EP3418550B1 - Threaded fuel rails - Google Patents
Threaded fuel rails Download PDFInfo
- Publication number
- EP3418550B1 EP3418550B1 EP17176934.2A EP17176934A EP3418550B1 EP 3418550 B1 EP3418550 B1 EP 3418550B1 EP 17176934 A EP17176934 A EP 17176934A EP 3418550 B1 EP3418550 B1 EP 3418550B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- tube
- fuel
- threads
- injector
- rail assembly
- 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.)
- Active
Links
- 239000000446 fuel Substances 0.000 title claims description 58
- 238000011144 upstream manufacturing Methods 0.000 claims description 15
- 238000002347 injection Methods 0.000 claims description 13
- 239000007924 injection Substances 0.000 claims description 13
- 210000002445 nipple Anatomy 0.000 claims description 9
- 238000005219 brazing Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 230000000712 assembly Effects 0.000 description 3
- 238000000429 assembly Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000013459 approach Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000004886 process control Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 230000000246 remedial effect Effects 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
Images
Classifications
-
- 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
- F02M55/00—Fuel-injection apparatus characterised by their fuel conduits or their venting means; Arrangements of conduits between fuel tank and pump F02M37/00
- F02M55/02—Conduits between injection pumps and injectors, e.g. conduits between pump and common-rail or conduits between common-rail and injectors
- F02M55/025—Common rails
-
- 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
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
- F02M2200/8015—Provisions for assembly of fuel injection apparatus in a certain orientation, e.g. markings, notches or specially shaped sleeves other than a clip
-
- 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
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/80—Fuel injection apparatus manufacture, repair or assembly
- F02M2200/8076—Fuel injection apparatus manufacture, repair or assembly involving threaded members
Definitions
- the technical domain of the invention relates to threaded fuel rails.
- One aspect of this disclosure incudes a fuel rail assembly for gasoline direct injection fuel delivery to an engine.
- a fuel rail or tube is often provided. Frequently, the main fuel is gasoline.
- Current high pressure fuel rail assemblies are made of a stainless steel tube and numerous stainless steel components such as injectors that are tack welded and thermally brazed together into a complete assembly.
- Current rail operating pressures are around 20 MPa (2900 PSI) maximum.
- Conventional designs have some difficulty in dealing with a higher maximum pressure of approximately 30 MPa (4400 PSI) and beyond. Such pressures raise concerns as to the integrity and reliability of the brazed joint connection.
- brazed joint One of the concerns on any welded or brazed joint is the inability to easily verify the reliability of the connection.
- a brazed joint can visually look satisfactory but be compromised due to variations in the braze process. At higher pressures this would raise concerns about rail safety and performance.
- Japanese patent Laid-Open No. 2005-69023 discloses a tube or rail along which fuel travels under pressure. Through holes are defined in a wall section of the tube.
- the fuel rail is formed of diverging branch pipes.
- metal fittings are connected to the tube by a brazing step after the metal fittings are inserted into through holes provided in a peripheral wall section of the main rail.
- Fuel rails made of aluminum for direct-injection internal combustion engines cannot be used where injection pressures may reach 150-250 MPa. This is because the strength of aluminum is low. Further, the fuel rail may have disadvantageous layout characteristics because the wall thickness of the rail must be sufficient to withstand high fuel pressures. Consequently, production costs rise because contact surfaces with fuel must be treated by expensive surface treatment protocols. This may be required if the aluminum fuel rail is sensitive to alcohol and corrosive fuel.
- One aspect of this disclosure involves gasoline direct injection fuel delivery systems in which screw threads are provided on the components to be assembled. This allows for process control that will ensure a reliable connection that can withstand increased pressure and performance requirements.
- one departure from conventional approaches and structures includes the method of attachment of injectors to the tube. A brazing step is no longer used. This attachment method and significantly increases allowable rail pressure and structural reliability while decreasing rail cost.
- the present disclosure relates to a fuel rail (a delivery pipe) for supplying high pressure fuel from fuel booster pumps. Fuel is injected through a fuel injector (an injection nozzle) into an engine cylinder.
- a fuel injector an injection nozzle
- One embodiment of a fuel rail assembly for gasoline direct injection fuel delivery to an engine includes a common rail tube with internal and external walls, an upstream end and a downstream end.
- the tube has one or more threaded orifices extending between the internal and external walls.
- Injector sockets are threadingly engaged with the orifices.
- Each of the injector sockets has a proximal nipple end region connected to the tube and a distal end region. Screw threads are disposed around the proximal nipple end region. At the tube and at the proximal end of the injector socket, the screw threads begin with a lead thread and thus form registered mechanical connections between the injector sockets and the tube that are adapted to withstand higher maximum pressures than those at which conventional fuel rail assemblies can operate safely.
- An orientation notch is provided in the distal end region of at least some of the injector sockets.
- the lead thread of an injector socket is defined so that it is aligned with an associated orientation notch, which has its own lead thread.
- the associated orientation notch is situated in a home position after threading engagement of the proximal nipple end regions of the one or more injector sockets by the tube.
- a pre-defined angular position of the injector sockets is created after torquing the injector sockets. In the predefined angular position, mechanical connections thereby formed seal the joints between the tube and the injector sockets.
- the fuel rail assembly has end threads defined in the internal wall of the tube at its the upstream and downstream ends.
- a fuel inlet with threads engages the upstream end thread at the upstream end of the tube.
- An end cap sensor boss with threads engages the downstream end thread at the downstream end of the tube.
- the disclosed structure is expected to be used at higher maximum pressures equal to or in excess of approximately 35 MPa (5000 PSI) and will address concerns as to the integrity and reliability of conventional brazed joint connection.
- One aspect of this disclosure involves gasoline direct injection fuel delivery systems that operate under pressures that may be as high as 35 MPa (5000 PSI).
- pressures that may be as high as 35 MPa (5000 PSI).
- precisely oriented screw threads are provided on the components to be assembled. This allows for process control that will ensure a reliable connection between a tube 10 and an injector socket 12 that can withstand the increased pressure and performance requirements ( FIGS. 1-5 ).
- one departure from conventional approaches and structures includes the method of attachment of the injectors 12 to the tube 10. A brazing step is no longer used.
- the disclosed attachment method allows safe and reliable operation under high rail pressures and provides structural reliability while decreasing rail cost.
- the present disclosure relates to a fuel rail (a delivery pipe, 10) for supplying high-pressure fuel from fuel booster pumps through an inlet 11. Fuel is injected through a fuel injector (an injection nozzle, 12) directly into an engine cylinder 13.
- a fuel injector an injection nozzle, 12
- a fuel rail assembly for gasoline direct injection fuel delivery to an engine includes a common rail tube 10 with internal 14 and external 16 walls, an upstream end 18 and a downstream end 20.
- the tube 10 has one or more threaded orifices 21 extending between the internal and external walls 14, 16.
- Injector sockets 12 are threadingly engaged with the orifices 32.
- Each of the injector sockets 12 has a proximal nipple end region 22 to be connected to the tube 10 and a distal end region 24.
- Screw threads 26 are disposed around the proximal nipple end region 22.
- the screw threads 26 begin with a lead thread which mates with a lead thread 30 in an aperture 32 that extends through the tube wall, thereby forming mechanical connections between the injector sockets 12 and the tube 10 that are adapted to withstand higher maximum pressures than those at which conventional fuel rail assemblies can operate safely.
- An orientation notch 34 is provided in the distal end region 24 of at least some of the injector sockets 12.
- the lead thread 28 is formed so that it is aligned with an associated orientation notch 34.
- the orientation notch 34 is oriented before engagement with the tube 10 in relation with a longitudinal axis A - A of the tube 10.
- the fuel rail assembly has end threads defined in the internal wall at the upstream 18 and downstream ends 20 of the tube 10.
- a fuel inlet 38 ( FIG. 3 ) with threads engages the upstream end thread at the upstream end 18 of the tube 10.
- An end cap sensor boss 44 with threads engages the downstream end thread at the downstream end 20 of the tube.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Fuel-Injection Apparatus (AREA)
Description
- The technical domain of the invention relates to threaded fuel rails.
- One aspect of this disclosure incudes a fuel rail assembly for gasoline direct injection fuel delivery to an engine.
- To deliver fuel to direct injection internal combustion engines, a fuel rail or tube is often provided. Frequently, the main fuel is gasoline. Current high pressure fuel rail assemblies are made of a stainless steel tube and numerous stainless steel components such as injectors that are tack welded and thermally brazed together into a complete assembly. Current rail operating pressures are around 20 MPa (2900 PSI) maximum. Conventional designs have some difficulty in dealing with a higher maximum pressure of approximately 30 MPa (4400 PSI) and beyond. Such pressures raise concerns as to the integrity and reliability of the brazed joint connection.
- One of the concerns on any welded or brazed joint is the inability to easily verify the reliability of the connection. A brazed joint can visually look satisfactory but be compromised due to variations in the braze process. At higher pressures this would raise concerns about rail safety and performance.
- Japanese patent Laid-Open No.
2005-69023 - When the fuel rail and fuel injectors are subjected to high pressures in direct injection gasoline engines, for example, there is sometimes a tendency for fuel to leak, especially if a positional accuracy and roughness sealing surfaces are suboptimal. See, e.g., Japanese patent Laid-Open No.
2003-129920 - Fuel rails made of aluminum for direct-injection internal combustion engines cannot be used where injection pressures may reach 150-250 MPa. This is because the strength of aluminum is low. Further, the fuel rail may have disadvantageous layout characteristics because the wall thickness of the rail must be sufficient to withstand high fuel pressures. Consequently, production costs rise because contact surfaces with fuel must be treated by expensive surface treatment protocols. This may be required if the aluminum fuel rail is sensitive to alcohol and corrosive fuel.
- Among the art considered before filing this patent application are: USPN
8,596,246 ; USPN8,844,500 ; USPN8,844,502 ; USPN8,074,624 ;EP 2284385 ;EP1378658 ,DE102013220788 andEP 2333302 . - One aspect of this disclosure involves gasoline direct injection fuel delivery systems in which screw threads are provided on the components to be assembled. This allows for process control that will ensure a reliable connection that can withstand increased pressure and performance requirements. As described further below, one departure from conventional approaches and structures includes the method of attachment of injectors to the tube. A brazing step is no longer used. This attachment method and significantly increases allowable rail pressure and structural reliability while decreasing rail cost.
- In one form, the present disclosure relates to a fuel rail (a delivery pipe) for supplying high pressure fuel from fuel booster pumps. Fuel is injected through a fuel injector (an injection nozzle) into an engine cylinder.
- One embodiment of a fuel rail assembly for gasoline direct injection fuel delivery to an engine includes a common rail tube with internal and external walls, an upstream end and a downstream end. The tube has one or more threaded orifices extending between the internal and external walls. Injector sockets are threadingly engaged with the orifices.
- Each of the injector sockets has a proximal nipple end region connected to the tube and a distal end region. Screw threads are disposed around the proximal nipple end region. At the tube and at the proximal end of the injector socket, the screw threads begin with a lead thread and thus form registered mechanical connections between the injector sockets and the tube that are adapted to withstand higher maximum pressures than those at which conventional fuel rail assemblies can operate safely.
- An orientation notch is provided in the distal end region of at least some of the injector sockets. The lead thread of an injector socket is defined so that it is aligned with an associated orientation notch, which has its own lead thread. After exerting a pre-defined rotational force to the injector socket, the associated orientation notch is situated in a home position after threading engagement of the proximal nipple end regions of the one or more injector sockets by the tube. Thus, a pre-defined angular position of the injector sockets is created after torquing the injector sockets. In the predefined angular position, mechanical connections thereby formed seal the joints between the tube and the injector sockets.
- In some embodiments, the fuel rail assembly has end threads defined in the internal wall of the tube at its the upstream and downstream ends. A fuel inlet with threads engages the upstream end thread at the upstream end of the tube. An end cap sensor boss with threads engages the downstream end thread at the downstream end of the tube.
- The disclosed structure is expected to be used at higher maximum pressures equal to or in excess of approximately 35 MPa (5000 PSI) and will address concerns as to the integrity and reliability of conventional brazed joint connection.
-
-
FIG. 1 is a quartering perspective view of a threaded fuel rail assembly according to one embodiment of the invention; -
FIG. 2 is a top view thereof; -
FIG. 3 is a longitudinal sectional view taken along the line 3-3 inFIG. 2 ; -
FIG. 4 is a sectional view of the fuel rail assembly taken along the line 4-4 inFIGS. 2 and5 ; and -
FIG. 5 is an enlargement of one representative injection socket shown inFIG. 3 . - One aspect of this disclosure involves gasoline direct injection fuel delivery systems that operate under pressures that may be as high as 35 MPa (5000 PSI). Preferably, precisely oriented screw threads are provided on the components to be assembled. This allows for process control that will ensure a reliable connection between a
tube 10 and aninjector socket 12 that can withstand the increased pressure and performance requirements (FIGS. 1-5 ). As described further below, one departure from conventional approaches and structures includes the method of attachment of theinjectors 12 to thetube 10. A brazing step is no longer used. The disclosed attachment method allows safe and reliable operation under high rail pressures and provides structural reliability while decreasing rail cost. - In one form, the present disclosure relates to a fuel rail (a delivery pipe, 10) for supplying high-pressure fuel from fuel booster pumps through an
inlet 11. Fuel is injected through a fuel injector (an injection nozzle, 12) directly into anengine cylinder 13. - One embodiment of a fuel rail assembly for gasoline direct injection fuel delivery to an engine includes a
common rail tube 10 with internal 14 and external 16 walls, anupstream end 18 and adownstream end 20. Thetube 10 has one or more threadedorifices 21 extending between the internal andexternal walls Injector sockets 12 are threadingly engaged with the orifices 32. - Each of the
injector sockets 12 has a proximalnipple end region 22 to be connected to thetube 10 and adistal end region 24.Screw threads 26 are disposed around the proximalnipple end region 22. Thescrew threads 26 begin with a lead thread which mates with a lead thread 30 in an aperture 32 that extends through the tube wall, thereby forming mechanical connections between theinjector sockets 12 and thetube 10 that are adapted to withstand higher maximum pressures than those at which conventional fuel rail assemblies can operate safely. - An
orientation notch 34 is provided in thedistal end region 24 of at least some of theinjector sockets 12. On a given injector socket, the lead thread 28 is formed so that it is aligned with an associatedorientation notch 34. Theorientation notch 34 is oriented before engagement with thetube 10 in relation with a longitudinal axis A - A of thetube 10. After threading engagement of the proximalnipple end regions 22 of the one ormore injector sockets 12 and after subjecting theinjector nozzle 12 to a predefined torque, theinjector sockets 12 are turned into registration with thetube 10 so that their rotational movement ends at a home or seated position (e.g. 20 degrees,FIG. 2 ). In that position, sealed mechanical connections are thereby formed between thetube 10 and theinjector sockets 12. - In some embodiments, the fuel rail assembly has end threads defined in the internal wall at the upstream 18 and downstream ends 20 of the
tube 10. A fuel inlet 38 (FIG. 3 ) with threads engages the upstream end thread at theupstream end 18 of thetube 10. An endcap sensor boss 44 with threads engages the downstream end thread at thedownstream end 20 of the tube. - As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
Claims (6)
- A fuel rail assembly for gasoline direct injection fuel delivery to an engine, the assembly comprising
a common rail tube (10) with a longitudinal axis, internal and external walls, an upstream end (18) and a downstream end (20), the tube (10) having
one or more threaded orifices extending between the internal and external walls (14, 16); and
one or more injector sockets (12) that are adapted to mate with the threaded orifices (32), each injector socket (12) having
a proximal nipple end region (22) connected to the tube (10) and a distal end region (24) through which fuel is delivered to the engine;
screw threads (26) disposed around the proximal nipple end region (22), the screw threads (26) including a lead thread (30), the screw threads (26) being received by the one or more threaded orifices, thereby forming one or more mechanical connections between the injector sockets (12) and the tube (10) that are adapted to withstand a maximum pressure of fuel;
the fuel rail assembly being characterised in that it further comprises:an orientation notch provided in the distal end region of at least some of the injector sockets (12), the lead thread of an injector socket (12) being formed so that it is pre-aligned with an associated orientation notch,the orientation notch (34) being located in relation to the longitudinal axis after threading engagement of the proximal nipple end regions (22) of the one or more injector sockets (12) with the tube (10) at a pre-defined angular position in relation to the longitudinal axis of the tube (10) after torquing the injector sockets (12) to seal the mechanical connections thereby formed between the tube (10) and the injector sockets (12). - The fuel rail assembly of claim 1, further comprising
end threads defined in the internal wall at the upstream and downstream ends (18, 20) of the tube (10);
a fuel inlet (11, 38) with threads that engage the upstream end thread at the upstream end of the tube (10); and
an end cap sensor boss (44) with threads that engage the downstream end thread at the downstream end of the tube (10). - The fuel rail assembly of claim 1 wherein imaginary centers of the one or more threaded orifices (32) are aligned with the longitudinal axis.
- The fuel rail assembly of claim 1, further comprising
end threads defined in the internal wall (14) at the upstream end of the tube (10); and
a fuel inlet (11, 38) with threads that engage the upstream end thread at the upstream end of the tube (10). - The fuel rail assembly of claim 1, further comprising
end threads defined in the internal wall (14) at the downstream ends of the tube (10); and
an end cap sensor boss (44) with threads that engage the downstream end thread at the downstream end of the tube (10). - The fuel rail assembly of claim 1, wherein the maximum pressure is 35 MPa (5000 PSI).
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PL17176934T PL3418550T3 (en) | 2017-06-20 | 2017-06-20 | Threaded fuel rails |
EP17176934.2A EP3418550B1 (en) | 2017-06-20 | 2017-06-20 | Threaded fuel rails |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP17176934.2A EP3418550B1 (en) | 2017-06-20 | 2017-06-20 | Threaded fuel rails |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3418550A1 EP3418550A1 (en) | 2018-12-26 |
EP3418550B1 true EP3418550B1 (en) | 2019-11-20 |
Family
ID=59093457
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP17176934.2A Active EP3418550B1 (en) | 2017-06-20 | 2017-06-20 | Threaded fuel rails |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP3418550B1 (en) |
PL (1) | PL3418550T3 (en) |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3996369B2 (en) | 2001-10-22 | 2007-10-24 | 臼井国際産業株式会社 | Fuel delivery pipe |
US6886537B2 (en) * | 2002-07-04 | 2005-05-03 | Denso Corporation | Accumulation type fuel injection system for engine |
JP2005069023A (en) | 2003-08-26 | 2005-03-17 | Usui Kokusai Sangyo Kaisha Ltd | Fuel accumulator for diesel internal combustion engine |
JP5510992B2 (en) | 2008-06-30 | 2014-06-04 | 臼井国際産業株式会社 | Fuel rail for high pressure direct injection internal combustion engine and method for manufacturing the same |
US8074624B2 (en) | 2009-05-04 | 2011-12-13 | Hitachi Automotive Systems, Ltd. | Fuel system component for a direct injection internal combustion engine |
EP2284385B1 (en) | 2009-07-07 | 2014-06-25 | Continental Automotive GmbH | Fuel rail device |
US8844500B2 (en) | 2011-01-22 | 2014-09-30 | Cummins Intellectual Property, Inc. | Enclosure for high pressure fuel rail |
US8844502B2 (en) | 2012-07-24 | 2014-09-30 | Ford Global Technologies, Llc | Fuel rail mount |
DE102013220788B3 (en) * | 2013-10-15 | 2014-11-13 | Continental Automotive Gmbh | Arrangement for a fuel injection system |
-
2017
- 2017-06-20 EP EP17176934.2A patent/EP3418550B1/en active Active
- 2017-06-20 PL PL17176934T patent/PL3418550T3/en unknown
Non-Patent Citations (1)
Title |
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Also Published As
Publication number | Publication date |
---|---|
EP3418550A1 (en) | 2018-12-26 |
PL3418550T3 (en) | 2020-06-29 |
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