EP2557306A1 - Fuel pump - Google Patents
Fuel pump Download PDFInfo
- Publication number
- EP2557306A1 EP2557306A1 EP11176843A EP11176843A EP2557306A1 EP 2557306 A1 EP2557306 A1 EP 2557306A1 EP 11176843 A EP11176843 A EP 11176843A EP 11176843 A EP11176843 A EP 11176843A EP 2557306 A1 EP2557306 A1 EP 2557306A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fuel
- frame
- pump
- casing
- fuel pump
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M59/00—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps
- F02M59/02—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps of reciprocating-piston or reciprocating-cylinder type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M59/00—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps
- F02M59/44—Details, components parts, or accessories not provided for in, or of interest apart from, the apparatus of groups F02M59/02 - F02M59/42; Pumps having transducers, e.g. to measure displacement of pump rack or piston
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
- F04B1/04—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
- F04B1/04—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement
- F04B1/0404—Details or component parts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
- F04B1/04—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement
- F04B1/0404—Details or component parts
- F04B1/0426—Arrangements for pressing the pistons against the actuated cam; Arrangements for connecting the pistons to the actuated cam
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B35/00—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
- F04B35/002—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for driven by internal combustion engines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
- F04B53/16—Casings; Cylinders; Cylinder liners or heads; Fluid connections
Definitions
- the present invention relates to the field of fuel pumps.
- the invention relates to a high-pressure fuel pump for supply of high-pressure fuel to a fuel injector. More specifically, but not exclusively, the present invention relates to a housing for such a pump.
- Fuel injection systems for modern internal combustion engines comprise a plurality of fuel injectors arranged to deliver an atomised spray of fuel to a respective combustion chamber for combustion.
- Known high-pressure pumps utilise a pumping element such as a steel plunger that reciprocates inside a close-fitting guide-bore, the plunger being driven by a driveshaft. Hence, as the driveshaft rotates, its rotational force is transferred to the plunger so that the plunger reciprocates within the guide bore.
- Fuel enters a pumping chamber at an end of the guide bore and is then pressurised as the reciprocating plunger applies a pressurising force to the pumping chamber. The fuel is then forced through a delivery valve into a high-pressure rail ready for injection by the fuel injectors.
- the components of the pump are supported by the housing.
- high-pressure fuel pump housings It is common to manufacture high-pressure fuel pump housings from cast steel to provide the strength required to withstand the stresses to which high-pressure fuel pumps are subjected. As pumps capable of producing higher pressure fuel have been developed, the thickness of the steel housing has also increased to withstand the relative increases in stress.
- Embodiments of the present invention therefore aim to at least partially mitigate one or more of the above-mentioned problems.
- a fuel pump for pressurising fuel in a high-pressure fuel injection system.
- the fuel pump comprises a pump head having a pumping chamber that is arranged to receive fuel to be pressurised.
- the fuel pump also includes a pumping element arranged to reciprocate responsive to movement of a driving element.
- the pumping element defines, in part, the pumping chamber so that, in use, as the pumping element reciprocates, a force, transferred from the driving element, is applied to the fuel within the pumping chamber to pressurise the fuel.
- the fuel pump also comprises a frame arranged to support the driving element and a casing which defines an internal volume for containing fluid. At least a part of the frame, at least a part of the drive element, and at least a part of the pumping element are received in the casing. This arrangement therefore provides a lighter, smaller pump.
- the frame and the casing together provide a housing for the pump.
- the frame may be arranged to hold the pump head and driving element in fixed positions relative to one another. Such an arrangement allows for correct operation of the fuel pump. In particular, a large force is transferred from the driving element to the pump head in order to pressurise fuel within the pump head to a very high pressure. The frame therefore needs to withstand such forces and keep the pump head and driving element in fixed positions relative to one another so that the pump continues to operate correctly.
- the frame may be constructed from a material having higher strength than a material from which the casing is constructed.
- the frame is provided to support the pump head and driving element, while the casing is provided for containing fluid. Hence, only the frame has to withstand the high forces transferred from the driving element to the pump head.
- the casing can therefore be made from a material of lower strength than the frame because it only has to contain fluid.
- the frame and casing can be made from the same material and the frame can be made thicker than the casing to provide the higher strength.
- the frame is made from aluminium because aluminium is relatively strong compared to other materials while being relatively low density compared to other materials.
- the materials for the frame and casing may be selected so that they are optimised for their specific function.
- the material for the frame may be selected so that it is of a sufficiently high strength for supporting the forces transferred from the driving element to the pump head.
- the material for the casing may be selected for containing fluid.
- the frame may be formed of a single piece. Forming the frame from a single piece allows for the frame to be stronger because it does not have any joins, which can lead to structural weaknesses. Furthermore, the frame may be formed of a single piece by means of an extrusion process. Such an extrusion process provides an easy means for manufacturing a frame in a single piece. Furthermore, such an extrusion process allows for additional features, such as screw holes, to be easily formed within the frame.
- the casing may be formed of a plastics-based material. Such an arrangement results in a light-weight and easy to manufacture casing.
- the frame may be arranged for mounting the fuel pump to an engine component.
- the frame supports the high-stress components of the fuel pump. It is therefore desirable to mount the fuel pump via the high-strength fuel pump frame.
- the fuel pump may further comprise a mounting arrangement for connecting the frame of the fuel pump to the engine component.
- the mounting arrangement provides a means for providing a strong connection between the frame and the engine component.
- the housing and the mounting arrangement may each comprise a complementary interference feature arranged for preventing rotation of the mounting arrangement with respect to the housing.
- One of the complementary interference features may comprise a protrusion and the other complementary interference feature may comprise a recess.
- Such interlocking interference features provide a strong connection between the frame and the mounting arrangement.
- the casing may comprise one or more integrated components.
- the one or more integrated components may include a back-leak device to aid recirculation of fluid.
- the one or more integrated components may include a fuel inlet to deliver fuel to the fuel pump.
- the one or more integrated components may include both the back-leak device and the fuel inlet. Providing these components integrated within the housing provides a smaller and easier to manufacture fuel pump.
- the driving element may be formed from a plurality of parts including a shaft portion and a cam portion. Such an arrangement is advantageous when using a frame formed of a single piece.
- the cam portion may be constructed from a higher strength material than the shaft portion. This is because the cam portion bears the majority of the load which is transferred to the pump head for pressurising the fuel. Such an arrangement provides a cheaper to manufacture driving element because only the expensive strong material is utilised for the part requiring a strong material.
- the pump head may be received within the casing. Including the pump head within the casing improves cooling of the pump head.
- Embodiments of the invention provide a high pressure fuel pump which is of lighter weight than currently known pumps.
- a high strength frame is provided to bear the pumping loads by supporting the high stress portions of the pump, such as the cam arrangement and the pump head, and a lightweight casing is then provided to seal the pump to prevent leakage of fuel from the pump.
- Embodiments of the invention provide a high pressure fuel pump that is smaller than known fuel pumps. Such embodiments utilise a support frame and lightweight casing.
- the casing can be relatively thin, and as such, the overall thickness of the housing is reduced because only a strong frame support is provided, rather than a strong housing that encases the whole pump.
- Embodiments of the invention reduce the cost and time for prototyping new pumps.
- the frame can be extruded from metal and a plastic moulded shell can be utilised to construct the casing.
- Such techniques do not require the slow and expensive provisions required to construct a cast steel housing.
- FIGS. 1 and 2 provide two alternative views of a pump 1 provided in accordance with a first embodiment of the present invention.
- the pump 1 shall initially be described primarily in respect of its operation.
- Low-pressure fuel enters the pump 1 through a fuel inlet 2, which is integrated into a casing 3 of the pump 1.
- the fuel then passes through an inlet metering valve (IMV) 4a of an IMV arrangement 4 mounted on the casing 3, which controls the rate of flow of fuel into the pump 1.
- the casing 3 forms part of a pump housing and defines an internal cavity 5 in which pumping and driving components of the pump 1 are arranged, the internal cavity 5 being filled with fuel.
- the IMV arrangement 4 is partially arranged between the fuel inlet 2 and the internal cavity 5; fuel therefore passes from the fuel inlet 2 through the IMV 4a and into the internal cavity 5.
- the fuel within the internal cavity 5 acts as a lubricant to the moving parts of the fuel pump 1, and it also acts to cool components of the pump 1 by absorbing heat generated in the pumping process so that the heat is transferred away from the pumping components of the pump 1.
- a back-leak device 6 such as a venturi device is provided to allow fuel to be drawn from internal cavity 5 and returned to a low pressure drain or engine cam box, so that the fuel is recirculated.
- the back-leak device 6 therefore aids the recirculation of fuel so that the heat generated by the pumping components is transferred away from the fuel pump 1.
- the pumping components include a pump head 7, a pumping element in the form of a plunger 8 and a drive arrangement comprising a follower arrangement 9 and a driveshaft or cam arrangement 10.
- the pumping process takes place within the pump head 7.
- the pump head is therefore made of a strong material, such as hardened steel, in order to withstand the high-pressure fuel which is pressurised within a pumping chamber 7a of the pump head 7, in addition to the large forces applied to the pump head 7 by the pumping element 8 in order to pressurise the fuel.
- the pumping chamber 7a of the pump head 7 is arranged at one end of a plunger bore 7b provided in the pump head 7 and is a cavity comprising a low-pressure fuel inlet (not shown) for receiving fuel from the internal cavity 5 defined by the casing 3, and a high-pressure fuel outlet (not shown) in the form of an outlet valve.
- the pumping chamber 7a is defined in part by a pumping head at a first end of the plunger 8.
- the plunger 8 is arranged to reciprocate so that a pumping head of the plunger increases and decreases the volume of the pumping chamber 7a. As the volume of the pumping chamber decreases, the pressure of fuel within the pumping chamber 7a increases.
- the outlet valve opens allowing the high-pressure fuel to pass through into a high-pressure rail (not shown) where the fuel is stored ready for injection by one or more fuel injectors (not shown).
- the follower arrangement 9 is arranged to cooperate with the cam arrangement 10 to transform a rotational movement of the cam arrangement 10 into the reciprocal movement of the plunger 8 within the plunger bore 7b.
- the cam arrangement 10 is provided with a shaft portion 10a located at least partially outside the casing 3 of the pump 1 to engage with a drive source (not shown), such as a drive gear.
- the cam arrangement 10 rotates responsive to the input force provided by the drive gear.
- the shaft portion 10a of the cam arrangement 10 is also located in part within the internal cavity 5 of the casing 3, and has a cam portion 10b connected on the shaft 10a at a portion within the internal cavity 5.
- the follower arrangement 9 comprises a roller 9a which abuts the cam 10b so that the roller 9a and cam 10b are communicatively coupled.
- the roller 9a is held within a roller shoe 9b connected to the second end of the plunger 8.
- the arrangement of the roller 9a and roller shoe 9b limits the transfer of lateral movement from the cam 10b to the plunger 8, while transferring reciprocal movement of the cam 10b to the plunger 8.
- a spring 11 is maintained in position between the pump head 7 and a spring seat 8a mounted on the plunger 8, in order to urge the plunger 8, and the roller shoe 9b connected thereto, into contact with the cam 10b. Due to the spring 11, the follower arrangement 9 continually follows the reciprocating movement of the cam 10b.
- the follower arrangement 9 also includes a shoe guide 9c, which is provided around the peripheral surface of the roller shoe 9b in order to guide the movement of the roller shoe 9b.
- the guide 9c therefore allows the roller shoe 9b to move along the axis of the plunger 8, allowing reciprocating movement, but restricting lateral movement, of the guide shoe 9c.
- the rotation of the cam arrangement 10 exerts a lateral force on the follower arrangement 9 and as such the shoe guide 9c is constructed of a strong material in order to resist such lateral movement and to withstand the stress associated with such resistance.
- the pump housing includes a frame 12 in addition to the casing 3.
- the frame 12 is provided to support various pumping and driving components, in particular, the pumping components 7, 9, 10 that are subjected to high levels of stress due to the pumping process.
- the frame 12 is arranged to support the pump head 7, the roller shoe 9, and the shaft 10a of the cam arrangement 10.
- the frame 12 is therefore made of a relatively strong material, such as aluminium, in order to withstand the high levels of stress within the pump 1, particularly due to the forces being transferred from the cam arrangement 10 to the plunger 8 and then into the fuel within the pump head 7.
- bushes 13a, 13b are provided at the portions of the frame 12 that support the cam arrangement 10.
- a mounting arrangement 14 is provided with a mounting plate 14a external to the casing 3 which connect the pump 1 to the engine.
- the mounting arrangement 14 connects to the frame 12 through the casing 3 in order to provide a solid support for the frame 12 and therefore the pump 1. Since the frame 12 and mounting arrangement 14 are connected through the casing 3, the mounting arrangement 14 includes a plurality of seals 14b, 14c in order to prevent leakage of fuel through the casing 3.
- the frame 12 is provided with two cam support sections 12a, 12b, which each define a hole 12c, 12d through which the cam arrangement 10 (shown in Figures 1 and 2 ) can be supported, wherein the cam 10b is located between the two cam support sections 12a, 12b.
- the holes 12c, 12d defined by the cam support sections 12a, 12b respectively are shaped so as to complement the external surface of the shaft 10a of the cam arrangement 10.
- the holes 12c, 12d are circular to complement the cylindrical shape of the shaft 10a of the cam arrangement 10. As such, smooth rotation of the cam arrangement 10 is possible.
- the dimensions of the frame 12 are arranged so that within the holes 12c, 12d defined by each cam support section 12a, 12b one of the bushes 13a, 13b can be placed in order to aid rotation of the shaft 10a of the cam arrangement 10.
- the fuel in the internal cavity 5 defined by the internal walls of the casing 3 helps to lubricate the frame 12 and bushes 13a, 13b in order to aid smooth rotation of the shaft 10a of the cam arrangement 10 and minimise wear.
- the cam support sections 12a, 12b bear the majority of the weight and stress of the cam arrangement 10. However, the mounting arrangement 14 bears a portion of the load applied to the cam support section 12a which is adjacent to the mounting arrangement 14.
- the frame 12 is also provided with a pump head support section 12e.
- This section 12e has a hole 12f for receiving the pump head 7.
- a front face of the pump head 7 protrudes, at least partially, through this hole 12f.
- the front face of the pump head 7 includes a recess defining, in part, the pumping chamber 7a into which the pumping head of the plunger 8 is inserted to thereby define the pumping chamber 7a.
- a plurality of screw holes 12g are provided in the pump head support section 12e of the frame 12 through which screws (not shown) can connect the pump head 7 to the frame 12.
- a strong clamping of the pump head 7 to the frame 12 is required in order to prevent the pump head 7 from being separated from the frame 12 when the plunger 8 drives into the pump head 7, in such a way that a force is provided that urges the pump head 7 away from the frame 12.
- the frame 12 could be arranged to provide at least one support member (not shown) that abuts a rear face of the pump head so that connection screws are not relied upon for holding the pump head 7 onto the frame 12.
- the frame 12 is also provided with shoe-guide support sections 12h (only one shown), which includes a plurality of struts (not shown) that support the shoe-guide 9c.
- the cam support sections 12a, 12b, pump head support section 12e and the shoe-guide support sections 12h are joined together by the main structure of the frame 12. Structural rigidity is required between these sections 12a, 12b, 12e, 12h, and in particular the cam support sections 12a, 12b and the pump head support section 12e because the pressurisation of the fuel is achieved by the relative movement of the plunger 8, driven by the cam arrangement 10, into the pump head 7. Hence, the position of the pump head 7 with respect to the cam arrangement 10 needs to remain constant in order to allow for correct operation of the pump 1.
- Holes or cut-outs 12i are provided within the main body of the frame 12 in order to reduce the weight of the frame 12 without reducing the relative strength of the frame 12 so that the frame 12 is able to provide strong support to the components of the pump subjected to high levels of stress.
- cam support sections 12a, 12b, pump head support section 12e and the shoe-guide support sections 12h are supported by the main body of the frame 12 in this embodiment of the invention
- strut supports could be provided between each of the sections of the frame 12 in order to link the sections together.
- Use of strut supports between the sections of the frame 12 could help to further reduce the weight of the frame 12, and in certain arrangements allow for a reduction in the size of the frame 12.
- the frame 12 is also provided with attachment holes 12j, 12k, 12l, 12m for connecting the pump 1, via the frame 12, to the mounting arrangement 14.
- the holes 12j, 12k, 12l, 12m and their relationship to the mounting arrangement 14 shall be discussed when the mounting arrangement 14 is described in detail with respect to Figures 5 and 6 .
- the frame 12 is made by extruding an aluminium bar.
- the extrusion process is fast and cheap to perform.
- the frame 12 can be formed of one part. That is, it is extruded from a single bar of metal and as such no parts have to be joined.
- casting processes require two or more parts to be cast, which are then joined together. There is a risk of structural weaknesses forming at the joins between these parts.
- the extrusion process overcomes these problems.
- the frame 12 is extruded, the amount of cutting and drilling of the frame is minimised.
- the extrusion process allows for certain characteristics of the frame 12, such as holes, to be formed in the frame 12 during the extrusion process.
- casting techniques require all characteristics to be added after the casting, therefore leading to further structural weaknesses.
- the frame 12 is described as being made of aluminium, any suitably strong material could be utilised.
- any suitable metal could be used or other materials like a composite plastic or composite plastic encapsulated in sintered metal. It is noted that while an extrusion process is preferable for constructing the frame 12, other construction processes such as casting could be utilised.
- the casing 3, which defines the internal cavity 5, is arranged to enclose the frame 12 and the pumping and driving components that the frame 12 supports.
- the pumping and driving components are at least partially arranged within the internal cavity defined by the frame 12.
- the casing 3 therefore provides a fluid tight shell around the pumping components so that fuel does not leak from the internal cavity.
- casing 3 is shown to enclose all pumping and driving components of the pump 1 it will be appreciated that the casing 3 is arranged to define an internal cavity containing fuel for cooling and lubrication purposes.
- the moving driving and pumping parts of the pump 1, such as the plunger 8, follower arrangement 9, and cam arrangement 10 therefore require such lubrication and cooling.
- the casing could be provided so that it joins a peripheral surface of the pump head 7 or the front face of the pump head 7.
- the front face of the pump head 7 would be in fluid communication with the fuel within the internal cavity 5, and at least part of the side portion and the whole of the rear portion of the pump head 7 would be external to the casing 3. It is noted that due to the constant flow of fuel through the pump head, the heat created within the pump is, at least in part, transferred away by the pressurised fuel, and therefore cooling of the pump head is not as important as cooling of the moving components of pumping process.
- the casing 3 is formed of two parts 3a, 3b, as shown in Figure 2 .
- the parts 3a, 3b are arranged to fit around the components attached to and within the frame 12.
- the two parts 3a, 3b of the plastic casing can then be joined together so that the two-part casing 3 seals fluid within.
- the two parts can be joined by any method capable of providing a fluid tight bond.
- Figure 4 shows one half 3a of the casing 3.
- the casing 3 has a plurality of internal supporting struts 3s.
- the supporting struts 3s stiffen the casing 3 to improve the strength of the casing 3. As such it is possible to have a thinner casing 3, while still providing sufficient strength.
- the struts 3s could also be provided to abut the outer surface of the frame 12 so that the casing 3 is tightly formed around the frame 12.
- the frame 12 is only joined to the casing 3 via the mounting arrangement 14.
- the casing 3 could be connected to the frame 12 in various ways, such as by utilisation of one or more connection screws having suitable sealing to prevent leakage from the casing 3.
- the two casing parts 3a, 3b are formed from plastic using an injection moulding technique. As such, high-frequency welding would provide a suitable bond between the two parts 3a, 3b.
- other materials such as a metal could be used for the casing 3.
- an aluminium frame 12 and casing 3 could be provided. Since the casing 3 only needs to provide fluid tightness it could be made much thinner than the frame 12.
- a metal casing 3 could be made much thinner than a plastic casing 3. Due to its conductive properties, a metal casing 3 would also assist in transferring heat away from the fuel within the internal cavity.
- the internal cavity 5 defined by the casing 3 is filled with fuel
- other fluid could be provided within the internal cavity 5.
- specific cooling/lubrication fluid could be contained in the internal cavity.
- the IMV arrangement 4 would connect directly, or via a contained channel, from the fuel inlet 2 to the pump head 7.
- a cooling fluid inlet (not shown) could be provided, and the back-leak device 6 would help to recirculate the cooling fluid.
- the casing 3 also defines various features of the fuel pump 1, as discussed below.
- the casing 3 includes an IMV connection portion 3b, which is arranged to enable the shell of the IMV arrangement 4 to be connected to the pump 1.
- the IMV connection portion 3b defines a hole 3c in which a portion of the IMV arrangement 4 can be positioned, so that the IMV 4a can connect to the fuel inlet 2.
- One or more connection holes 3d can be provided within the casing 3 to enable the IMV arrangement 4 to be attached to the casing so that the IMV arrangement 4 is held in place on the pump 1.
- the casing 3 also provides an integrated back-leak device 6, and an integrated fuel inlet 2. Integrating these components into the casing 3 is advantageous when the casing 3 is constructed from plastic using an injection moulding method because the components are formed as part of the casing 3 in the moulding process. Furthermore, integrating these components within the casing 3 simplifies the overall manufacturing process of the fuel pump 1 and reduces the size of the fuel pump 1.
- the housing which includes the frame 12 and the casing 3, is much smaller than known housings. This is because the minimum structural support required can be provided by the frame 12, and then a comparatively thin and light casing 3 can be provided to provide a fluid-tight seal for the pump 1. Overall, this allows for the overall size of the housing and therefore the pump 1 to be reduced. In addition, the materials used for the frame 12 and casing 3 can be selected so as to best suit their respective functions, which allows for the weight of the housing and the therefore pump 1 to be reduced.
- a further advantage of such a housing construction is that it is possible to place the IMV arrangement 4 much closer to the pump head 7 than is possible in a fuel pump that utilises a cast steel housing. This is because the frame 12 can be provided only in those portions that require support, and the casing 3 can be arranged to closely surround this frame 12, enabling the IMV arrangement 4 to be positioned close to the pump head 7. As such, the overall pump head 7 can be reduced further.
- the frame 12 has been described as being arranged within the casing 3 above, it will be appreciated that the frame 12 could be provided so that it is only partially within the casing 3.
- the main structure of the frame 12 could be provided outside the casing 3 with support arms extending through the casing 3 to support the high stress components of the pump 1.
- the mounting arrangement 14 can be easily connected to the frame 12, or even be formed integrally with the frame 12.
- the mounting arrangement 14 comprises a mounting plate 14a, which is arranged to connect to a component of the engine to secure and stabilise the pump 1.
- the mounting plate 14 is a substantially planar structure with a plurality of holes or cutaways to reduce the weight of the plate 14a.
- the mounting plate 14a is provided with a plurality of screw holes 14d, 14e, 14f for screws (not shown) to connect the mounting plate to the engine.
- Further screw holes 14g, 14h, 14i, 14j are provided to allow the mounting plate 14 to be connected by screws through holes in the casing 3 and connect to the frame 12.
- one face of the mounting plate 14a is arranged to sit flush against the casing 3, connected through the casing 3 to the frame 12, so that the casing 3 is held between the mounting plate 14a and the frame 12.
- first and second seals 14b, 14c which seal the gap between the mounting plate 14a and the casing 3, and the gap on the outer surface of the mounting plate 14a, respectively.
- the first seal 14b takes the form of a gasket positioned between the mounting plate 14a and the casing 3.
- the gasket 14b is arranged so that it surrounds all of the screw holes in the casing 3 and those 14g, 14h, 14i, 14j in the mounting plate 14 thereby creating an internal cavity between the mounting plate 14a and the casing 3 for fluid.
- the gasket 14b is clamped between the mounting plate 14a and casing 3 due to the screws clamping the frame 12 and the mounting plate 14a together.
- the gasket 14b therefore provides a fluid-tight seal between the casing 3 and the mounting plate 14a.
- the first seal could be provided by a plurality of gaskets, each provided around an individual screw hole.
- the second seal 14c takes the form of a rubber O-gasket and is arranged on an outer surface of the mounting plate 14a.
- the O-gasket 14c prevents fuel leaking from around the heads of the screws that pass through the mounting plate 14a.
- the casing 3 is provided with a plurality of protrusions 3m, which are arranged to engage with a plurality of complementary recesses 14k within the mounting plate 14a.
- this engagement of the casing 3 and mounting plate 14a helps to prevent rotation of the mounting plate 14a with respect to the casing 3.
- this feature of the mounting arrangement 14 provides an interference which is radial with respect to the shaft 10a of the cam arrangement 10, in order to help prevent rotation of the mounting arrangement 14.
- the radial interference features provided between the casing 3 and the mounting plate 14a could include further protrusions in the frame 12 which protrude into the rear of the protrusions 3m in the casing 3. As such, the frame 12 would support the protrusions 3m and thereby provide additional resistance to the relative rotation of the housing and mounting plate 14.
- the mounting plate 14a can be extruded from an aluminium bar. Such a manufacturing process is cheap and quick. However, any suitable material or manufacturing process could be used.
- driveshafts are constructed from a single piece of metal and supported by a two-part cast steel housing, which is constructed around the driveshaft.
- a two-part cast steel housing which is constructed around the driveshaft.
- a multiple part cam arrangement 10 is provided.
- the cam arrangement 10 includes three portions: the shaft 10a, the cam 10b and a rear bearing journal 10c.
- the shaft 10a runs along the length of the cam arrangement 10 and the cam 10b and rear bearing journal 10c are mounted thereon so that the cam arrangement 10 can be constructed within the fixed frame 12.
- the shaft 10a is an elongate structure with a stepped cylindrical form, having a plurality of cylindrical parts, which reduce in diameter towards one end of the shaft 10.
- the shaft has a first reduced diameter portion 10aa onto which the cam 10b is press-fitted, and a neighbouring second reduced diameter section 10ab at an end of the shaft 10a onto which the rear bearing journal 10c is press-fitted.
- the second reduced diameter section 10ab has a smaller diameter than the first reduced diameter section 10aa.
- Figure 8 shows an alternative cam arrangement 100, which utilises a key interference join.
- the cam arrangement 100 includes a shaft 100a, a cam 100b, a rear bearing journal and two engagement elements (or keys) 100d, 100e.
- the shaft 100a and the cam 100b are provided with recessed portions 100aa, 100ba, 100bb (or keyways) with which the engagement elements 100d, 100e engage.
- the engagement elements 100d, 100e therefore act as intermediate connecting parts which provide a join or bridge between the shaft 100a and the cam 100b in order to help prevent the parts of the cam arrangement 100 moving out of position with respect to one another.
- the arrangement 100 of Figure 8 therefore provides a driveshaft arrangement 100 which is stronger than the above-mentioned arrangement 10 that relies upon press-fitting of parts.
- cam arrangement 10, 100 Constructing the cam arrangement 10, 100 from multiple parts allows for a cheaper cam arrangement to be constructed compared to a driveshaft made from a single piece.
- the cam 10b, 100b can be made from high-tensile steel because it takes the majority of the stress and then the shaft and rear bearing journal can be made of cheaper grade steel.
- the cam arrangement 10 of the illustrated embodiment serves as a drive element of the pump for transferring a driving force to the pumping element for pressurising fuel within the pump head. It will be appreciated that other drive elements could be contemplated.
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- Engineering & Computer Science (AREA)
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- Fuel-Injection Apparatus (AREA)
Abstract
Description
- The present invention relates to the field of fuel pumps. In particular, the invention relates to a high-pressure fuel pump for supply of high-pressure fuel to a fuel injector. More specifically, but not exclusively, the present invention relates to a housing for such a pump.
- Fuel injection systems for modern internal combustion engines, particularly engines that utilise compression ignition, comprise a plurality of fuel injectors arranged to deliver an atomised spray of fuel to a respective combustion chamber for combustion.
- In order to improve atomisation of fuel within engines utilising compression ignition it is preferable to atomise the fuel as much as possible. Greater atomisation of fuel improves the efficiency of the combustion process, which in turn improves the fuel efficiency and reduces harmful emissions such as carbon monoxide produced by the combustion process. The most common way to improve atomisation is to increase the pressure of the fuel to be injected. As such, there has been a continual desire to manufacture pumps capable of pressurising fuel to higher pressures.
- Known high-pressure pumps utilise a pumping element such as a steel plunger that reciprocates inside a close-fitting guide-bore, the plunger being driven by a driveshaft. Hence, as the driveshaft rotates, its rotational force is transferred to the plunger so that the plunger reciprocates within the guide bore. Fuel enters a pumping chamber at an end of the guide bore and is then pressurised as the reciprocating plunger applies a pressurising force to the pumping chamber. The fuel is then forced through a delivery valve into a high-pressure rail ready for injection by the fuel injectors. The components of the pump are supported by the housing.
- In order to increase the pressure of fuel that a high-pressure fuel pump is capable of providing, a greater energy has to be put into the system through the rotating driveshaft so that the plunger applies a greater force to the fuel. Hence, as the pressures that pumps are capable of providing has increased, so has the relative strength of the pump housing due to the increase in physical energy used within the pump.
- It is common to manufacture high-pressure fuel pump housings from cast steel to provide the strength required to withstand the stresses to which high-pressure fuel pumps are subjected. As pumps capable of producing higher pressure fuel have been developed, the thickness of the steel housing has also increased to withstand the relative increases in stress.
- Increasing the thickness of a cast steel pump housing results in the pump being heavier. As such, the fuel efficiency of the vehicle in which the pump is used is reduced due to the heavier components it is having to carry. Furthermore, as the thickness of the cast steel pump housing increases, so does the overall size of the pump.
- It would be desirable to provide a high pressure fuel pump that is of reduced weight and size. This is particularly of relevance to "ecoefficiency" concept vehicles, where overall weight reduction of a vehicle is a key component in improving the efficiency to thereby reduce the environmental impact of the vehicle. Furthermore, minimising the size of a pump is desirable because such a pump takes up less space within a vehicle.
- Embodiments of the present invention therefore aim to at least partially mitigate one or more of the above-mentioned problems.
- According to a first aspect of the present invention, there is provided a fuel pump for pressurising fuel in a high-pressure fuel injection system. The fuel pump comprises a pump head having a pumping chamber that is arranged to receive fuel to be pressurised. The fuel pump also includes a pumping element arranged to reciprocate responsive to movement of a driving element. The pumping element defines, in part, the pumping chamber so that, in use, as the pumping element reciprocates, a force, transferred from the driving element, is applied to the fuel within the pumping chamber to pressurise the fuel. The fuel pump also comprises a frame arranged to support the driving element and a casing which defines an internal volume for containing fluid. At least a part of the frame, at least a part of the drive element, and at least a part of the pumping element are received in the casing. This arrangement therefore provides a lighter, smaller pump.
- The frame and the casing together provide a housing for the pump.
- The frame may be arranged to hold the pump head and driving element in fixed positions relative to one another. Such an arrangement allows for correct operation of the fuel pump. In particular, a large force is transferred from the driving element to the pump head in order to pressurise fuel within the pump head to a very high pressure. The frame therefore needs to withstand such forces and keep the pump head and driving element in fixed positions relative to one another so that the pump continues to operate correctly.
- The frame may be constructed from a material having higher strength than a material from which the casing is constructed. The frame is provided to support the pump head and driving element, while the casing is provided for containing fluid. Hence, only the frame has to withstand the high forces transferred from the driving element to the pump head. The casing can therefore be made from a material of lower strength than the frame because it only has to contain fluid. Alternatively, the frame and casing can be made from the same material and the frame can be made thicker than the casing to provide the higher strength. Preferably the frame is made from aluminium because aluminium is relatively strong compared to other materials while being relatively low density compared to other materials.
- The materials for the frame and casing may be selected so that they are optimised for their specific function. The material for the frame may be selected so that it is of a sufficiently high strength for supporting the forces transferred from the driving element to the pump head. The material for the casing may be selected for containing fluid.
- The frame may be formed of a single piece. Forming the frame from a single piece allows for the frame to be stronger because it does not have any joins, which can lead to structural weaknesses. Furthermore, the frame may be formed of a single piece by means of an extrusion process. Such an extrusion process provides an easy means for manufacturing a frame in a single piece. Furthermore, such an extrusion process allows for additional features, such as screw holes, to be easily formed within the frame.
- The casing may be formed of a plastics-based material. Such an arrangement results in a light-weight and easy to manufacture casing.
- The frame may be arranged for mounting the fuel pump to an engine component. The frame supports the high-stress components of the fuel pump. It is therefore desirable to mount the fuel pump via the high-strength fuel pump frame.
- The fuel pump may further comprise a mounting arrangement for connecting the frame of the fuel pump to the engine component. The mounting arrangement provides a means for providing a strong connection between the frame and the engine component.
- The housing and the mounting arrangement may each comprise a complementary interference feature arranged for preventing rotation of the mounting arrangement with respect to the housing. When the fuel pump is in operation large forces are transferred between the driving arrangement and the pump head. The forces applied by these components result in the frame of the fuel pump attempting to move in response to these forces. It is therefore advantageous to include complementary interference features which will prevent rotation between the frame and the mounting arrangement, thereby helping to hold the fuel pump securely in position.
- One of the complementary interference features may comprise a protrusion and the other complementary interference feature may comprise a recess. Such interlocking interference features provide a strong connection between the frame and the mounting arrangement.
- The casing may comprise one or more integrated components. The one or more integrated components may include a back-leak device to aid recirculation of fluid. The one or more integrated components may include a fuel inlet to deliver fuel to the fuel pump. The one or more integrated components may include both the back-leak device and the fuel inlet. Providing these components integrated within the housing provides a smaller and easier to manufacture fuel pump.
- The driving element may be formed from a plurality of parts including a shaft portion and a cam portion. Such an arrangement is advantageous when using a frame formed of a single piece. The cam portion may be constructed from a higher strength material than the shaft portion. This is because the cam portion bears the majority of the load which is transferred to the pump head for pressurising the fuel. Such an arrangement provides a cheaper to manufacture driving element because only the expensive strong material is utilised for the part requiring a strong material.
- The pump head may be received within the casing. Including the pump head within the casing improves cooling of the pump head.
- Embodiments of the invention provide a high pressure fuel pump which is of lighter weight than currently known pumps. A high strength frame is provided to bear the pumping loads by supporting the high stress portions of the pump, such as the cam arrangement and the pump head, and a lightweight casing is then provided to seal the pump to prevent leakage of fuel from the pump.
- Embodiments of the invention provide a high pressure fuel pump that is smaller than known fuel pumps. Such embodiments utilise a support frame and lightweight casing. The casing can be relatively thin, and as such, the overall thickness of the housing is reduced because only a strong frame support is provided, rather than a strong housing that encases the whole pump.
- Embodiments of the invention reduce the cost and time for prototyping new pumps. In particular, the frame can be extruded from metal and a plastic moulded shell can be utilised to construct the casing. Such techniques do not require the slow and expensive provisions required to construct a cast steel housing.
- Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used for like parts, and in which:
-
Figure 1 illustrates a cross-sectional view of a pump according to a first embodiment of the present invention; -
Figure 2 provides an exploded view of the pump ofFigure 1 ; -
Figure 3 illustrates a frame of a pump housing of the pump ofFigure 1 ; -
Figure 4 illustrates a casing of the pump ofFigure 1 ; -
Figure 5 provides an exploded view of a fixing arrangement of the pump inFigure 1 ; -
Figure 6 provides an exploded view of the fixing arrangement ofFigure 5 from an alternative angle; -
Figure 7 provides an exploded view of the cam arrangement illustrated inFigures 1 and2 ; and -
Figure 8 provides an exploded view of an alternative cam arrangement. - Reference shall firstly be made to
Figures 1 and2 , which provide two alternative views of a pump 1 provided in accordance with a first embodiment of the present invention. The pump 1 shall initially be described primarily in respect of its operation. - Low-pressure fuel enters the pump 1 through a fuel inlet 2, which is integrated into a casing 3 of the pump 1. The fuel then passes through an inlet metering valve (IMV) 4a of an
IMV arrangement 4 mounted on the casing 3, which controls the rate of flow of fuel into the pump 1. The casing 3 forms part of a pump housing and defines aninternal cavity 5 in which pumping and driving components of the pump 1 are arranged, theinternal cavity 5 being filled with fuel. TheIMV arrangement 4 is partially arranged between the fuel inlet 2 and theinternal cavity 5; fuel therefore passes from the fuel inlet 2 through the IMV 4a and into theinternal cavity 5. - The fuel within the
internal cavity 5 acts as a lubricant to the moving parts of the fuel pump 1, and it also acts to cool components of the pump 1 by absorbing heat generated in the pumping process so that the heat is transferred away from the pumping components of the pump 1. In order to aid the cooling process a back-leak device 6 such as a venturi device is provided to allow fuel to be drawn frominternal cavity 5 and returned to a low pressure drain or engine cam box, so that the fuel is recirculated. The back-leak device 6 therefore aids the recirculation of fuel so that the heat generated by the pumping components is transferred away from the fuel pump 1. - The pumping components include a
pump head 7, a pumping element in the form of aplunger 8 and a drive arrangement comprising a follower arrangement 9 and a driveshaft orcam arrangement 10. The pumping process takes place within thepump head 7. The pump head is therefore made of a strong material, such as hardened steel, in order to withstand the high-pressure fuel which is pressurised within apumping chamber 7a of thepump head 7, in addition to the large forces applied to thepump head 7 by thepumping element 8 in order to pressurise the fuel. - The
pumping chamber 7a of thepump head 7 is arranged at one end of a plunger bore 7b provided in thepump head 7 and is a cavity comprising a low-pressure fuel inlet (not shown) for receiving fuel from theinternal cavity 5 defined by the casing 3, and a high-pressure fuel outlet (not shown) in the form of an outlet valve. Thepumping chamber 7a is defined in part by a pumping head at a first end of theplunger 8. Theplunger 8 is arranged to reciprocate so that a pumping head of the plunger increases and decreases the volume of thepumping chamber 7a. As the volume of the pumping chamber decreases, the pressure of fuel within thepumping chamber 7a increases. When the fuel within thepumping chamber 7a reaches a predetermined pressure, the outlet valve opens allowing the high-pressure fuel to pass through into a high-pressure rail (not shown) where the fuel is stored ready for injection by one or more fuel injectors (not shown). - At a second end of the
plunger 8, remote from thepumping chamber 7a, the follower arrangement 9 is arranged to cooperate with thecam arrangement 10 to transform a rotational movement of thecam arrangement 10 into the reciprocal movement of theplunger 8 within the plunger bore 7b. - The
cam arrangement 10 is provided with ashaft portion 10a located at least partially outside the casing 3 of the pump 1 to engage with a drive source (not shown), such as a drive gear. Thecam arrangement 10 rotates responsive to the input force provided by the drive gear. Theshaft portion 10a of thecam arrangement 10 is also located in part within theinternal cavity 5 of the casing 3, and has a cam portion 10b connected on theshaft 10a at a portion within theinternal cavity 5. - The follower arrangement 9 comprises a roller 9a which abuts the cam 10b so that the roller 9a and cam 10b are communicatively coupled. The roller 9a is held within a roller shoe 9b connected to the second end of the
plunger 8. As the cam 10b rotates, the roller 9a rotates within the roller shoe 9b. The arrangement of the roller 9a and roller shoe 9b limits the transfer of lateral movement from the cam 10b to theplunger 8, while transferring reciprocal movement of the cam 10b to theplunger 8. A spring 11 is maintained in position between thepump head 7 and aspring seat 8a mounted on theplunger 8, in order to urge theplunger 8, and the roller shoe 9b connected thereto, into contact with the cam 10b. Due to the spring 11, the follower arrangement 9 continually follows the reciprocating movement of the cam 10b. - The follower arrangement 9 also includes a shoe guide 9c, which is provided around the peripheral surface of the roller shoe 9b in order to guide the movement of the roller shoe 9b. The guide 9c therefore allows the roller shoe 9b to move along the axis of the
plunger 8, allowing reciprocating movement, but restricting lateral movement, of the guide shoe 9c. The rotation of thecam arrangement 10 exerts a lateral force on the follower arrangement 9 and as such the shoe guide 9c is constructed of a strong material in order to resist such lateral movement and to withstand the stress associated with such resistance. - While the above-mentioned follower arrangement 9 has been described as a roller-based arrangement it will be appreciated that any suitable following arrangement could be used (e.g. a tappet or other intermediate drive component).
- The pump housing includes a
frame 12 in addition to the casing 3. Theframe 12 is provided to support various pumping and driving components, in particular, thepumping components frame 12 is arranged to support thepump head 7, the roller shoe 9, and theshaft 10a of thecam arrangement 10. Theframe 12 is therefore made of a relatively strong material, such as aluminium, in order to withstand the high levels of stress within the pump 1, particularly due to the forces being transferred from thecam arrangement 10 to theplunger 8 and then into the fuel within thepump head 7. - In order to aid rotation of the
cam arrangement 10, and prevent excessive load and wear to theframe 12, bushes 13a, 13b are provided at the portions of theframe 12 that support thecam arrangement 10. - As can be seen in
Figure 2 , a mountingarrangement 14 is provided with a mountingplate 14a external to the casing 3 which connect the pump 1 to the engine. The mountingarrangement 14 connects to theframe 12 through the casing 3 in order to provide a solid support for theframe 12 and therefore the pump 1. Since theframe 12 and mountingarrangement 14 are connected through the casing 3, the mountingarrangement 14 includes a plurality of seals 14b, 14c in order to prevent leakage of fuel through the casing 3. - Each of the components of the pump 1 shall now be discussed in more detail with reference to various figures.
- The construction of the
frame 12 shall be discussed with further reference toFigure 3 , which shows theframe 12 of the pump of the first embodiment of the present invention. - The
frame 12 is provided with twocam support sections hole Figures 1 and2 ) can be supported, wherein the cam 10b is located between the twocam support sections holes cam support sections shaft 10a of thecam arrangement 10. Hence, in this case theholes shaft 10a of thecam arrangement 10. As such, smooth rotation of thecam arrangement 10 is possible. The dimensions of theframe 12 are arranged so that within theholes cam support section shaft 10a of thecam arrangement 10. The fuel in theinternal cavity 5 defined by the internal walls of the casing 3 helps to lubricate theframe 12 and bushes 13a, 13b in order to aid smooth rotation of theshaft 10a of thecam arrangement 10 and minimise wear. Thecam support sections cam arrangement 10. However, the mountingarrangement 14 bears a portion of the load applied to thecam support section 12a which is adjacent to the mountingarrangement 14. - The
frame 12 is also provided with a pump head support section 12e. This section 12e has a hole 12f for receiving thepump head 7. In particular, a front face of thepump head 7 protrudes, at least partially, through this hole 12f. The front face of thepump head 7 includes a recess defining, in part, thepumping chamber 7a into which the pumping head of theplunger 8 is inserted to thereby define thepumping chamber 7a. - A plurality of screw holes 12g (only one shown in
Figure 3 ) are provided in the pump head support section 12e of theframe 12 through which screws (not shown) can connect thepump head 7 to theframe 12. A strong clamping of thepump head 7 to theframe 12 is required in order to prevent thepump head 7 from being separated from theframe 12 when theplunger 8 drives into thepump head 7, in such a way that a force is provided that urges thepump head 7 away from theframe 12. Alternatively, theframe 12 could be arranged to provide at least one support member (not shown) that abuts a rear face of the pump head so that connection screws are not relied upon for holding thepump head 7 onto theframe 12. - The
frame 12 is also provided with shoe-guide support sections 12h (only one shown), which includes a plurality of struts (not shown) that support the shoe-guide 9c. - The
cam support sections guide support sections 12h are joined together by the main structure of theframe 12. Structural rigidity is required between thesesections cam support sections plunger 8, driven by thecam arrangement 10, into thepump head 7. Hence, the position of thepump head 7 with respect to thecam arrangement 10 needs to remain constant in order to allow for correct operation of the pump 1. - Holes or cut-
outs 12i are provided within the main body of theframe 12 in order to reduce the weight of theframe 12 without reducing the relative strength of theframe 12 so that theframe 12 is able to provide strong support to the components of the pump subjected to high levels of stress. - It will be appreciated that while the
cam support sections guide support sections 12h are supported by the main body of theframe 12 in this embodiment of the invention, alternatively, strut supports could be provided between each of the sections of theframe 12 in order to link the sections together. Use of strut supports between the sections of theframe 12 could help to further reduce the weight of theframe 12, and in certain arrangements allow for a reduction in the size of theframe 12. - In this example, the
frame 12 is also provided with attachment holes 12j, 12k, 12l, 12m for connecting the pump 1, via theframe 12, to the mountingarrangement 14. The holes 12j, 12k, 12l, 12m and their relationship to the mountingarrangement 14 shall be discussed when the mountingarrangement 14 is described in detail with respect toFigures 5 and 6 . - The
frame 12 is made by extruding an aluminium bar. The extrusion process is fast and cheap to perform. By forming theframe 12 by an extrusion process theframe 12 can be formed of one part. That is, it is extruded from a single bar of metal and as such no parts have to be joined. In contrast, casting processes require two or more parts to be cast, which are then joined together. There is a risk of structural weaknesses forming at the joins between these parts. Hence, the extrusion process overcomes these problems. - Furthermore, since the
frame 12 is extruded, the amount of cutting and drilling of the frame is minimised. In particular, the extrusion process allows for certain characteristics of theframe 12, such as holes, to be formed in theframe 12 during the extrusion process. In contrast, casting techniques require all characteristics to be added after the casting, therefore leading to further structural weaknesses. - It will be appreciated that while the
frame 12 is described as being made of aluminium, any suitably strong material could be utilised. In particular, any suitable metal could be used or other materials like a composite plastic or composite plastic encapsulated in sintered metal. It is noted that while an extrusion process is preferable for constructing theframe 12, other construction processes such as casting could be utilised. - The casing 3, which defines the
internal cavity 5, is arranged to enclose theframe 12 and the pumping and driving components that theframe 12 supports. In other words, the pumping and driving components are at least partially arranged within the internal cavity defined by theframe 12. The casing 3 therefore provides a fluid tight shell around the pumping components so that fuel does not leak from the internal cavity. - While in
Figure 1 the casing 3 is shown to enclose all pumping and driving components of the pump 1 it will be appreciated that the casing 3 is arranged to define an internal cavity containing fuel for cooling and lubrication purposes. The moving driving and pumping parts of the pump 1, such as theplunger 8, follower arrangement 9, andcam arrangement 10 therefore require such lubrication and cooling. As such, it will be appreciated that it is not necessary for the whole of thepump head 7 to be enclosed within the casing 3. The casing could be provided so that it joins a peripheral surface of thepump head 7 or the front face of thepump head 7. In such circumstances the front face of thepump head 7 would be in fluid communication with the fuel within theinternal cavity 5, and at least part of the side portion and the whole of the rear portion of thepump head 7 would be external to the casing 3. It is noted that due to the constant flow of fuel through the pump head, the heat created within the pump is, at least in part, transferred away by the pressurised fuel, and therefore cooling of the pump head is not as important as cooling of the moving components of pumping process. - The casing 3 is formed of two parts 3a, 3b, as shown in
Figure 2 . The parts 3a, 3b are arranged to fit around the components attached to and within theframe 12. The two parts 3a, 3b of the plastic casing can then be joined together so that the two-part casing 3 seals fluid within. The two parts can be joined by any method capable of providing a fluid tight bond. -
Figure 4 shows one half 3a of the casing 3. InFigure 4 , it can be seen that the casing 3 has a plurality of internal supportingstruts 3s. The supportingstruts 3s stiffen the casing 3 to improve the strength of the casing 3. As such it is possible to have a thinner casing 3, while still providing sufficient strength. Thestruts 3s could also be provided to abut the outer surface of theframe 12 so that the casing 3 is tightly formed around theframe 12. - In this embodiment of the invention the
frame 12 is only joined to the casing 3 via the mountingarrangement 14. However, it will be appreciated that the casing 3 could be connected to theframe 12 in various ways, such as by utilisation of one or more connection screws having suitable sealing to prevent leakage from the casing 3. - The two casing parts 3a, 3b are formed from plastic using an injection moulding technique. As such, high-frequency welding would provide a suitable bond between the two parts 3a, 3b. However, other materials such as a metal could be used for the casing 3. For example, an
aluminium frame 12 and casing 3 could be provided. Since the casing 3 only needs to provide fluid tightness it could be made much thinner than theframe 12. Furthermore, due to the relative strength of metal compared to plastic, a metal casing 3 could be made much thinner than a plastic casing 3. Due to its conductive properties, a metal casing 3 would also assist in transferring heat away from the fuel within the internal cavity. - While in the embodiment of the invention discussed in respect of
Figures 1 and2 theinternal cavity 5 defined by the casing 3 is filled with fuel, it will be appreciated that other fluid could be provided within theinternal cavity 5. For example, specific cooling/lubrication fluid could be contained in the internal cavity. In such circumstances, theIMV arrangement 4 would connect directly, or via a contained channel, from the fuel inlet 2 to thepump head 7. In such an arrangement a cooling fluid inlet (not shown) could be provided, and the back-leak device 6 would help to recirculate the cooling fluid. - As well as defining the
internal cavity 5, the casing 3 also defines various features of the fuel pump 1, as discussed below. - The casing 3 includes an IMV connection portion 3b, which is arranged to enable the shell of the
IMV arrangement 4 to be connected to the pump 1. The IMV connection portion 3b defines a hole 3c in which a portion of theIMV arrangement 4 can be positioned, so that the IMV 4a can connect to the fuel inlet 2. One ormore connection holes 3d can be provided within the casing 3 to enable theIMV arrangement 4 to be attached to the casing so that theIMV arrangement 4 is held in place on the pump 1. - The casing 3 also provides an integrated back-leak device 6, and an integrated fuel inlet 2. Integrating these components into the casing 3 is advantageous when the casing 3 is constructed from plastic using an injection moulding method because the components are formed as part of the casing 3 in the moulding process. Furthermore, integrating these components within the casing 3 simplifies the overall manufacturing process of the fuel pump 1 and reduces the size of the fuel pump 1.
- The housing, which includes the
frame 12 and the casing 3, is much smaller than known housings. This is because the minimum structural support required can be provided by theframe 12, and then a comparatively thin and light casing 3 can be provided to provide a fluid-tight seal for the pump 1. Overall, this allows for the overall size of the housing and therefore the pump 1 to be reduced. In addition, the materials used for theframe 12 and casing 3 can be selected so as to best suit their respective functions, which allows for the weight of the housing and the therefore pump 1 to be reduced. - A further advantage of such a housing construction is that it is possible to place the
IMV arrangement 4 much closer to thepump head 7 than is possible in a fuel pump that utilises a cast steel housing. This is because theframe 12 can be provided only in those portions that require support, and the casing 3 can be arranged to closely surround thisframe 12, enabling theIMV arrangement 4 to be positioned close to thepump head 7. As such, theoverall pump head 7 can be reduced further. - While the
frame 12 has been described as being arranged within the casing 3 above, it will be appreciated that theframe 12 could be provided so that it is only partially within the casing 3. For example, the main structure of theframe 12 could be provided outside the casing 3 with support arms extending through the casing 3 to support the high stress components of the pump 1. In such a case, the mountingarrangement 14 can be easily connected to theframe 12, or even be formed integrally with theframe 12. - The mounting
arrangement 14 shown inFigure 2 shall now be described in further detail with reference toFigures 5 and 6 . - The mounting
arrangement 14 comprises a mountingplate 14a, which is arranged to connect to a component of the engine to secure and stabilise the pump 1. The mountingplate 14 is a substantially planar structure with a plurality of holes or cutaways to reduce the weight of theplate 14a. The mountingplate 14a is provided with a plurality ofscrew holes Further screw holes 14g, 14h, 14i, 14j are provided to allow the mountingplate 14 to be connected by screws through holes in the casing 3 and connect to theframe 12. As such, one face of the mountingplate 14a is arranged to sit flush against the casing 3, connected through the casing 3 to theframe 12, so that the casing 3 is held between the mountingplate 14a and theframe 12. - Since the screws for connecting the mounting
plate 14a to theframe 12 pass through the casing 3 it is necessary to provide a mounting arrangement sealing means. This is achieved by providing first and second seals 14b, 14c, which seal the gap between the mountingplate 14a and the casing 3, and the gap on the outer surface of the mountingplate 14a, respectively. - The first seal 14b takes the form of a gasket positioned between the mounting
plate 14a and the casing 3. The gasket 14b is arranged so that it surrounds all of the screw holes in the casing 3 and those 14g, 14h, 14i, 14j in the mountingplate 14 thereby creating an internal cavity between the mountingplate 14a and the casing 3 for fluid. The gasket 14b is clamped between the mountingplate 14a and casing 3 due to the screws clamping theframe 12 and the mountingplate 14a together. The gasket 14b therefore provides a fluid-tight seal between the casing 3 and the mountingplate 14a. Alternatively, the first seal could be provided by a plurality of gaskets, each provided around an individual screw hole. - The second seal 14c takes the form of a rubber O-gasket and is arranged on an outer surface of the mounting
plate 14a. The O-gasket 14c prevents fuel leaking from around the heads of the screws that pass through the mountingplate 14a. - To prevent rotation of the housing with respect to the mounting
plate 14a, the casing 3 is provided with a plurality ofprotrusions 3m, which are arranged to engage with a plurality ofcomplementary recesses 14k within the mountingplate 14a. In use, this engagement of the casing 3 and mountingplate 14a helps to prevent rotation of the mountingplate 14a with respect to the casing 3. Hence, this feature of the mountingarrangement 14 provides an interference which is radial with respect to theshaft 10a of thecam arrangement 10, in order to help prevent rotation of the mountingarrangement 14. - It will be appreciated that the radial interference features provided between the casing 3 and the mounting
plate 14a could include further protrusions in theframe 12 which protrude into the rear of theprotrusions 3m in the casing 3. As such, theframe 12 would support theprotrusions 3m and thereby provide additional resistance to the relative rotation of the housing and mountingplate 14. - The mounting
plate 14a can be extruded from an aluminium bar. Such a manufacturing process is cheap and quick. However, any suitable material or manufacturing process could be used. - The construction of the
cam arrangement 10 shown inFigures 1 and2 shall now be considered in detail with reference toFigure 7 . - In general, known driveshafts are constructed from a single piece of metal and supported by a two-part cast steel housing, which is constructed around the driveshaft. However, when utilised with an extruded aluminium frame or any fixed frame structure it is not possible to utilise a standard driveshaft.
- In the embodiment of the invention shown in
Figures 1 and2 a multiplepart cam arrangement 10 is provided. Thecam arrangement 10 includes three portions: theshaft 10a, the cam 10b and a rear bearing journal 10c. Theshaft 10a runs along the length of thecam arrangement 10 and the cam 10b and rear bearing journal 10c are mounted thereon so that thecam arrangement 10 can be constructed within the fixedframe 12. - The
shaft 10a is an elongate structure with a stepped cylindrical form, having a plurality of cylindrical parts, which reduce in diameter towards one end of theshaft 10. The shaft has a first reduced diameter portion 10aa onto which the cam 10b is press-fitted, and a neighbouring second reduced diameter section 10ab at an end of theshaft 10a onto which the rear bearing journal 10c is press-fitted. The second reduced diameter section 10ab has a smaller diameter than the first reduced diameter section 10aa. - In order to assemble the
cam arrangement 10 within theframe 12 it is firstly necessary to insert the cam 10b through the gap between the twocam support sections Figure 3 . Then, theshaft 10a is inserted through the firstcam support section 12a of theframe 12 and through the cam 10b and into the rear bearing journal 10c which is arranged to support theshaft 10a within the secondcam support section 12b of theframe 12. -
Figure 8 shows analternative cam arrangement 100, which utilises a key interference join. In this embodiment of the invention thecam arrangement 100 includes ashaft 100a, a cam 100b, a rear bearing journal and two engagement elements (or keys) 100d, 100e. Theshaft 100a and the cam 100b are provided with recessed portions 100aa, 100ba, 100bb (or keyways) with which the engagement elements 100d, 100e engage. The engagement elements 100d, 100e therefore act as intermediate connecting parts which provide a join or bridge between theshaft 100a and the cam 100b in order to help prevent the parts of thecam arrangement 100 moving out of position with respect to one another. Thearrangement 100 ofFigure 8 therefore provides adriveshaft arrangement 100 which is stronger than the above-mentionedarrangement 10 that relies upon press-fitting of parts. - It will be appreciated that while press-fit and key-interference fit arrangements have been described, the parts of the cam arrangement could be connected by any suitable means such as a serial interference, a thermal expansion interference, a spline interference, or by hyrdo-forming.
- Constructing the
cam arrangement - The
cam arrangement 10 of the illustrated embodiment serves as a drive element of the pump for transferring a driving force to the pumping element for pressurising fuel within the pump head. It will be appreciated that other drive elements could be contemplated. - For example, even though use of a fixed
frame 12 with acam arrangement 10 made of multiple parts has been described herein it will be appreciated that in certain circumstances it may be preferable to utilise a drive element comprising a single-part driveshaft and a frame made of multiple parts. - The invention has been described with use of a linear pumping arrangement, wherein a cam 10b, 100b drives an
elongate plunger 8 to drive into apumping chamber 7a. However, it will be appreciated that alternative pumping arrangements could be used. For example, a drive element comprising a rocker-arm type pumping arm can be utilised. In such a case, drive members of the rocker arrangement could be supported by the frame in a similar way to the cam arrangement illustrated inFigure 1 . - The above-mentioned embodiments of the present invention have been described with reference to a single pump 1 having a
single pump head 7 andsingle cam arrangement 10. However, it will be appreciated that the principles of the present invention apply equally to pumping systems including multiple pumping heads, with one or more driveshafts. - Further variations and modifications will be apparent to a person skilled in the art without departing from the scope of the invention as defined in the appended claims.
Claims (15)
- A fuel pump (1) for pressurising fuel in a high-pressure fuel injection system, the fuel pump (1) comprising:a pump head (7) having a pumping chamber (7a) that is arranged to receive fuel to be pressurised;a pumping element (8) arranged to reciprocate responsive to movement of a driving element (10), the pumping element (8) defining, in part, the pumping chamber (7a) so that, in use, as the pumping element (8) reciprocates, a force, transferred from the driving element (10), is applied to the fuel within the pumping chamber (7a) to pressurise the fuel;a frame (12) arranged to support the driving element (10) and the pump head (7); anda casing (3) defining an internal volume (5) for containing fluid;wherein at least a part of the frame (12), at least a part of the drive element (10), and at least a part of the pumping element (8) are received in the casing (3).
- The fuel pump (1) according to claim 1, wherein the frame (12) is arranged to hold the pump head (7) and driving element (10) in fixed positions relative to one another to support the transfer of force from the driving element (10) to the pump head (7).
- The fuel pump (1) according to claim 1 or claim 2, wherein the frame (12) is constructed from a material having higher strength than a material from which the casing (3) is constructed.
- The fuel pump (1) according to any preceding claim, wherein the frame (12) is formed of a single piece.
- The fuel pump (1) according to claim 4, wherein the frame (12) is formed of a single piece by means of an extrusion process.
- The fuel pump (1) according to any preceding claim, wherein the casing (3) is formed of a plastics-based material.
- The fuel pump (1) according to any preceding claim, wherein the frame (12) is arranged for mounting the fuel pump (1) to an engine component.
- The fuel pump (1) according to claim 7, further comprising:a mounting arrangement (14) for connecting the frame (12) of the fuel pump (1) to the engine component.
- The fuel pump (1) according to claim 8, wherein the housing (3, 12) and the mounting arrangement (14) each comprise a complementary interference feature (3m, 14k) arranged for preventing rotation of the mounting arrangement (14) with respect to the housing (3, 12).
- The fuel pump (1) according to claim 9, wherein one of the complementary interference features comprises a protrusion (3m) and the other complementary interference feature comprises a recess (14k).
- The fuel pump (1) according to any preceding claim, wherein the casing (3) comprises one or more integrated components (2, 6) including one or more of a back-leak device (6) to aid recirculation of fluid, and a fuel inlet (2) to deliver fuel to the fuel pump (1).
- The fuel pump (1) according to any preceding claim, wherein the driving element (10) is formed from a plurality of parts including a shaft portion (10a) and a cam portion (10b).
- The fuel pump (1) according to claim 12, wherein the cam portion (10b) is constructed from a higher strength material than the shaft portion (10a).
- The fuel pump (1) according to any preceding claim, wherein the pump head (7) is received within the casing (3).
- The fuel pump (1) according to any preceding claim, wherein the frame comprises at least one bearing (12c, 12d, 13a, 13b) arranged to support the drive element (10) for rotational movement with respect to the bearing (12c, 12d, 13a, 13b).
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP11176843A EP2557306A1 (en) | 2011-08-08 | 2011-08-08 | Fuel pump |
US14/237,578 US20140170002A1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
KR1020147004994A KR101567794B1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
JP2014524320A JP5863969B2 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
EP12735582.4A EP2742231B1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
CN201280038611.4A CN103717872B (en) | 2011-08-08 | 2012-07-19 | Petrolift |
PCT/EP2012/064209 WO2013020789A1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
ES12735582.4T ES2543318T3 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP11176843A EP2557306A1 (en) | 2011-08-08 | 2011-08-08 | Fuel pump |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2557306A1 true EP2557306A1 (en) | 2013-02-13 |
Family
ID=46514411
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11176843A Withdrawn EP2557306A1 (en) | 2011-08-08 | 2011-08-08 | Fuel pump |
EP12735582.4A Active EP2742231B1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12735582.4A Active EP2742231B1 (en) | 2011-08-08 | 2012-07-19 | Fuel pump |
Country Status (7)
Country | Link |
---|---|
US (1) | US20140170002A1 (en) |
EP (2) | EP2557306A1 (en) |
JP (1) | JP5863969B2 (en) |
KR (1) | KR101567794B1 (en) |
CN (1) | CN103717872B (en) |
ES (1) | ES2543318T3 (en) |
WO (1) | WO2013020789A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016045852A1 (en) * | 2014-09-26 | 2016-03-31 | Robert Bosch Gmbh | Camshaft and pump having a camshaft |
WO2016055203A1 (en) * | 2014-10-08 | 2016-04-14 | Continental Automotive Gmbh | High-pressure fuel pump and drive shaft |
WO2019243297A1 (en) * | 2018-06-18 | 2019-12-26 | Delphi Technologies Ip Limited | Fuel pump and driveshaft assembly therefor |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9879659B2 (en) * | 2014-07-25 | 2018-01-30 | S.P.M. Flow Control, Inc. | Support for reciprocating pump |
KR101905990B1 (en) * | 2016-10-24 | 2018-10-08 | 현대자동차주식회사 | Fuel cut apparatus |
JP2021032100A (en) * | 2019-08-21 | 2021-03-01 | 株式会社デンソー | Fuel injection pump |
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EP0516196A2 (en) * | 1988-11-24 | 1992-12-02 | Nippondenso Co., Ltd. | Variable-discharge high pressure pump |
EP1394403A2 (en) * | 2002-08-31 | 2004-03-03 | Robert Bosch Gmbh | Fuel system for an internal combustion engine |
EP1770274A1 (en) * | 2005-09-29 | 2007-04-04 | Denso Corporation | Fluid pump having plunger and method of monoblock casting for housing of the same |
DE102008007028A1 (en) * | 2008-01-31 | 2009-08-06 | Continental Automotive Gmbh | High-pressure pump, particularly feeding pump for feeding fluid for storage injection system for internal-combustion engine of motor vehicle, has carrier element and driving shaft that is mounted in carrier element |
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JPH09100759A (en) * | 1995-10-06 | 1997-04-15 | Toyota Motor Corp | Variable discharge high pressure pump |
JP3581861B2 (en) * | 1996-07-05 | 2004-10-27 | 株式会社日本自動車部品総合研究所 | High pressure supply pump |
JPH1122594A (en) * | 1997-06-30 | 1999-01-26 | Unisia Jecs Corp | Fuel pressurizng pump for fuel injection device |
TW384358B (en) * | 1997-09-25 | 2000-03-11 | Mitsubishi Electric Corp | High pressure fuel supply pump body for an in-cylinder fuel injection engine |
JPH11247742A (en) * | 1998-03-02 | 1999-09-14 | Zexel:Kk | Plunger pump |
JP2000230463A (en) | 1999-02-09 | 2000-08-22 | Yanmar Diesel Engine Co Ltd | Discharge valve structure of fuel injection pump |
DE19938504A1 (en) * | 1999-08-13 | 2001-03-08 | Bosch Gmbh Robert | Single cylinder high pressure pump |
JP3936119B2 (en) * | 2000-04-18 | 2007-06-27 | トヨタ自動車株式会社 | High pressure pump and high pressure pump assembly structure |
US6668806B2 (en) * | 2001-12-26 | 2003-12-30 | Visteon Global Technologies, Inc. | Fuel pump assembly including a filter outlet to pump inlet isolator |
DE10341841A1 (en) * | 2003-09-09 | 2005-04-07 | Siemens Ag | According to the gerotor principle working fuel pump |
JP4052220B2 (en) * | 2003-10-08 | 2008-02-27 | 株式会社デンソー | Fuel injection pump |
JP2011094596A (en) * | 2009-11-02 | 2011-05-12 | Denso Corp | Tappet device and fuel supply pump using the same |
-
2011
- 2011-08-08 EP EP11176843A patent/EP2557306A1/en not_active Withdrawn
-
2012
- 2012-07-19 WO PCT/EP2012/064209 patent/WO2013020789A1/en active Application Filing
- 2012-07-19 JP JP2014524320A patent/JP5863969B2/en active Active
- 2012-07-19 EP EP12735582.4A patent/EP2742231B1/en active Active
- 2012-07-19 KR KR1020147004994A patent/KR101567794B1/en active IP Right Grant
- 2012-07-19 CN CN201280038611.4A patent/CN103717872B/en not_active Expired - Fee Related
- 2012-07-19 ES ES12735582.4T patent/ES2543318T3/en active Active
- 2012-07-19 US US14/237,578 patent/US20140170002A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0516196A2 (en) * | 1988-11-24 | 1992-12-02 | Nippondenso Co., Ltd. | Variable-discharge high pressure pump |
EP1394403A2 (en) * | 2002-08-31 | 2004-03-03 | Robert Bosch Gmbh | Fuel system for an internal combustion engine |
EP1770274A1 (en) * | 2005-09-29 | 2007-04-04 | Denso Corporation | Fluid pump having plunger and method of monoblock casting for housing of the same |
DE102008007028A1 (en) * | 2008-01-31 | 2009-08-06 | Continental Automotive Gmbh | High-pressure pump, particularly feeding pump for feeding fluid for storage injection system for internal-combustion engine of motor vehicle, has carrier element and driving shaft that is mounted in carrier element |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016045852A1 (en) * | 2014-09-26 | 2016-03-31 | Robert Bosch Gmbh | Camshaft and pump having a camshaft |
WO2016055203A1 (en) * | 2014-10-08 | 2016-04-14 | Continental Automotive Gmbh | High-pressure fuel pump and drive shaft |
WO2019243297A1 (en) * | 2018-06-18 | 2019-12-26 | Delphi Technologies Ip Limited | Fuel pump and driveshaft assembly therefor |
CN112292520A (en) * | 2018-06-18 | 2021-01-29 | 德尔福知识产权有限公司 | Fuel pump and drive shaft assembly thereof |
Also Published As
Publication number | Publication date |
---|---|
KR101567794B1 (en) | 2015-11-11 |
US20140170002A1 (en) | 2014-06-19 |
EP2742231A1 (en) | 2014-06-18 |
KR20140041899A (en) | 2014-04-04 |
CN103717872B (en) | 2016-06-01 |
EP2742231B1 (en) | 2015-06-17 |
WO2013020789A1 (en) | 2013-02-14 |
JP5863969B2 (en) | 2016-02-17 |
ES2543318T3 (en) | 2015-08-18 |
CN103717872A (en) | 2014-04-09 |
JP2014521877A (en) | 2014-08-28 |
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