Valve Pin and Sealing Element Uncoupling for Wear Reduction
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Solution Overview
Problem
High-pressure valves in accumulator injection systems for internal combustion engines face challenges in maintaining reliable operation and tolerance ranges due to heavy loads and wear, especially in high-pressure pumps exceeding 2000 bar, requiring innovative solutions for long-term service life and precise control.
Innovation Solution
A valve design incorporating a spring, actuator with an electromagnet, and a pin-sealing element system, where the pin is coupled to a magnet armature and limited by a stop element made of harder material, allowing independent movement of the sealing element and pin, enabling reliable operation and fluid flow management without fixed connections, and allowing passive opening during suction strokes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pin is firmly connected to the sealing element, then the valve can be reliably actuated, but wear and tolerance fluctuations increase due to impact loads
Solution Approach 1:
The connection between the pin and sealing element is divided into two independent components: the pin and the sealing element. This segmentation allows each component to be optimized independently - the pin for actuation reliability and the sealing element for sealing function - while reducing wear through the uncoupled design that eliminates impact transmission.
2Device complexity
If the pin movement is limited by the pole core, then the actuator structure is simplified, but wear increases and tolerance stability decreases
Solution Approach 1:
A stop element is introduced as an intermediary component between the pin and the pole core. This stop element serves as a dedicated wear surface that limits pin movement while protecting the pole core from direct impact. The stop element can be made of harder material or designed as a replaceable component, maintaining tolerance stability without increasing overall actuator complexity.
3Ease of operation
If the sealing element is firmly connected to the pin, then actuation control is improved, but the ability to open passively during suction strokes is reduced
Solution Approach 1:
The connection between the pin and sealing element is made dynamic rather than fixed. The uncoupled design allows the sealing element to move independently in response to pressure differentials during suction strokes, enabling passive opening. During actuation, the pin can still effectively control the sealing element through their proximity and force transmission, maintaining ease of operation while gaining adaptability.
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
The design ensures reliable operation over a long service life with reduced wear, precise fluid control, and the ability to open passively during suction, supporting both intake and delivery phases with minimal electrical control, while maintaining fluid flow integrity and tolerance stability.
Implementation Method 1
The actuator includes an electromagnet. The electromagnet includes a coil surrounding a pole core. The actuator also includes a magnet armature. The magnet armature can be moved by means of the electromagnet.
Data Source
Figure 1
AI summary
A valve comprises: a spring (101) with a spring force (Ff), an actuator (200) with an actuator force (Fa) which can act against the spring force (Ff), a pin (102) which can be actuated by means of the actuator (200), a sealing element (103) which can be coupled with the pin (102), and a seal seat (104) so that the valve is closed when the sealing element (103) rests against the seal seat (104). The pin (102) can be moved in the direction of the sealing element (103) by means of the actuator (200), and the pin (102) can be moved in the direction away from the sealing element (103) by means of the spring (101). The sealing element (103) can be moved into an open position independently of the pin (102), wherein a fluid flow through the valve is released in the open position.