixes the first anchor assembly component 36a and the second anchor assembly component 36b. A press-fitting length L1 of the press-fitting portion 36c is set to a length at which the second anchor assembly component 36b and the suction valve 30 are separated from each other in a state where the suction valve 30 is closed.