Variable Hole Size Nozzle Fuel Injector for Emission Reduction
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Solution Overview
Problem
Internal combustion engines face challenges in reducing particulate matter emissions during low engine load conditions due to inefficient fuel dispersion and mixing, leading to incomplete combustion and increased NOx production, which complicates compliance with emissions regulations.
Innovation Solution
A fuel injector with a nozzle body featuring multiple rows of nozzle holes with varying diameters and angles, and a piston bowl design that redirects fuel for enhanced air-fuel mixing, allowing for tailored fuel injection strategies based on engine load conditions to improve combustion efficiency and reduce emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple rows of nozzle holes with varying diameters and angles are used, then fuel dispersion and mixing are improved, but device complexity increases
Solution Approach 1:
The nozzle is divided into multiple rows of holes (first row, second row, third row) with different characteristics. Each row is segmented to perform specific functions: the first row provides coarse fuel dispersion, while subsequent rows provide finer mixing. This segmentation allows the system to achieve improved combustion efficiency without requiring a single complex hole design.
Solution Approach 2:
Different rows of holes have different local qualities - varying diameters, angles, and positions are assigned to different rows based on their specific functions. The first row has larger diameter holes for initial fuel dispersion, while second and third rows have smaller holes for refined mixing. This local differentiation optimizes combustion efficiency while managing overall device complexity.
2Object-generated harmful factors
If higher injection pressure is used to reduce emissions, then particulate matter and NOx are reduced, but initial cost increases
Solution Approach 1:
The invention changes geometric parameters of the nozzle holes (diameter, angle, position) to optimize fuel spray characteristics. By carefully selecting hole diameters and angles in different rows, the system achieves improved fuel-air mixing and combustion efficiency that reduces emissions without requiring proportionally higher injection pressures, thereby controlling system cost.
Solution Approach 2:
The invention adds a spatial dimension to the solution by using multiple rows of holes at different positions and angles rather than simply increasing pressure. The multi-row configuration creates three-dimensional fuel dispersion patterns that enhance mixing efficiency, providing an alternative approach to emission reduction that doesn't solely depend on pressure increases.
3Device complexity
If uniform spray penetration is used with large diameter holes, then fuel injection is simplified, but combustion completeness deteriorates
Solution Approach 1:
The nozzle spray function is segmented into multiple rows with progressively smaller hole diameters. The first row provides initial fuel delivery, while subsequent rows progressively refine the spray penetration and mixing. This segmentation transforms a single large-hole design into a multi-stage system that achieves complete combustion while maintaining reasonable design simplicity.
Solution Approach 2:
Different local qualities (hole diameters, angles) are assigned to different rows to optimize combustion completeness. The first row uses larger holes for initial fuel delivery, while second and third rows use smaller holes for refined mixing and complete combustion. This local differentiation ensures combustion completeness without requiring all holes to be uniformly small and complex.
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 solution effectively reduces particulate matter emissions while maintaining engine performance and after-treatment system efficiency, enabling compliance with stringent emissions regulations by optimizing fuel dispersion and mixing under various engine loads.
Implementation Method 1
The nozzle holes of the upper row are configured to provide a plume of fuel that corresponds to a shape of a piston bowl
Implementation Method 2
a piston bowl design that redirects fuel for enhanced air-fuel mixing
Implementation Method 3
improve fuel dispersion in the combustion chamber to increase combustion efficiency
Data Source
AI summary
A fuel injector, comprising a nozzle body having a proximal end and a distal end, an upper row of nozzle holes being equally spaced about a first circumference of the nozzle body, and a lower row of nozzle holes located between the distal end and the upper row of nozzle holes, wherein the upper row has a first number of holes that is greater than a second number of holes in the lower row and wherein one of the first number of holes and the second number of holes is odd.