Patent Grant
10288022
The present invention relates to a fuel injector that supplies fuel to an internal combustion engine, and particularly, to a fuel injector that is driven by an electromagnetic force.
A background art of the technical field is disclosed in JP-A-2005-307750 (PTL 1). This publication discloses an electromagnetic fuel injector that includes a coil, a fixed core, a movable core, a fuel pipe, and a spring as parts of an electromagnetic drive unit. The fuel pipe has a large-diameter circular cylindrical portion and a small-diameter circular cylindrical portion, and the small-diameter circular cylindrical portion is provided at a lower end of the large-diameter circular cylindrical portion. The fixed core is mounted on an outer circumference of the small-diameter circular cylindrical portion, and the winding coil is mounted inside of the fixed core. The fixed core has an inner circumferential core portion and an outer circumferential core portion, an inner circumferential magnetic path is formed by the inner circumferential core portion, and an outer circumferential magnetic path is formed by the outer circumferential core portion. End surfaces of the inner circumferential magnetic path and the outer circumferential magnetic path face an end surface of the movable core. Magnetic fluxes generated by the energization of the coil flow between the end surface of the inner circumferential magnetic path and the end surface of the movable core, and between the end surface of the outer circumferential magnetic path and the end surface of the movable core, and a magnetic force (suction force) corresponding to a magnetic flux density is applied therebetween (refer to paragraphs 0034 and 0036).
A lower end portion of the small-diameter circular cylindrical portion of the fuel pipe extends toward a nozzle needle from the end surfaces of the inner circumferential magnetic path and the outer circumferential magnetic path. A cover is provided such that both axial end portions of the cover are respectively laser-welded to the entire outer circumference of the lower end portion of the small-diameter circular cylindrical portion and the entire outer circumference of the large-diameter circular cylindrical portion of the fuel pipe. The fixed core and the coil are accommodated in an inner space that is bounded by the cover and the fuel pipe, and fuel is prevented from infiltrating the fixed core and the coil (refer to paragraph 0040).
In regard to positions in which the cover is laser-welded to the outer circumference of the lower end portion of the small-diameter circular cylindrical portion, and the outer circumference of the large-diameter circular cylindrical portion, while deterioration in the magnetic characteristics of the fixed core induced by heat of fusion during welding is taken into consideration, the cover is joined to portions other than a movable core-side end surface of the fixed core, specifically, portions which are relatively separated from the movable core-side end surface of the fixed core, or a separate member (refer to paragraph 0050).
PTL 1 discloses an electromagnetic fuel injector that includes a cover made of a non-magnetic material which covers only the coil between an end surface of the inner circumferential magnetic path and an end surface of the outer circumferential magnetic path. This cover prevents fuel from infiltrating the coil. The cover is made thin, and may be made of a magnetic material, and when the cover is made of a magnetic material, the thickness of a bridge portion between the end surface of the inner circumferential magnetic path and the end surface of the outer circumferential magnetic path is set to be smaller than those of other portions (refer to paragraphs 0087 to 0089 and
PTL 1: JP-A-2005-307750
PTL 1 discloses the cover that covers the end surface of the inner circumferential magnetic path, the end surface of the outer circumferential magnetic path, and the coil between both of the end surfaces, and the cover that covers only the coil between the end surface of the inner circumferential magnetic path and the end surface of the outer circumferential magnetic path. In the former case, a portion of the cover, which covers the coil, is made of a non-magnetic material, and in the latter case, the cover is made of a non-magnetic material. These covers are provided so as to prevent fuel from infiltrating the fixed core or the coil, and PTL 1 merely discloses a configuration in which the cover is formed in the shape of a thin plate. In a design of the cover which covers only the coil between the end surface of the inner circumferential magnetic path and the end surface of the outer circumferential magnetic path, the fixation of the cover via welding is not taken into consideration.
In particular, when high pressurization of fuel is taken into consideration, the cover is preferably fixed via welding so that the cover can maintain sealability over a long period of time while counteracting fuel pressure. In a configuration disclosed in PTL 1, when the cover, which covers only the coil between the end surface of the inner circumferential magnetic path and the end surface of the outer circumferential magnetic path, is fixed via welding, welding need to be performed from the surface of the cover, which faces the movable core, with respect to an end surface of the inner circumferential core portion and an end surface of the outer circumferential core portion.
When welding is performed from the surface of the cover, which faces the movable core, with respect to the end surface of the inner circumferential core portion and the end surface of the outer circumferential core portion, sputters generated during welding, fusion-induced deformation, or heat-induced distortion are formed on the inner circumferential core portion, the outer circumferential core portion, and the movable core-side end surface of the cover. For this reason, a defect rate of the electromagnetic drive unit increases, a time or an workload required to perform an aftertreatment of removing sputter or deformation increases.
In a design of the electromagnetic fuel injector disclosed in PTL 1, deterioration in the magnetic characteristics of the fixed core induced by heat of fusion during welding is taken into consideration, and in contrast, deformation including distortion of the fixed core and the cover induced by heat of fusion is not taken into consideration.
Also in a case where treatments other than welding is performed, for example, a treatment of generating heat by applying energy to the cover is performed, when energy is applied to the end surface of the cover facing the movable core, the end surface of the cover facing the movable core is likely to be deformed (distorted). Hereinafter, the treatment (including welding) of generating heat by applying heat to a target member is referred to as a heat treatment.
In the following description, the fixed core and the movable core are respectively referred to as a fixed iron core and a movable iron core. Accordingly, the inner circumferential core portion and the outer circumferential core portion are respectively referred to as an inner circumferential fixed iron core portion and an outer circumferential fixed iron core portion.
In an electromagnetic fuel injector which is structured such that both end surfaces of an inner circumferential iron core portion and an outer circumferential iron core portion face a movable iron core, and a non-magnetic portion made of a metal material is provided between both end surfaces, an object of the present invention is to realize a structure in which a heat treatment is unlikely to affect the surface facing the movable iron core.
In an electromagnetic fuel injector of the present invention which is structured such that both end surfaces of an inner circumferential iron core portion and an outer circumferential iron core portion face a movable iron core, and a non-magnetic portion made of a metal material is provided between both end surfaces, in order to achieve this object, heat in a target member to be heat treated is generated by applying energy to a target member's surface which is different from a target member's surface that faces the movable iron core. More preferably, energy is applied to a surface different from a surface on a side that faces the movable iron core.
According to the present invention, in an electromagnetic fuel injector which is structured such that both end surfaces of an inner circumferential iron core portion and an outer circumferential iron core portion face a movable iron core, and a non-magnetic portion made of a metal material is provided between both end surfaces, it is possible to realize a structure of the electromagnetic fuel injector in which a surface of a target member to be heat treated is unlikely to be affected by a heat treatment, with the surface facing the movable iron core.
A task, a configuration, and effects which have not been described above become apparent from embodiments to be described hereinafter.
Hereinafter, embodiments of the present invention will be described.
Embodiment 1 of the present invention will be described with reference to
The entire configuration of an electromagnetic fuel injector 1 will be described with reference to
The electromagnetic fuel injector 1 is configured to include a fuel supply unit 2 that supplies fuel; a valve unit 3 that allows or shut off a flow of fuel; and an electromagnetic drive unit 4 that drives the valve unit 3. In the embodiments, an electromagnetic fuel injector for an gasoline internal combustion engine will be exemplarily explained. In the electromagnetic fuel injector 1 of the embodiments, the fuel supply unit 2, the electromagnetic drive unit 4, and the valve unit 3 are sequentially disposed along a direction of a central axis 1a. The fuel supply unit 2 is attached to a fuel delivery pipe (not illustrated), and the valve unit 3 is attached in such a way as to face the inside of an intake manifold or a cylinder, both of which are not illustrated. Fuel of the electromagnetic fuel injector 1 flows from the fuel supply unit 2 to the valve unit 3 along substantially the direction of the central axis of the electromagnetic fuel injector 1. That is, a fuel passage inside the electromagnetic fuel injector 1 is formed along substantially the direction of the central axis 1a of the electromagnetic fuel injector 1. For this reason, a fuel passage 106 is formed by a through hole 105 that passes through the centers of a fuel pipe 201 and an inner circumferential fixed iron core 401a along the direction of the central axis. A through hole 402a-5, which is a fuel passage, is formed in a first movable iron core 402a in such a way as to face an opening of a through hole 150. A concave portion 101a-2, which is a fuel passage, and a communication hole 101a-3 are provided in a diameter expansion portion 101a of a plunger rod 101 in such a way as to face an opening of the through hole 402a-5, and the communication hole 101a-3 serves as a fuel passage through which an inner circumferential side of the concave portion 101a-2 communicates with an outer circumferential side of the diameter expansion portion 101a. A through hole 402b-8, which is a fuel passage, is provided in a bottom surface of a concave portion of a second movable iron core 402b, and the first movable iron core 402a is accommodated in the concave portion of the second movable iron core 402b. Accordingly, fuel sequentially flows through the fuel passage 106 of the fuel pipe 201, the through hole 402a-5, the concave portion 101a-2, the communication hole 101a-3, and the through hole 402b-8, and then flows to the fuel passage 106 inside a nozzle body 111.
The fuel supply unit 2 is formed by the fuel pipe 201 that extends from a first end portion of the inner circumferential fixed iron core 401a of the electromagnetic drive unit 4 (to be described later), and a fuel supply port 201a opens in an end portion of the fuel pipe 201. A diameter expansion portion 201b is provided in the vicinity of the fuel supply port 201a of the fuel pipe 201, and the diameter of the diameter expansion portion 201b is expanded such that a stepped portion is formed. An O-ring 202 is attached between the diameter expansion portion 201b and the fuel supply port 201a. Backup rings 203a and 203b are disposed in a stacked manner between the O-ring 202 and the diameter expansion portion 201b. The O-ring 202 works as a seal that prevents leakage of fuel when the fuel supply port 201a is attached to the fuel delivery pipe. The backup rings 203a and 203b back up the O-ring 202. A filter 204 is provided inside of the fuel supply port 201a so as to filter foreign matter mixed into fuel.
The valve unit 3 includes an injection hole formation member 301 in which a fuel injection hole 301a and a valve seat 301b are formed; a guide member 302 that is disposed inside the injection hole formation member 301; and a valve body 303 that is provided in one end portion (tip end) of the plunger rod 101. The injection hole formation member 301 is fitted to the inner circumferential surface 111a of a concave portion that is formed in a tip end portion of the nozzle body 111. The guide member 302 guides the one end portion of the plunger rod 101 such that the plunger rod 101 moves in the direction (valve opening and closing direction) of the central axis 1a of the electromagnetic fuel injector 1. During valve closing, the valve body 303 comes into contact with the valve seat 301b, and seals fuel along with the valve seat 301b. The guide member 302 is provided with a fuel passage 302a through which fuel on an upstream side of the guide member 302 is sent to a fuel passage portion that is formed between the valve body 303 and the valve seat 301b, seals fuel during valve closing, and allows a flow of fuel during valve opening. The valve unit 3 is a main part that injects fuel sprays, and serves as a spray formation portion that forms sprays.
The electromagnetic drive unit 4 includes a fixed iron core 401 that serves as an electromagnet generating an electromagnetic force; a movable iron core 402; a coil 403; a first spring member (spring) 404 that biases the movable iron core 402 in a valve closing direction; and a spring force adjustment member 405 that adjusts a spring force of the spring member 404. The valve body 303 is driven by the electromagnetic drive unit 4 such that the valve body 303 moves away from the valve seat 301 or comes into contact with the valve seat 301, that is, a valve opening and closing operation is performed. In the embodiments, the movable iron core 402 is configured to include the first movable iron core 402a and the second movable iron core 402b, and a second spring member (spring) 406 is provided to bias the movable iron core 402 in a valve opening direction.
The nozzle body 111 is a housing member that accommodates portions from the movable iron core 402 of the electromagnetic drive unit 401 to the valve unit 3.
Hereinafter, the electromagnetic drive unit 4 will be described in detail with reference to
First, the configuration of the stator iron core 401 will be described in detail. The stator iron core 401 is configured to include the inner circumferential fixed iron core 401a that is provided on an inner circumferential side; the outer circumferential fixed iron core 401b that is provided on an outer circumferential side, while the coil 403 wound around a bobbin 407 is interposed between the inner circumferential fixed iron core 401a and the outer circumferential fixed iron core 401b; and an upper fixed iron core 401c that connects an end portion of the inner circumferential fixed iron core 401a to an end portion of the outer circumferential fixed iron core 401b. The outer circumferential fixed iron core 401b is an outer circumferential yoke portion (first yoke portion), the inner circumferential fixed iron core 401a is an inner circumferential yoke portion (second yoke portion), and the upper fixed iron core 401c is an upper yoke portion (third yoke portion).
An inner circumferential magnetic pole is formed on an end surface 401a-1 of the inner circumferential fixed iron core 401a which faces the movable iron core 402, and the inner circumferential magnetic path extends from the end surface 401a-1 toward the other end. The outer circumferential fixed iron core 401b is configured to include a first outer circumferential fixed iron core 401b-1 that faces the movable iron core portion 402, and a second outer circumferential fixed iron core 401b-2 that covers an outer circumference of the coil 403. An outer circumferential magnetic pole is formed on an end surface 401b-3 of the outer circumferential fixed iron core 401b which faces the movable iron core 402, and the outer circumferential magnetic pole extends from the end surface 401b-3 toward the other end. The upper fixed iron core 401c forms an upper (bridge portion) magnetic path.
A non-magnetic portion 401d is provided between an end portion 401a-2 and an end portion 401b-4, the end surface 401a-1 of the inner circumferential fixed iron core 401a is formed, and the end surface 401b-3 of the outer circumferential fixed iron core 401b is formed. The non-magnetic portion 401d is provided so as to reduce magnetic fluxes (leakage of magnetic fluxes) flowing without passing through the movable element 402 by disconnecting the end portion (in which the end surface 401a-1 of the inner circumferential fixed iron core 401a is formed) from the end portion (in which the end surface 401b-3 of the outer circumferential fixed iron core 401b is formed). In the embodiments, each of the inner circumferential fixed iron core 401a and the outer circumferential fixed iron core 401b is made of a metal material with magnetism, and a member made of a non-magnetic metal material is used as the non-magnetic portion 401d.
The configuration of the movable iron core portion 402 will be described in detail. The movable iron core portion 402 is configured to include the first movable iron core 402a and the second movable iron core 402b.
A concave portion 402b-1 is formed in an upper end surface (which faces the fixed iron core 401) 402b-2 of the second movable iron core 402b in such a way as to be recessed toward the other end surface (lower surface) of the second movable fixed iron core 402b. The first movable iron core 402a is accommodated in the concave portion 402b-1.
An outer circumferential portion of an upper end surface 402a-2 of the first movable iron core 402a faces the end surface 401a-1 of the inner circumferential fixed iron core 401a, and a lower end portion of the first spring member 404 is in contact with a central (inner circumferential) portion of the first movable iron core 402a. That is, a magnetic path, through which magnetic fluxes pass, is formed in the outer circumferential portion of the upper end surface 402a-2, and the inner circumferential portion serves as a spring seat for the first spring member 404. The first movable iron core 402a is biased in the valve closing direction by the first spring member 404. The first movable iron core 402a is provided with a concave portion 402a-3 that is recessed toward the upper end surface 402a-2 from the end surface (lower end surface) that is opposite to the upper end surface 402a-2, and the diameter expansion portion 101a of an upper end portion of the plunger rod 101 is inserted into the concave portion 402a-3. The first movable iron core 402a and the diameter expansion portion 101a of the plunger rod 101 are not fixed together, and can move relative to each other in the direction (valve opening and closing direction) of the central axis 1a. The outer circumferential surface of the diameter expansion portion 101a slides against the inner circumferential surface of the concave portion 402a-3 of the first movable iron core 402a, and the movement of the plunger rod 101 (the valve body 303) in the valve opening and closing direction is guided by the inner circumferential surface of the concave portion 402a-3.
A disk-shaped portion 402b-5 is formed in the second movable iron core 402b, and the upper end surface 402b-2 formed in the disk-shaped portion 402b-5 faces the end surface 401a-1 of the inner circumferential fixed iron core 401a and the end surface 401b-3 of the outer circumferential fixed iron core 401b. An upper end of the second spring member 406 is in contact with an end surface (lower end surface) 402b-3 opposite to the upper end surface 402b-2 of the second movable iron core 402b. A lower end of the second spring member 406 is in contact with a lower end surface (bottom surface) 111b of an accommodation chamber that is formed in the nozzle body 111 so as to accommodate the movable iron core 402 and the second spring member 406. That is, the lower end surface 111b of the accommodation chamber serves as a spring seat for the second spring member 406. The lower end surface 111b of the accommodation chamber faces the lower end surface 402b-3 of the second movable iron core 402b. The second movable iron core 402b is biased in the valve opening direction by the second spring member 406.
A convex portion 402b-5 is formed in an annular shape on the circumference of a small-diameter portion of the second movable iron core 402b which is positioned below the disk-shaped portion 402b-4. The convex portion 402b-5 is in contact with an inner circumferential surface 111c of the nozzle body 111, and the movement of the second movable iron core 402b in the direction of the central axis 1a is guided by the inner circumferential surface 111c. That is, the inner circumferential surface 111c serves as a guide surface that guides the movement of the second movable iron core 402b in the valve opening and closing direction. An outer circumferential surface 402a-1 of the first movable iron core 402a is in contact with an inner circumferential surface 402b-6 of the concave portion 402b-1 of the second movable iron core 402b, and the movement of the first movable iron core 402a in the direction of the central axis 1a is guided by the inner circumferential surface 402b-6. That is, the inner circumferential surface 402b-6 serves as a guide surface that guides the movement of the first movable iron core 402a in the valve opening and closing direction. The first movable iron core 402a and the second movable iron core 402b are configured to be able to move relative to each other in the direction of the central axis 1a, and the inner circumferential surface 111c guides the first movable iron core 402a via the second movable iron core 402b.
In a valve closed state (valve closed and stop state) illustrated in
The configuration of magnetic paths of the electromagnetic drive unit 4 and a valve opening and closing operation of the electromagnetic fuel injector 1 will be described with reference to
The end surface 401a-1 of the inner circumferential fixed iron core 401a and the end surface 401b-3 of the outer circumferential fixed iron core 401b form magnetic poles, respectively, and suction the first movable iron core 402a and the second movable iron core 402b.
The flow direction of magnetic fluxes through the magnetic path B can be opposite to a direction of the arrow in
When the coil 403 is energized, and magnetic fluxes are generated on the magnetic path B, the first movable iron core 402a is suctioned by the magnetic pole 401a-1 such that the first movable iron core 402a moves in the valve opening direction, and the second movable iron core 402b is suctioned by the magnetic poles 401a-1 and 401b-3 such that the second movable iron core 402b moves in the valve opening direction. When the second movable iron core 402b moves the gap (preliminary stroke) g3, the bottom surface 402b-7 of the second movable iron core 402b comes into contact with the lower end surface 101a-1 of the diameter expansion portion 101a of the plunger rod 101. Due to this contact, the second movable iron core 402b and the plunger rod 101 integrally move in the valve opening direction. The plunger rod 101 is closed until the second movable iron core 402b comes into contact with the diameter expansion portion 101a, and after the second movable iron core 402b comes into contact with the diameter expansion portion 101a, the plunger rod 101 starts to open. Accordingly, the operation of the plunger rod 101 can be prevented from being affected by a delay time from when the coil starts to be energized to when the second movable iron core 402b receives a magnetic suction force, and starts to move.
When the upper end surface (suctioned surface) 402a-2 of the first movable iron core 402a, and the upper end surface (suctioned surface) 402b-2 of the second movable iron core 402b come into contact with the end surface 401a-1 of the inner circumferential fixed iron core 401a and the end surface 401b-3 of the outer circumferential fixed iron core 401b, a valve opening operation is completed, and the valve is brought into a valve open and stop state.
In the valve open and stop state, a fuel pressure is applied to the diameter expansion portion 101a of the plunger rod 101 such that the plunger rod 101 is biased in the valve closing direction, and thus the lower end surface 101a-1 of the diameter expansion portion 101a is in contact with the bottom surface 402b-7 of the second movable iron core 402b. For this reason, a gap equivalent to the gap g3 is formed as a preliminary stroke between the bottom surface of the concave portion 402a-3 of the first movable iron core 402a and the upper end surface of the diameter expansion portion 101a. A gap (g1-g2) is formed between the lower end surface 402a-4 of the first movable iron core 402a and the bottom surface 402b-7 of the second movable iron core 402b.
A valve opening operation period refers to a period from when a magnetic suction force starts to be applied to the first movable iron core 402a and the second movable iron core 402b in the valve closed and stop state to when the first movable iron core 402a and the second movable iron core 402b move a full stroke such that the valve open and stop state is reached.
When the coil 403 is de-energized, a magnetic suction force decreases rapidly. At this time, the first movable iron core 402a is biased in the valve closing direction by the first biasing spring member 404, and thus when the magnetic suction force cannot counteract the biasing force of the first biasing spring member 404, the first movable iron core 402a starts to move in the valve closing direction. In contrast, since the second movable iron core 402b is biased in the valve opening direction by the second spring member 406, the second movable iron core 402b is stopped. Since the second spring member 406 biases the plunger rod 101 in the valve opening direction via the second movable iron core 402b, the plunger rod 101 is also stopped. When the first movable iron core 402a moves the gap (g1-g2) that is formed between the lower end surface 402a-4 of the first movable iron core 402a and the bottom surface 402b-7 of the second movable iron core 402b, the lower end surface 402a-4 of the first movable iron core 402a comes into contact with the bottom surface 402b-7 of the second movable iron core 402b, and the first movable iron core 402a and the second movable iron core 402b integrally move in the valve closing direction. Accordingly, the plunger rod 101 also moves in the valve closing direction.
When the valve body 303 comes into contact with the valve seat 301b, the plunger rod 101 stops moving in the valve closing direction. At this time, the plunger rod 101 may rebound to some extent. When the plunger rod 101 stops moving in the valve closing direction, the bottom surface of the concave portion 402a-3 of the first movable iron core 402a comes into contact with the upper end surface of the diameter expansion portion 101a of the plunger rod 101, and the first movable iron core 402a and the plunger rod 101 are integrated together. Even after the plunger rod 101 stops moving in the valve closing direction, due to an inertia force, the second movable iron core 402b moves away from the first movable iron core 402a, and continuously moves in the valve closing direction. When the second movable iron core 402b moves to some extent in the valve closing direction, the inertia force is attenuated by the biasing force of the second spring member 406, and the second movable iron core 402b stops moving. Thereafter, the second movable iron core 402b is pushed in the valve opening direction by the biasing force of the second spring member 406, the bottom surface 402b-7 of the second movable iron core 402b comes into contact with the lower end surface 402a-4 of the first movable iron core 402a, and a valve closing operation is completed in a state where the first movable iron core 402a and the second movable iron core 402b are integrated together. A valve closing operation period refers to a period from when the coil 403 is de-energized to when the valve closing operation is completed, and the valve closed and stop state is reached.
During valve closing, particularly, when the valve body 303 sits on the valve seat, since the second movable iron core 402b moves away from the first movable iron core 402a, mass of a movable element is decreased. As a result, the valve body 303 (the plunger rod 101) can be prevented from rebounding.
Hereinafter, a method of assembling the non-magnetic portion 401d of the fixed iron core 401 into the electromagnetic drive unit 4 will be described with reference to
The non-magnetic portion 401d is provided between the end portion 401a-2 (in which the end surface 401a-1 of the inner circumferential fixed iron core 401a is formed) and the end portion 401b-4 (in which the end surface 401b-3 of the outer circumferential fixed iron core 401b is formed). An annular member is used as the non-magnetic portion 401d, and an annular concave portion 401d-1 is circumferentially formed in an outer circumferential surface of the non-magnetic portion 401d. A bottom portion of the annular concave portion 401d-1 is welded all around as illustrated by W1, and thus the annular concave portion 401d-1 is fixed to the inner circumferential fixed iron core 401a, and a gap between the inner circumferential surface of the non-magnetic portion 401d and the outer circumferential surface of the inner circumferential fixed iron core 401a is sealed. In addition, all around welding is performed at a position illustrated by W1 such that the first outer circumferential fixed iron core portion 401b-1 and the non-magnetic portion 401d are fixed together, and a gap between the outer circumferential surface of the non-magnetic portion 401d and the inner circumferential surface of the first outer circumferential fixed iron core portion 401b-1 is sealed.
All around welding illustrated by W1 is performed in a state where the non-magnetic portion 401d is assembled to the outer circumferential surface of the inner circumferential fixed iron core 401a. At this time, the coil 403 wound around the bobbin 407, the outer circumferential fixed iron core 401b, the upper fixed iron core 401c, and the nozzle body 111 have not yet been assembled. Accordingly, it is possible to perform welding by applying energy for welding from the outside of the outer circumferential surface of the non-magnetic portion 401d. Laser welding or the like can be used as a welding method. During laser welding, laser beams are irradiated to the bottom surface of the concave portion 401d-1 from the outside of the outer circumferential surface of the non-magnetic portion 401d. The non-magnetic portion 401d may be welded all around to the inner circumferential fixed iron core 401a in a state where the non-magnetic portion 401d is assembled to the inner circumferential fixed iron core 401a via press fitting.
All around welding illustrated by W2 is performed in a state where the first outer circumferential fixed iron core portion 401b-1 is assembled to an assembly of the inner circumferential fixed iron core 401a and the non-magnetic portion 401d. At this time, the coil 403 wound around the bobbin 407, the second outer circumferential fixed iron core portion 401b-2, the upper fixed iron core 401c, and the nozzle body 111 have not yet been assembled. Accordingly, it is possible to perform welding by applying energy for welding to surfaces of the non-magnetic portion 401d and the first outer circumferential fixed iron core portion 401b-1, with the surfaces opposite to the end surface 401b-3 that faces the movable iron core 402. Laser welding or the like can be used as a welding method. During laser welding, the surfaces of the non-magnetic portion 401d and the first outer circumferential fixed iron core portion 401b-1 are irradiated with laser beams from the outside of the surfaces thereof, with the surfaces opposite to the end surface 401b-3 that faces the movable iron core 402. The all around welding W2 may be performed in a state where the first outer circumferential fixed iron core portion 401b-1 and the non-magnetic portion 401d are assembled together via press fitting.
Since the second outer circumferential fixed iron core portion 401b-2 has not yet been assembled when the all around welding W2 is performed, it is easy to apply energy to a welded portion, and for example, during laser welding, a welded portion is easily irradiated with laser beams. A thin wall portion 401b-1a for the attachment of the second outer circumferential fixed iron core portion 401b-2 is provided in an upper end portion of the first outer circumferential fixed iron core portion 401b-1. In order for a welded portion to be easily irradiated with laser beams, preferably, accuracy in fixing the second outer circumferential fixed iron core portion 401b-2 and rigidity of the thin wall portion 401b-1a are ensured, and a height h of the thin wall portion 401b-1a is decreased.
In the embodiments, it is possible to perform the welding W1 and the welding W2 by applying energy the surface of the fixed iron core 401, which is different from the end surface (the end surface 401b-3 of the first outer circumferential fixed iron core portion 401b-1, and the end surface 401a-1 of the inner circumferential fixed iron core portion 401a) that faces the movable iron core 402. For this reason, it is possible to prevent or suppress the occurrence of distortion or deformation of the end surface of the fixed iron core 401 which faces the movable iron core 402. Sputters generated during welding can be prevented from adhering to the end surface of the fixed iron core 401 which faces the movable iron core 402. In addition, since the welding W1 can be performed in a direction perpendicular to the outer circumferential surfaces of the non-magnetic portion 401d and the inner circumferential fixed iron core 401a, reliability of the welded portion is improved.
Hereinafter, the configuration of a member used as the non-magnetic portion 401d of the embodiments will be described with reference to
In
In contrast, when the first outer circumferential fixed iron core 401b-1 is press-fitted and fixed to the member used as the non-magnetic portion 401d, a press-fit load is increased. As illustrated in
As illustrated by the dotted line in
The second outer circumferential fixed iron core portion 401b-2 is assembled to an assembly of the inner circumferential fixed iron core 401a, the non-magnetic portion 401d, and the first outer circumferential fixed iron core portion 401b-1 which are assembled via the welding W1 and the welding W2. This assembly is performed via press fitting. The thin wall portions 401b-1a and 401b-2a are respectively provided in fitting portions of the first outer circumferential fixed iron core portion 401b-1 and the second outer circumferential fixed iron core portion 401b-2. Welding W3 is performed by applying energy to the outer circumferential surface of the thin wall portion 401b-1a such that the thin wall portion 401b-1a is fixed to the thin wall portion 401b-2a. Laser welding or the like can be used as a welding method. Since sealability is not required for the welding W3, all around welding is not required to be performed, and spot welding may be performed as the welding W3.
An assembly 150 of the inner circumferential fixed iron core 401a, the non-magnetic portion 401d, the first outer circumferential fixed iron core portion 401b-1, and the second outer circumferential fixed iron core portion 401b-2 is built via the aforementioned welding process. A longitudinal sectional view of the assembly 150 is illustrated in
The coil 403 wound around the bobbin 407 is mounted in the accommodation space 401e of the assembly 150, and thereafter, the upper fixed iron core 401c is attached to an upper opening of the accommodation space 401e. The upper fixed iron core 401c is press-fitted to the outer circumferential surface of the inner circumferential fixed iron core 401a, and welding W4 is performed by applying energy from the outside of the outer circumferential surface of the outer circumferential fixed iron core portion 401b-2. Laser welding or the like can be used as a welding method. All around welding cannot be performed due to wirings of terminals 119, which is not a problem because sealability is not required for the welding W4. Spot welding may be performed as the welding W4. As a result, the upper fixed iron core 401c is fixed to the outer circumferential fixed iron core portion 401b-2. Welding W5 is performed on the upper surface of the upper fixed iron core 401c, and thus the upper fixed iron core 401c is fixed to the inner circumferential fixed iron core 401a. Since sealability is not required for the welding W5, spot welding may be used as the welding W5.
The terminals 119, which are electrically connected to the coil 403, lead from the upper fixed iron core 401c. Resin molding 120 is applied to the surroundings of the coil 403 in the accommodation space 401e (refer to
A fixed iron core 401-side assembly has been built, the movable element made up of the movable iron core 402 and the plunger rod 101, and the second spring member 406 are accommodated in an accommodation space 111d of the nozzle body 111, and the nozzle body 111 is fixed to the fixed iron core 401-side assembly. This fixing is done by all around welding W6 that is performed by applying energy from the outside of an upper end portion 111e of the nozzle body 111. Laser welding or the like can be used as a welding method. At this time, the injection hole formation member 301 and the guide member 302 may be in a state of being attached to the nozzle body 111, or after the nozzle body 111 is assembled to the fixed iron core 401-side assembly, the injection hole formation member 301 and the guide member 302 may be assembled to the nozzle body 111. It is necessary to adjust a stroke of the valve body 303 (the plunger rod 101), and depending on a stroke adjustment method, it is possible to change an assembly sequence in which the injection hole formation member 301 and the guide member 302 are assembled to the nozzle body 111. A description of the stroke adjustment will be omitted.
Examples, in which the shape of the member used as the non-magnetic portion 401d is modified, will be described with reference to
The member used as the non-magnetic portion 401d may have a shape illustrated in
Also in this example, the welding portion W1 between the non-magnetic portion 401d and the inner circumferential fixed iron core 401a, the welding portion W2 between the non-magnetic portion 401d and the first outer circumferential fixed iron core portion 401b-1 are performed by applying energy (irradiation of laser beams) to the surface that is different from the surface of the non-magnetic portion 401d which faces the movable iron core 402. In particular, in this example, it is possible to perform the welding W1 and the welding W2 at two locations on the surface opposite to the surface that faces the movable iron core 402. For this reason, after the member used as the non-magnetic portion 401d is assembled to the first outer circumferential fixed iron core portion 401b-1 before being assembled to the inner circumferential fixed iron core 401a, the member used as the non-magnetic portion 401d can also be assembled to the inner circumferential fixed iron core 401a.
The longitudinal section of the member used as the non-magnetic portion 401d may have a rectangular (or square) shape illustrated in
The longitudinal section of the member used as the non-magnetic portion 401d may have a shape bent at 90 degrees (right angle) as illustrated in
Embodiment 2 of the present invention will be described with reference to
Similar to
First, a configuration illustrated in
In the embodiment, the inner circumferential fixed iron core 401a and the first outer circumferential fixed iron core portion 401b-1 are formed as a single component (single member) in which the inner circumferential fixed iron core 401a and the first outer circumferential fixed iron core portion 401b-1 are connected to each other via a non-magnetic region 401d-2. Typically, the non-magnetic region 401d-1 is made of a magnetic material; however, the non-magnetic region 401d-1 is brought into a state of being not magnetized via a non-magnetization process such as a heat treatment. A void 401d-2 is formed in a surface of the non-magnetic region 401d-1 which faces the movable iron core 402, and the non-magnetic portion 401d is configured to include the void 401d-2 and the non-magnetic region 401d-1. The void 401d-2 is an annular concave portion (groove) that is formed between the end surface 401a-1 of the inner circumferential fixed iron core 401a and the end surface 401b-3 of the first outer circumferential fixed iron core portion 401b-1.
In the embodiment, welding is not required; however, a non-magnetization process such as a heat treatment is required to form the non-magnetic region 401d-1. During a non-magnetization process, a surface (opposite to the surface that faces the movable iron core 402) of the non-magnetic region 401d-1 is irradiated with laser beams such that energy for a heat treatment is applied thereto. Even if the irradiated surface is distorted due to the irradiation of laser beams, since the distorted irradiated surface is opposite to the surface that faces the movable iron core 402, the surface facing the movable iron core 402 can be less affected.
In the embodiment, it is possible to reduce the number of components, and it is possible to reduce an assembly time by reducing a time required to align the positions of the components. In the embodiment, the inner circumferential fixed iron core 401a, the non-magnetic region 401d-1, and the first outer circumferential fixed iron core portion 401b-1 are formed as a single component, and thus sealability of this region is ensured.
As illustrated in
In contrast, in a configuration illustrated in
In the configurations illustrated in
Hereinafter, characteristics which are common to Embodiments 1 and 2 will be described with reference to FIGS. 2 and 3. The description will be given on the condition that the non-magnetic portion 401 is a portion of the fixed iron core 401.
In Embodiments 1 and 2, energy for welding or a non-magnetization process is applied to the surface (referred to as a second surface) of the stator iron core 401 which is opposite to the surface (referred to as a first surface) that faces the movable iron core 402. For this reason, the first surface is not affected or is unlikely to be affected by distortion or deformation that is formed on the second surface. When welding or a non-magnetization process is performed by irradiating a target object with laser beams, the second surface is irradiated with laser beams. Hereinafter, laser welding or a non-magnetization process using laser beams will be described.
When the second surface is irradiated with laser beams, an irradiated portion irradiated with laser beams is positioned at the bottom of an annular concave portion that is surrounded between the inner circumferential fixed iron core 401a and the outer circumferential fixed iron core 401b. For this reason, the outer circumferential fixed iron core 401b is partitioned into two components (the first outer circumferential fixed iron core 401b-1 and the second outer circumferential fixed iron core 401b-2). The location of partitioning of the outer circumferential fixed iron core 401b into the first outer circumferential fixed iron core 401b-1 and the second outer circumferential fixed iron core 401b-2 is positioned lower (closer to the end surface 401b-3) than an upper end portion 403 of a winding portion of the coil 403. A welding joining location W3 between the first outer circumferential fixed iron core 401b-1 and the second outer circumferential fixed iron core 401b-2 is positioned lower than the upper end portion 403 of the winding portion of the coil 403.
The outer circumferential surface of the second outer circumferential fixed iron core 401b-2 forms the outer circumferential surface of a metal housing which is positioned in an uppermost portion of the electromagnetic drive unit 4, and the outer circumferential surface of the first outer circumferential fixed iron core 401b-1 forms the outer circumferential surface of the metal housing which is positioned therebelow.
The outer circumferential surface of the nozzle body 111 forms the outer circumferential surface of a metal housing that surrounds an outer circumference of the movable iron core 402 of the electromagnetic drive unit 4. In order to assemble the movable iron core 402, the second spring member 406, and the plunger rod 101, the nozzle body 111 has to be partitioned from the outer circumferential surface of the metal housing which are formed by the outer circumferential surfaces of the second outer circumferential fixed iron core 401b-2 and the first outer circumferential fixed iron core 401b-1. The location of partitioning is positioned on a movable iron core side end surface of the fixed iron core 401, that is, is positioned above the end surface 401b-3 of the first outer circumferential fixed iron core 401b-1 (on the outer circumferential surface of the second outer circumferential fixed iron core 401b-2). The outer circumferential surfaces of three metal components form the outer circumferential surface of the metal housing that surrounds the electromagnetic drive unit 4.
As illustrated in
As illustrated in
When energy for welding is applied to a member made of a magnetic material, and the member is heated, magnetism may be lost or be decreased. In particular, when sealability is not required, spot welding or the like may be performed, and a heated portion may be limited to a narrow range. Magnetism which is decreased due to heating associated with welding can be restored via annealing.
The present invention is not limited to the configurations in the embodiments, and includes various modification examples. For example, the embodiments have been described in detail so as to easily describe the present invention, and the present invention is not necessarily limited to an embodiment including all of the configurational elements. A portion of configurational elements of an embodiment can be replaced with configurational elements of another embodiment, and configurational elements of another embodiment can be added to the configuration of an embodiment. Other configurational elements can be added to, be removed from, or be replaced with a portion of the configuration of each of the embodiments.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-051103 | Mar 2013 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/051616 | 1/27/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2014/141757 | 9/18/2014 | WO | A |
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| 20050006492 | Brooks et al. | Jan 2005 | A1 |
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| International Search Report (PCT/ISA/210) dated May 13, 2014 with English-language translation (five (5) pages). |
| Number | Date | Country | |
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| 20160025052 A1 | Jan 2016 | US |
