DE102007009963A1 - Fuel injector for use with magnetic valve, has magnetic head with sleeve body, where sleeve body has magnetic core and magnetic coil, and magnetic coil is electrically connected through connector pins - Google Patents

Abstract

Fuel injector has a magnetic head (10) with sleeve body (16), where sleeve body has magnetic core (26) and magnetic coil (28), and the magnetic coil is electrically connected through connector pins (42). The sleeve body is a deep drawn hot or cold transformed metallic component. The sleeve body has a circulating recess (30) at its exterior (18) for locking clamping bracket and has a tool insert.

Description

State of the art

DE 196 501 586 A1 refers to solenoid valve for controlling the fuel pressure in a control chamber in an injection valve such as a common rail injection system. About the fuel pressure in the control chamber, a stroke movement of a valve piston is controlled, with which an injection port of the injection valve is opened or closed. The solenoid valve comprises an electromagnet, a movable armature and a valve member which is moved with the armature and acted upon by a valve closing spring in the closing direction, which cooperates with the valve seat of the magnet valve and thus controls the fuel drain from a control chamber.

In known solenoid valves occurring in operation bouncing of the armature and / or the valve member has a very disadvantageous. By a ringing of the impinging on the valve seat anchor plate, the anchor plate takes an undefined position. Thus, in subsequent injections with the same control to different opening times of the solenoid valve and thus to a dispersion of the injection start and the injection quantity. According to the DE 196 50 586 A1 and one out DE 197 98 104 A1 known solution of the armature of the solenoid valve is designed as a two-part armature so as to reduce the moving mass of the unit armature valve member and thus the bouncing kinetic energy.

In Today's high-pressure injection systems, such as high-pressure accumulator injection systems (Common Rail) used solenoid valves, a magnetic head is so fixed on the injector body, that the magnet indirectly or supported directly on a shoulder in the injector body is. Optionally, a housing, which the Magnet positively includes, pressed against this shoulder become. The fixation is usually done with a magnetic clamping nut, which the magnet or a magnet enclosing Sleeve from above and on one on the injector body located external thread is screwed. The valve piece, on which the valve seat of the solenoid valve is formed is by means of a second Schraubverbandes inside the injector body pressed against a second shoulder. In operation, the valve piece from below with system pressure, d. H. in the high pressure reservoir (Common Rail) prevailing pressure level applied. As a result, that will Valve piece within his Schraubverbandes by some shifted upwards, causing the axial position of the valve seat relative to the injector body as a function of System pressure, d. H. the prevailing in high-pressure accumulator (common rail) Pressure changes.

Lies the upper stop for the solenoid valve is also inside the Schraubverbandes for fixing the valve piece, so Both the valve seat and the upper stroke stop will be under system pressure moved up and it comes to a system pressure-dependent Reduction of the previously elaborately set residual air gap. Around to maintain a minimum residual air gap even at maximum system pressure, becomes this pressure-dependent reduction of the residual air gap held in his attitude. This behavior leads However, in turn, that's actually available standing magnetic force can not be fully utilized. is the upper stop for the solenoid valve within the first screw for the magnetic head, it comes as a result of the displacement of the valve seat to one of the system pressure dependent reduction of the valve lift. This is special disadvantageous because the displacement of the valve seat in the valve lift adjustment must be kept and thus for stability the switching behavior desired, as low as possible Valve lift at medium and low pressures no longer is present.

Of the Structure of a solenoid valve assembly, d. H. of the solenoid valve in the fuel injector is similar in most embodiments. A twisted magnet sleeve takes a magnetic coil, the magnetic core and a drain spigot usually made as a rotated component on. The hydraulic seal on the inside is done by means of one or more O-rings. After assembling the items will be the assembly crimps and then done the assembly of the connector lugs for contacting the magnetic coil as well as a welding of the pins. After all an encapsulation of the received preassembled module takes place for forming the plug geometry and the outer geometry of the magnetic head. To cover several plug variants and around different outlet angles of connectors are to be a variety of extrusion dies, the different embodiments allow this final plastic injection, kept. In As a rule, a radial alignment of the connector lugs takes place the mounting of the magnetic head by means of a device before or when screwing a magnetic clamping nut. The current construction however, the magnet assembly is relatively expensive to manufacture afflicted. By crimping and plastic extrusion is a disassembly of a faulty magnet assembly no longer possible so that represents this committee. For some Embodiments of fuel injectors is the crimping process classified as very critical, as this has a very negative impact on may have the Hubdrift of the armature.

Presentation of the invention

According to the invention, a magnetic head for a solenoid valve assembly proposed, which is modular and has a clip-on plug contact. The radial alignment of the plug outlet can be adjusted infinitely variable. The male clip can be selected to realize different connector types and different angular outputs of the male contacts. Due to the modular design of the magnetic head with a clip-on connector, the process of flanging, the execution of a cohesive connection by welding the connector pins and the encapsulation of the magnetic head can be completely eliminated. The elimination of this work or assembly steps, a significant cost reduction can be achieved, the functionality of such a trained magnetic head of a solenoid valve assembly is maintained. In addition, can be achieved by the erfindungsgmäß proposed solution that eliminates the magnetic clamping nut. In one embodiment of the idea underlying the invention, the magnetic head housing is manufactured as a deep-drawn, hot or cold formed cup-shaped steel component, which includes a return pipe in its design. The pot-shaped component comprises an external thread, a disassembly favoring hexagon and two openings for the passage of the connector pins and finally a screwed-in groove for engaging retaining clips. Furthermore, a return pipe is formed on the pot-shaped component. During assembly, the magnetic coil is first inserted into the magnetic core and held in it by means of two molded plastic detents. An extended Drahtumspritzung ensures the centering or isolation of the pins to the housing. The support of the core is possible either by using a spacer sleeve, by gluing or by using a snap ring. A rubber seal or a rubber plate or the like insulates the magnetic core, or the magnetic coil to the injector body and takes over the sealing of the connector pins to the outside.

Of the clip-on connector clip is preferably made as an injection molded part and includes the inserted connector lugs. Show the connector flags on one side the plug geometry depending on the application purpose and on the other hand, the connector lugs are as resilient elements educated. As a result, you can clip on the position-oriented of the plug clip these resilient elements engage the connector pins and form a lasting connection with them, always with them a self-bias is guaranteed.

at the assembly takes place the screwing or assembly of the magnetic head on the already pre-assembled and populated Injector. The magnetic head can be, for example, by means of taken on this trained hexagon on a screw become. After performing the connection between the head and the injector body may have a high pressure tightness as well as a low pressure tightness test done as well a quantity measurement via a removable mounting adapter. Depending on the constructive design of the support of the magnetic core in the injector body can this completely be dismantled, which are carried out until after the wet test can, so no magnetic head assemblies are made as scrap become. After the high-pressure tightness test and before the Labeling by means of a laser can avoid the plug top be mounted by committee in the last assembly step. To hedge the electrical contact points connector pin / spring element leaves perform a simple current or resistance test. Alternatively, the magnetic head assembly may also be initially be completed completely and then in this form go through the wet test.

Brief description of the drawings

 Based In the drawings, the invention will be described below in more detail.

It shows:

1 a section through the inventively proposed magnetic head of a valve assembly,

2 an external view of the solenoid valve body receiving sleeve body,

3.1 to 3.3 different embodiments of the fixation of the magnetic core in the sleeve body,

4 a contacting possibility of the magnet coil accommodated in the magnetic core,

5.1 and 5.2 Representations of a arranged between the cap and sleeve body of the magnetic head sealing washer,

6 a representation of the area within which the sealing disc between Hül senkörper and cap is fixed,

7 an enlarged view of the connector pin area,

8th a top view of the plug connection,

9.1 and 9.2 Embodiments of the contact within the cap between the head of the connector pin and contact semicircles as shown 8th and

10.1 and 10.2 a plan view and a side view of the cap of the magnetic head.

embodiments

The representation according to 1 is a section through the inventively proposed magnetic head of a valve assembly refer.

1 shows a magnetic head 10 that with a cap 14 is covered. The magnetic head 10 includes the upper part of a sleeve body 16 , which is symmetrical to an axis 12 is constructed. The sleeve body 16 has an outside 18 and an inside 20 and is formed substantially cylindrical. In the cap 14 is a process 22 integrated, over which fuel from a the magnetic head 10 flowing back fuel injector in the low-pressure side return of the fuel injection system.

Between the bottom of the cap 14 and the top of the sleeve body 16 there is a sealing washer 24 , The sealing washer 24 has one in the cap 14 integrated process 22 aligned opening through which diverted control amount flows out of the fuel injector.

The sleeve body 16 encloses a magnetic core 26 , in turn, a magnetic coil 28 is embedded. The magnetic coil 28 is over plug pins 42 in a contact 44 inside the cap 14 contacted. For electrical contacting of the connector pins 42 at the contact 44 has the cap 14 a plug connection 46 on. The radial orientation of the plug connection 46 can be adjusted infinitely variable. The with the interposition of the sealing disc 24 on the top of the sleeve body 16 clipped cap 14 can be made as a selection group, under different, plug connections 46 as well as different outlets configured with regard to the angular position.

On the outside 18 of the sleeve body 16 There is a recess, for example, made as an annular groove 30 into which a hook 40 at least one in a joint 38 the cap 14 articulated clamp 54 is engaged. For manufacturing technology advantageously, the recess 30 as a recess on the outside 18 of the sleeve body 16 be made.

Furthermore, located on the outside 18 of the sleeve body 16 a gasket holder 32 , in which a, for example, as an O-ring manufactured sealing ring 34 can be admitted. The outside 18 of the sleeve body 16 also has a threaded spout 36 on.

The representation according to 1 In addition, it can be seen that a front side of the magnetic core 26 of the magnetic head 10 by reference numerals 48 is marked. With the front side 48 It aligns with the magnetic core 26 taken in magnet coil 28 , One end of the cap 14 , which of the sealing washer 24 assigns is by the reference numeral 50 identified. Between the example, designed as a groove-shaped recess recess 30 on the outside 18 of the sleeve body 16 and the gasket holder 32 , is a tool approach 52 on the sleeve body 16 formed, which may be designed, for example, a screw head like a hexagon or the like. An opening 56 in the sleeve body 16 serves to carry out the connector pins 42 through the cap 14 for electrical contacting of the magnetic core 26 enclosed magnetic coil 28 ,

At the in 1 illustrated sleeve body 16 it is a deep-drawn, hot or cold formed steel component into which the drain 22 is integrated. At the sleeve body 16 there is a thread 36 like the already mentioned tool approach 52 as well as the two openings 56 to carry out the connector pins 42 ,

The magnetic coil 28 gets into the magnetic core 26 inserted and can be held in this example, via one or more molded plastic catches. The plug pins 42 are surrounded by an encapsulation, over which the connector pins 42 opposite the sleeve body 16 on the one hand are isolated and centered on the other. The cap 14 is called z. B. manufactured as a plastic injection molded part and includes inserted connector flags. The connector lugs have the plug geometry on one side and a spring element on the other side. As a result, in the position-sensitive clipping of the cap 14 on the gasket 24 and fixing the cap 14 with the at least one clamp 54 a permanent connection to the contacts 44 be achieved. The resilient elements of the contacts 44 snap on the connector pins 42 and form there a permanent connection, whereby always a self-bias is maintained.

2 shows the in 1 sectioned sleeve body.

Out 2 it turns out that the recess 30 continuous on the outside 18 of the sleeve body 16 runs. Below the recess 30 on the outside of the sleeve body 16 extends the tool approach 52 , under which in turn a gasket holder 32 located. Below the gasket holder 32 is a part of the thread 36 shown.

In the 3.1 to 3.3 embodiments of the fixation of the magnetic core can be seen in the sleeve body.

3.1 shows that according to this embodiment, the magnetic coil 28 enclosing magnetic core 26 through an adhesive layer 60 on the inside 20 of the sleeve body 16 is attached. The adhesive layer 60 extends between the upper end side of the magnetic core 26 and an inside 62 the lid of the sleeve body 16 , In the magnetic core 26 there are cavities, in which on the one hand the magnetic coil 28 and on the other hand, the connector pins 42 are included. These are aligned in the assembled state with the front side 48 of the magnetic core 26 ,

In addition to the as in 3.1 illustrated embodiment of a fixation of the magnetic core 26 over the adhesive layer 60 , can - as in 3.2 represented - the magnetic core 26 also by means of one in the inside 20 in a groove 68 taken in retaining ring 64 be fixed. The retaining ring 64 points in relation to the inside 20 of the sleeve body 16 a supernatant 66 on. About the supernatant 66 depending on the depth of the groove 68 as well as the depth of the Haltringes 64 is, the magnetic core can 26 just in the sleeve body 16 be clipped. Analogous to in 3.1 illustrated embodiment is located in the magnetic core 26 Cavities for the connector pins 42 or for the magnetic core 26 enclosed magnetic coil 28 , The magnetic core 26 is symmetrical to the axis 12 executed and over the retaining ring 64 to the inside 62 on the lid of the sleeve body 16 hired.

3.3 shows that the magnetic core 26 from a support sleeve 70 is supported. The support sleeve 70 is formed substantially as an annular member and includes a first annular surface 72 and a second annular surface 74 , While the second ring surface 74 for example, supported on the injector body, supports the first annular surface 72 the support sleeve 70 the front side 48 of the magnetic core 26 from. Through the support sleeve 70 and the contact between the first ring surface 72 and the front side 48 of the magnetic core 26 this is on the inside 62 the lid of the sleeve body 16 hired.

For all in the 3.1 . 3.2 , and 3.3 illustrated embodiments, that the magnetic core 26 symmetrical to the axis 12 is formed and cavities for receiving the magnetic coil 28 and for receiving the magnetic coil 28 electrically contacting plug pins 42 having.

4 shows a detailed representation of the contacting of the magnetic coil.

Out 4 it turns out that the magnet coil 28 from the magnetic core 26 is enclosed and the lower end face of the solenoid 28 with the front side 48 of the magnetic core 26 flees. The solenoid 28 electrically contacting connector pin 42 is from an insulation sleeve 76 enclosed. The insulation sleeve 76 encloses the connector pin 42 in an axial length which is the thickness of the material of the sleeve body 16 and about half the thickness of the magnetic core 26 equivalent. The plug pins 42 and the enclosing this insulating sleeve 76 extend through the opening 56 in the lid of the sleeve body 16 as well as through the top of the sleeve body 16 applied sealing washer 24 ,

The connector pin 42 has a groove 78 on, so that when contacting the connector pins 42 at the contact 44 through the cap 14 a snap closure is formed. The groove 78 at the connector pin 42 creates on the one hand a secure contact and on the other hand one by the arrow 80 indicated holding force 80 that can be used to prevent that from the magnetic core 26 enclosed magnetic coil 28 their installation position in the sleeve body 16 leaves. Moreover, due to the undercut between the solenoid coil 28 and the magnetic core 26 achieved that when electrical contacting the connector pins 42 not just the magnetic coil 28 but also the magnetic core 26 in the sleeve body 16 secured in its installed position.

The 5.1 and 5.2 show the sealing disc, which is arranged in the magnetic head between the cap and the sleeve body.

The representation according to 5.1 is removable, that the sealing disc 24 a central opening 82 that with the integrated flow 22 the cap 14 , compare 1 flees. In the material of the sealing disc 24 is one of the number of connector pins 42 corresponding number of openings 84 formed, through which the connector pins 42 extend.

Out 5.2 is a sectional view through the in 5.1 shown in plan view sealing washer.

The sealing washer 24 is symmetrical to the axis 12 formed and forms on the one hand a seal between the cap 14 and the lid of the sleeve body 16 on the other hand, a seal between the cap 14 and the opening 56 in the sleeve body 16 with regard to the control amount and further a seal at the point of passage of the connector pins 42 through the opening 56 in the sleeve body 16 , The sealing washer 24 is preferably made of a material such. B. Viton ago posed.

6 shows a representation of the area within which the sealing disc between the sleeve body and the cap is fixed.

6 is removable, that on the front side 50 the preferably produced as a plastic injection molded cover cap 14 a ribbing or gearing 86 or the like is formed. This grips the edge region of the disk-shaped sealing disc 24 and pulls them when mounting the cap 14 on the gasket 24 in the radial direction downwards, so that the sealing disc 24 to the ceiling of the substantially cylindrical sleeve body 16 snugly. After moving in the radial direction over the ribbing or gearing 86 taking place tensioning of the sealing disc 24 becomes the cap 14 about the in 1 illustrated clamp 54 fixed.

The outside 18 of the sleeve body 16 is thus in the roof area of the substantially cylindrical sleeve body 16 sealed. The inside of the sleeve body 16 is by reference numerals 20 indicated.

7 shows an enlarged view of the Steckerpinbereiches and its seal against the external environment.

From the illustration according to 7 shows that the connector pin 42 over which the magnetic coil 28 is contacted by the insulation sleeve 76 is enclosed. In the in 7 illustrated embodiment, the insulating sleeve 76 between the solenoid 28 and an area 88 at the front 50 the cap 14 clamped. At the front 50 the cap 14 , which is preferably produced as a plastic injection molded component, there is the nose-shaped configured ring 88 , which the upper end face of the insulation sleeve 76 contacted the circumference of the connector pin 42 encloses. The insulation sleeve 76 as well as the enclosed by this connector pin 42 extends through the sealing washer 24 , compare 5.1 and 5.2 ,

Also in the in 7 illustrated embodiment, the connector pin comprises 42 the groove 78 with which - as in connection with 4 shown - a holding force 80 , as in 4 drawn, is generated. About this groove 78 at the connector pin 42 can directly the magnetic coil 28 in their position within the sleeve body 16 be secured and indirectly by the solenoid 28 embraced magnetic core 26 ,

8th shows the top view of the plug connection of the magnetic head proposed according to the invention.

8th shows that the cap 14 in the area of the plug connection 46 the two contacts 44 (See also illustration according to 1 ). From the illustration according to 8th shows that the two contacts 44 each contact semi-circles 94 have, which the connector pins 42 to contact. Due to the fact that the contact semicircles 94 the heads of the connector pins 42 enclose over an angular range of about 180 °, it is possible to adjust the connector outlet so that this rotation angle 90 swept by at least 170 ° and thus can be placed in different angular positions. The two contact semicircles 94 are in the cap 14 through a gap 92 interrupted. reference numeral 90 denotes the angle of rotation, which in the illustration according to 8th about 170 °.

The 9.1 and 9.2 Embodiments of the contact within the cap between the head of the connector pin and the contact semicircles - as in 8th shown - to take.

9.1 shows a variant of the contact semi-circle 94 in which a contact point 98 on the circumference of the connector pin 42 lies. In this embodiment, the contact half-circle encloses 94 the head of the connector pin 42 and projects laterally into the groove-shaped recess with its open leg end 78 at the connector pin 42 into it. From the illustration according to 9.2 , it appears that the contacting shown there 44 at least one contact semi-circle 94 having. In contrast to the variant in 9.1 shows the in 9.2 illustrated embodiment of the contact 44 a contact half circle 94 that a rejuvenation 96 having. Through this rejuvenation 96 on the outer circumference of the contact half-circle 94 arises inside the contacting 44 , ie contact semicircle 94 an accumulation of material according to 9.2 in the groove 78 at the connector pin 42 protrudes. In this way, the connector pin 42 positive fit with the contact semi-circle 94 connected, wherein in the groove-shaped recess 78 in the head area of the connector pin 42 at least one contact point 98 is formed.

Through the two in the 9.1 and 9.2 illustrated embodiments of the contact 44 Make sure that on the connector pins 42 with groove-shaped recess 78 which in connection with 4 illustrated holding force 80 acts, which prevents magnetic coil 28 complete with magnetic core 26 from its installed position within the sleeve body 16 fall out.

The 10.1 and 10.2 show top or side views of the cap.

From the illustration according to 10.1 going apparent that the cap 14 a top 104 having. On the top 104 are single dome-shaped joints 38 educated. Each of the joints 38 has a recording 102 on, in the axes of rotation 100 the clamp 54 are inserted. With reference number 46 is the lateral plug connection of the cap 14 designated. From the illustration according to 10.1 can be further seen that in this embodiment on the clip with the sleeve body 16 connectable cap 14 two clamps 54 are provided.

10.2 shows that the clamp 54 at one end the axis of rotation 100 and at the other end already in 1 illustrated hooks 40 , The hook 40 engages in the clipped state of the cap 14 into the recess 30 on the outside 18 of the sleeve body 16 one. The rotation axis 100 turn is in the recording 102 the dome-shaped joints 38 at the top 104 the cap 14 plugged in. Depending on the clamping force height and the required sealing effect, the elasticity of the legs of the clamp can 54 adjusted the spring preload and thus the holding force can be adjusted.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 196501586 A1 [0001]
• - DE 19650586 A1 [0002]
• DE 19798104 A1 [0002]

Claims (12)

Fuel injector with a magnetic valve, which has a magnetic head ( 10 ) with a sleeve body ( 16 ), in which a magnetic core ( 26 ) and a magnetic coil ( 28 ) and the magnetic coil ( 28 ) via plug pins ( 42 ) is electrically contacted, characterized in that the electrical contacting of the magnetic coil ( 28 ) via a rotatably arranged cap ( 14 ) carried out on the sleeve body ( 16 ) is clipped. Fuel injector according to claim 1, characterized in that the sleeve body ( 16 ) is a deep-drawn, hot or cold formed metallic component. Fuel injector according to claim 1, characterized in that the sleeve body ( 16 ) on its outside ( 18 ) a circumferential recess ( 30 ) for latching clamps ( 40 . 54 ) as well as a tool approach ( 52 ) having. Fuel injector according to claim 1, characterized in that between a front side ( 50 ) of the cap ( 14 ) and the sleeve body ( 16 ) a sealing washer ( 24 ) is arranged. Fuel injector according to claim 1, characterized in that the sealing disc ( 24 ) on its outer periphery by one on the front side ( 50 ) of the cap ( 14 ) formed gearing or ribbing ( 86 ) is biased. Fuel injector according to claim 1, characterized in that the cap ( 14 ) a lateral plug connection ( 46 ), which with contacts ( 40 ), in which heads of the connector pins ( 42 ) for electrically contacting the magnetic coil ( 28 protrude). Fuel injector according to one or more of the preceding claims, characterized in that the cap ( 14 ) is manufactured as an injection-molded component, in particular as a plastic injection-molded component. Fuel injector according to one or more of the preceding claims, characterized in that the cap ( 14 ) an upper side ( 104 ), on the dome-shaped joints ( 38 ) are arranged, each having at least one receptacle ( 102 ) for at least one clamp ( 54 ) exhibit. Fuel injector according to claim 1, characterized in that the magnetic coil ( 28 ) surrounding magnetic core ( 26 ) by means of an adhesive layer ( 60 ) in the sleeve body ( 16 ), via a retaining ring ( 60 ) in the sleeve body ( 16 ) or via a support sleeve ( 70 ) in the sleeve body ( 16 ) is supported. Fuel injector according to one or more of the preceding claims, characterized in that the plug pins ( 42 ) in its head region at least one annular recess ( 78 ) for making an electrical contact ( 98 ) at a contacting ( 44 ) and over their axial extent of an insulating sleeve ( 76 ) are enclosed. Fuel injector according to claim 10, characterized in that in the end face ( 50 ) of the cap ( 14 ) a ring ( 88 ) is formed, which the insulating sleeve ( 76 ), the openings ( 56 ) in the sleeve body ( 16 ) as well as openings ( 84 ) in the sealing disc ( 24 ), seals. Fuel injector according to one or more of the preceding claims, characterized in that the cap ( 14 ) a preformed, integrated return ( 22 ) and in the cap ( 14 ) formed contacts ( 44 ) as contact semicircles ( 94 ) are formed, which a rotation of the cap ( 14 ) relative to the heads of the connector pins ( 42 ) in a rotation angle ( 90 ) enable.