Information
-
Patent Grant
-
6626150
-
Patent Number
6,626,150
-
Date Filed
Wednesday, April 4, 200123 years ago
-
Date Issued
Tuesday, September 30, 200320 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Argenbright; Tony M.
- Castro; Arnold
Agents
- Brinks Hofer Gilson & Lione
-
CPC
-
US Classifications
Field of Search
US
- 123 457
- 123 458
- 123 510
- 123 511
- 123 514
- 251 12909
- 251 1291
- 251 12915
- 251 12916
- 251 12921
- 251 12922
-
International Classifications
-
Abstract
A fuel pressure regulator is provided for producing more than one fuel pressure. The fuel pressure regulator includes a pressure plate that restricts fuel flow between an input line and an output line. A spring is provided for applying a force to the pressure plate. A coil and armature are also provided. The coil attracts the armature to a casing or head pole, thus applying more force to the pressure plate.
Description
BACKGROUND
The present invention relates generally to automotive fuel systems, and more particularly, to a fuel pressure regulator.
In automotive vehicles, the fuel supplied to the engine is pressurized before being fed to the engine. Typically, automotive fuel is stored unpressurized in a fuel tank. Through a series of pumps, valves and fuel lines, the fuel system then pressurizes the fuel to a final pressure before introducing the fuel to the engine. The final pressure of the fuel, however, is closely controlled to ensure proper performance of the engine.
Commonly, automotive fuel systems use a conventional fuel pressure regulator in at least one stage of fuel pressurization. The fuel pressure regulator may be located within the fuel tank of the vehicle, although the regulator may be located elsewhere in the fuel system. Typically, high pressure fuel is supplied to the fuel pressure regulator from a pump powered by a DC motor. The pressure level of the fuel supplied by the pump usually fluctuates. One reason for these pressure fluctuations is that the voltage supplied to the DC motor varies depending on the loads applied to the vehicle's electrical system and temperature and pressure changes in the fuel delivery system. The fuel pressure regulator removes these pressure fluctuations by introducing a pressure drop and supplying an output fuel line with lower pressure fuel with a generally constant pressure level.
Conventional fuel pressure regulators are usually preset by the manufacturer to provide a single pressure level at the output line. This is often achieved by calibrating a bias valve, such as a spring valve, during assembly of the fuel system. Although these systems are relatively inexpensive and simple to assemble, they are unable to provide variable pressure levels at the output line. As the demand for fuel efficiency and higher performance has increased, a need now exists for fuel systems that can provide variable fuel pressure depending on the operating conditions of the vehicle. Moreover, it is desirable to provide electronic control of the fuel system so the vehicle's central processing unit can automatically adjust the fuel pressure.
One alternative fuel system involves providing a brushless DC motor with speed control circuitry to power the fuel pump. A pressure sensor is also provided to monitor the pressure level of the fuel exiting the fuel pump. Thus, by monitoring the pressure level with the pressure sensor, the vehicle's central processing unit can adjust the speed of the motor to achieve the desired fuel pressure. The problem with this alternative is the high cost of the system compared to conventional fuel systems. For example, the brushless DC motor with speed control circuitry is more expensive than the standard DC motor used in conventional systems. An expensive pressure sensor is also required which is unnecessary in conventional systems. In addition, this alternative fuel system is more complicated and difficult to assemble than conventional fuel systems.
SUMMARY
The present invention is defined by the following claims, and nothing in this section should be taken as a limitation on those claims. By way of introduction, the embodiments described below include an electronically controlled continuous, fuel pressure regulator that produces more than one fuel pressure. The fuel pressure regulator includes an input line, an output line and a pressure plate that restricts fuel from passing from the input line to the output line. A spring is provided for resisting movement of the pressure plate. A coil, armature and casing or head pole are also provided for further resisting movement of the pressure plate. When electric current is supplied to the coil, a magnetic force attracts the armature toward the casing- or head pole.
Different embodiments of the fuel pressure regulator are provided. One embodiment includes a connecting tube. In this embodiment, the spring is compressed by the connecting tube when electric current is supplied to the coil. In other embodiments, a shaft is connected to the pressure plate and to the armature. In these embodiments, the armature resists movement of the pressure plate when electric current is supplied to the coil.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, including its construction and method of operation, is illustrated more or less diagrammatically in the drawings, in which:
FIG. 1
is a cross-section view of a first embodiment of a fuel pressure regulator;
FIG. 2
is a cross-section view of the first embodiment of the fuel pressure regulator, showing fuel flow through the fuel pressure regulator;
FIG. 3
is a cross-section view of a second embodiment of the fuel pressure regulator;
FIG. 4
is a cross-section view of a third embodiment of the fuel pressure regulator;
FIG. 5
is a cross-section view of a fourth embodiment of the fuel pressure regulator;
FIGS. 6A-6C
are cross-section views of a portion of one embodiment of a fuel pressure regulator, showing three different stops that may be used between the casing, armature or head pole; and
FIG. 7
is a schematic view of an electronic control circuit.
DESCRIPTION
Referring now to the drawings, several embodiments of a fuel pressure regulator are provided that can produce more than one fuel pressure. The first embodiment is shown in
FIGS. 1 and 2
. Like conventional fuel systems, the fuel pressure regulator
10
is installed within the fuel tank (not shown) of an automotive vehicle. The fuel pressure regulator
10
may also be installed elsewhere in the fuel system as desired. A fuel pump (not shown) supplies high pressure fuel to the fuel pressure regulator
10
through an input line
12
. As will be explained in detail below, the fuel pressure regulator
10
then passes the fuel from the input line
12
to the output line
14
.
The regulator
10
reduces the pressure of the fuel from the input line
12
and provides a controlled, lower pressure fuel at the output line
14
. The first embodiment generally produces one of two possible fuel pressures at the output line
14
. Accordingly, when no electric current is supplied to a coil
36
, a spring
40
generates a force that results in low fuel pressure in the output line
14
. However, when electric current is supplied to the coil
36
, the spring
40
and magnetic force generate a larger force that results in high fuel pressure in the output line
14
.
The fuel pressure regulator
10
includes a front housing
16
and a rear housing
18
. The front housing
16
is sealed and fixedly attached to the input line
12
, while the rear housing
18
is sealed and fixedly attached to the output line
14
. The rear housing
18
may also be attached to the output line
14
in other ways that are well known to those in the art. Along the circumference of the front housing
16
is a series of holes
20
that allow fuel from the input line to flow into the regulator
10
. The rear surface of the rear housing
18
includes a single hole
22
that allows fuel to pass out of the regulator
10
and into the output line
14
. As shown in
FIG. 2
, the fuel flows through a connecting tube
24
from the input line
12
to the output line
14
.
The connecting tube
24
is fixedly attached to an armature
26
, and the connecting tube
24
and armature assembly
26
freely slide within first
28
and second
30
guide diameters. The connecting tube
24
and armature assembly
26
is also sealed to the casing
34
with bellow seals
32
to prevent fuel leakage through the first
28
and second
30
guide diameters. A variety of seals may be used, such as bellows seals
32
that are affixed at one end to the connecting tube
24
or armature
26
and at the other end to the casing
34
.
The casing
34
is sealed and fixedly attached to both the front housing
16
and the rear housing
18
. The electrical coil
36
is installed within the casing
34
and around the tube
24
and can be supplied with electric current through electrical terminals (not shown).
Fixedly attached to the front side of the front housing
16
is a support plate
38
. A spring
40
is attached at one end to the rear surface of the support plate
38
. At the other end, the spring
40
is attached to a moveable pressure plate
42
. A bellow
43
, or membrane, seals one side of the pressure plate
42
from the input line
12
, thereby creating a cavity behind the pressure plate
42
.
In the low pressure mode, little or no electric current is supplied to the coil
36
. Therefore, in the low pressure state, the connecting tube
24
and armature
26
assembly moves rearward until the rear surface of the armature
26
abuts against the rear housing
18
. Thus, the spring
40
forces the pressure plate
42
against the front end of the connecting tube
24
.
High pressure fuel flows from the fuel pump to the regulator
10
through the input line
12
. The high pressure fuel enters the regulator
10
through the radial holes
20
in the front housing
16
. The high pressure fuel then applies a force to the pressure plate
42
that is proportional to the surface area of the pressure plate
42
and to the pressure level of the fuel. As shown in
FIG. 2
, the force applied by the high pressure fuel causes the pressure plate
42
to move forward (i.e., toward the left in
FIGS. 1 and 2
) and away from the connecting tube
24
, thereby compressing the spring
40
. The fuel then passes into and through the connecting tube
24
and flows out of the regulator
10
through the axial hole
22
in the rear housing
18
. The fuel then flows to the rest of the fuel system through the output line
14
.
Accordingly, the regulator
10
causes a drop in the fuel pressure from the input line
12
to the output line
14
. The fuel pressure in the output line
14
is also generally constant even if the level of fluid pressure in the input line
12
varies. Thus, when the fuel pressure from the fuel pump is relatively high, the fuel pressure compresses the spring
40
farther and causes the pressure plate
42
to move farther away from the connecting tube
24
. In contrast, when the fuel pressure from the fuel pump is relatively low, the spring
40
is compressed less by the fuel pressure and the pressure plate
42
remains closer to the connecting tube
24
.
The regulator
10
can also operate in a high pressure mode. In the high pressure mode, electric current is supplied to the coil
36
through the electrical terminals. The coil
36
then generates a magnetic field that forces the connecting tube
24
and armature
26
assembly to move forward. The casing
34
and armature
26
are preferably made of a ferro-magnetic material, such as iron or steel. The connecting tube
24
and armature
26
assembly move forward until the front surface
44
of the armature
26
abuts against a rear surface
46
of the casing
34
.
The forward end of the tube
24
moves the pressure plate
42
forward and compresses the spring
40
. As a result, the preload force of the spring
40
is higher in the high pressure mode than in the low pressure mode. Therefore, the high pressure fuel from the fuel pump moves the pressure plate
42
a smaller distance from the connecting tube
24
than the pressure plate
42
is moved in the low pressure mode. Thus, fuel pressure in the output line
14
is higher than in the low pressure mode.
The regulator
10
can be used in different configurations. For example, in the embodiment described above, the maximum gap between the front surface
44
of the armature
26
and the rear surface
46
of the casing
34
(as shown in the
FIGS. 1 and 2
) may be about 1 mm. This configuration results in about a 5 psi change in pressure in the output line
14
between the low pressure mode and the high pressure mode. However, other gap sizes can be used and other pressure ranges may be achieved.
FIG. 3
shows a second embodiment of a fuel pressure regulator
50
. Since the components and operation of the first embodiment of the regulator
10
have been described in detail, descriptions of similar components and operating principles of the second and following embodiments need not be repeated. In the second embodiment, the fuel pump supplies the high pressure fuel through the input line
52
. The fuel enters the input line
52
through a hole
56
in the circumference of the input line
52
. The output line
54
is positioned coaxially within the input line
52
, and supports
58
are installed within the input line
52
to position the output line
54
. The input line
52
is fixedly attached to the housing
60
of the regulator
50
.
The housing
60
includes a first guide diameter
62
along the front side of the housing
60
. A head pole
64
is fixedly attached to the inside of the housing
60
. The head pole
64
includes a second guide diameter
66
. A coil
68
is then installed inside the housing
60
between the front wall of the housing
60
and the head pole
64
. The coil
68
extends around the head pole
64
. Electrical terminals (not shown) are provided for supplying the coil
68
with electric current.
A connecting shaft
70
is fixedly attached at one end to an armature
72
and is fixedly attached at the other end to a pressure plate
74
. Thus, the armature
72
and shaft
70
assembly can slide forward and rearward through the first
62
and second
66
guide diameters. A spring
76
is positioned within the housing
60
between the head pole
64
and the pressure plate
74
. A seal
78
prevents fuel from entering the interior of the regulator
50
. The seal
78
is attached at one side to the housing
60
and is attached at the other side to the pressure plate
74
. In alternative embodiments, the seal is attached to the pressure plate
74
and slightly engages the housing
60
.
In the low pressure mode, little or no electric current is supplied to the coil
68
. The spring
76
forces the pressure plate
74
against the rear end of the output line
54
. When the pressure level of the fuel from the fuel pump exceeds the preload force of the spring
76
, the pressure plate
74
moves away from the output line
54
and compresses the spring
76
. Thus, the fuel pressure in the output line
54
is less than the fuel pressure in the input line
52
and is generally constant as previously described.
In the high pressure mode, electric current is supplied to the coil
68
. As a result, the rear surface
80
of the armature
72
is attracted towards the front surface
82
of the head pole
64
. Therefore, the armature
72
resists movement away from the head pole
64
.
Accordingly, the high pressure fuel from the fuel pump overcomes both the preload force of the spring
76
and the resistance of the armature
72
. Thus, an increased fuel pressure results in the output line
54
in the high pressure mode compared to the low pressure mode.
One advantage of the second embodiment is that multiple modes are possible for providing a greater range of fuel pressures in the output line
54
. This can be achieved by varying the amount of electric current supplied to the coil
68
, thereby increasing or decreasing the resistance of the armature
72
to forward movement. Thus, a relationship between the amount of electric current supplied to the coil
68
and the resulting pressure in the output line
54
can be determined and used to control fuel pressure.
Another advantage is that the amount of electric current and the size of the coil
68
may be reduced compared to the first embodiment. The attraction between the front surface
82
of the head pole
64
and the rear surface
80
of the armature
72
becomes considerably higher when these surfaces
80
,
82
are positioned relatively close to each other. In contrast to the first embodiment shown in
FIGS. 1 and 2
, the gap between the front surface
82
of the head pole
64
and the rear surface
80
of the armature
72
may be as small as 0.1 mm. Thus, with the two surfaces
80
,
82
being positioned relatively close to each other, a smaller amount of electric current is supplied to the coil
68
to achieve the desired resistance to movement of the pressure plate
74
. The size of the coil
68
may alternatively be reduced.
Another advantage of the second embodiment is the ease of assembly. Although the regulator
50
may be assembled in a variety of ways, one possible assembly procedure is as follows. First, the pressure plate
74
is fixedly attached to the connecting shaft
70
, and the shaft
70
is installed through the spring
76
and the second guide diameter
66
in the head pole
64
. The armature
72
is then installed onto the shaft
70
. Second, a calibrated force is applied to the pressure plate
74
and against the spring
76
while the armature
72
is secured in place. Once the spring
76
is compressed, the armature
72
is fixedly attached to the shaft
70
. Third, the coil
68
and electrical terminals are installed over the armature
72
, and the assembly is installed into the housing
60
. The head pole
64
is then fixedly attached to the housing
60
. Fourth, the housing
60
is installed onto the input line
52
and the output line
54
. Another calibrated force is then applied to the housing
60
to force the output line
54
against the pressure plate
74
. This calibrated force is larger than the first calibrated force, and therefore, causes the spring
76
to compress slightly. As a result, the rear surface
80
of the armature
72
moves a small distance away from the front surface
82
of the head pole
64
. The housing
60
is then fixedly attached to the input line
52
.
FIG. 4
shows a third embodiment of the fuel pressure regulator
90
. The components and operation of the third embodiment are similar to the second embodiment shown in FIG.
3
. However, in this embodiment, a smaller spring
92
is provided, and the location of the spring
92
is changed. The advantage of this embodiment is that the size of the regulator
90
can be further reduced.
Accordingly, the spring
92
is now positioned along the outer surface of the armature
72
. One end of the spring
92
abuts against a rear surface of the housing
60
, and the other end abuts against a stop
94
. The stop
94
is fixedly attached to the armature
72
.
The operating principles of the third embodiment are the same as the second embodiment. Thus, in the low pressure mode, little or no electric current is supplied to the coil
68
. The high pressure fuel in the input line
52
then forces the pressure plate
74
away from the output line
54
, thereby compressing the spring
76
. In the high pressure mode (or one of the multi-modes), electric current is supplied to the coil
68
. The fuel in the input line
52
overcomes both the preload force in the spring
92
and the resistance of the armature
72
.
FIG. 5
shows a fourth embodiment of the fuel pressure regulator
100
. The fourth embodiment is similar to the second and third embodiments. In this embodiment, a spring
102
is installed along the outer surface of a casing
104
. One end of the spring
102
abuts against a rear surface of the housing
60
, and the other end abuts against the front surface of the pressure plate
74
. The casing
104
is fixedly attached to the housing
60
through a support
106
at the front of the casing
104
. The fourth embodiment operates like the second and third embodiments described above.
As shown in
FIGS. 6A-6C
, several types of stops
110
,
112
,
114
can be used in the gap between the armature
26
,
72
and the casing
34
,
104
or head pole
64
. The stops
110
,
112
,
114
may be used in any of the embodiments described above. The stops
110
,
112
,
114
are useful in the first embodiment of
FIGS. 1 and 2
to prevent the armature
26
from completely abutting against the casing
34
, which could result in magnetic remanence. The stops
110
,
112
,
114
are also useful in the second, third and fourth embodiments to precisely maintain a small gap distance between the armature
72
and the head pole
64
or casing
104
. In
FIG. 6A
, a dimple
110
is shown attached to either the armature
26
,
72
, casing
34
,
104
or head pole
64
. Typically, three or more dimples
110
may be used around the circumference of the gap. The dimples
110
, like the stops
112
,
114
described below, are preferably made from a nonmagnetic material. One type of material that may be used for the dimples
110
is stainless steel.
In
FIG. 6B
, a ring
112
is shown attached to either the armature
26
,
72
, casing
34
,
104
or head pole
64
. The ring
112
may be either segmented or continuous around the circumference of the gap.
In
FIG. 6C
, a laminated, deposited, or bonded surface
114
is shown within the gap. The laminated surface
114
extends around the circumference of the gap. One type of material that may be used for the laminated surface
114
is bronze.
FIG. 7
shows an electronic control circuit that may be used with any of the embodiments of the fuel pressure regulator described above. The control circuit
120
connects the coil
128
of the fuel pressure regulator to a electric power source, such as a battery
122
, and to a switching device
124
. In the described control circuit
120
, the battery
122
and the switching device
124
are connected in series. The switching device
124
may be an electrical transistor, such as a MOSFET, or another type of switching device. The switching device
124
is then controlled by a control signal
126
from a low power electronic control system, such as the electronic fuel delivery control system or engine control system commonly used in conventional automotive systems.
It is now apparent that all of the embodiments of the fuel pressure regulator
10
,
50
,
90
,
100
provide several advantages over conventional pressure regulators and alternative fuel pressure systems. Compared to conventional pressure regulators, the fuel pressure regulator
10
,
50
,
90
,
100
improves automotive vehicle performance by providing more than one fuel pressure to the fuel system. The desired fuel pressure may be readily changed by changing the amount of electric current supplied to the coil
36
,
68
. Compared to alternative fuel pressure systems, the fuel pressure regulator
10
,
50
,
90
,
100
is less expensive, smaller and easier to assemble. Thus, whereas alternative fuel pressure systems typically include an expensive pressure sensor and a brushless DC motor with speed control circuitry, the fuel pressure regulator described herein requires none of these additional components. Instead, the fuel pressure regulator operates similar to conventional pressure regulators but with the added advantage of being able to provide multi-mode fuel pressure.
While a preferred embodiment of the invention has been described, it should be understood that the invention is not so limited, and modifications may be made without departing from the invention. The scope of the invention is defined by the appended claims, and all devices that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein.
Claims
- 1. A fuel pressure regulator comprising an input line; an output line; a pressure plate disposed adjacent said output line in a position to restrict flow from said input line to said output line, said pressure plate being moveable away from said output line thereby allowing fuel to pass from said input line to said output line; an electrical coil; a moveable armature disposed within said coil, said armature applying a force to said pressure plate thereby resisting said pressure plate movement away from said output line when electric current is supplied to said coil; and a spring resisting said pressure plate movement away from said output line, wherein said spring is a compression spring contacting one side of said pressure plate, and wherein said spring is disposed on an opposite side of said pressure plate from said coil and said armature.
- 2. The fuel pressure regulator according to claim 1, further comprising a casing or head pole disposed between said armature and said pressure plate, said coil attracting said armature toward said casing or head pole when supplied with said electric current.
- 3. The fuel pressure regulator according to claim 1, wherein said coil attracts said armature to a surface when supplied with said electric current thereby applying a force to said pressure plate.
- 4. A fuel pressure regulator comprising an input line; an output line; a pressure plate disposed adjacent said output line in a position to restrict flow from said input line to said output line, said pressure plate being moveable away from said output line thereby allowing fuel to pass from said input line to said output line; an electrical coil; a moveable armature disposed within said coil, said armature applying a force to said pressure plate thereby resisting said pressure plate movement away from said output line when electric current is supplied to said coil; and a connecting tube attached at one end to said armature and abutting said pressure plate at another end.
- 5. The fuel pressure regulator according to claim 4, further comprising a housing with an axial hole, said axial hole disposed adjacent said connecting tube and disposed within said output line.
- 6. The fuel pressure regulator according to claim 4, further comprising a seal attached to said connecting tube.
- 7. The fuel pressure regulator according to claim 4, further comprising a seal connected to said pressure plate sealing said input line from one side of said pressure plate.
- 8. The fuel pressure regulator according to claim 1, in combination with an electronic control system comprising an electric power supply connected with said coil, a switching device connected with said coil, and a signal controlling said switching device.
- 9. The fuel pressure regulator according to claim 4, further comprising a casing or head pole disposed between said armature and said pressure plate, said coil attracting said armature toward said casing or head pole when supplied with said electric current.
- 10. The fuel pressure regulator according to claim 4, wherein said coil attracts said armature to a surface when supplied with said electric current thereby applying a force to said pressure plate.
- 11. The fuel pressure regulator according to claim 4, in combination with an electronic control system comprising an electric power supply connected with said coil, a switching device connected with said coil, and a signal controlling said switching device.
- 12. A fuel pressure regulator comprising an input line; an output line; a pressure plate disposed adjacent said output line in a position to restrict flow from said input line to said output line, said pressure plate being moveable away from said output line thereby allowing fuel to pass from said input line to said output line; an electrical coil; a moveable armature disposed within said coil, said armature applying force to said pressure plate thereby resisting said pressure plate movement away from said output line when electric current is supplied to said coil; a spring positioned to resist said pressure plate movement away from said output line; a casing or head pole disposed between said armature and said pressure plate; wherein said coil attracts said armature to a surface of said casing or head pole when supplied with said electric current thereby applying a force to said pressure plate; and a connecting tube attached at one end to said armature and abutting said pressure plate at another end.
- 13. The fuel pressure regulator according to claim 12, wherein said spring is a compression spring contacting one side of said pressure plate; andfurther comprising a housing with an axial hole, said axial hole disposed adjacent said connecting tube and disposed within said output line.
- 14. The fuel pressure regulator according to claim 13, further comprising a seal attached to said connecting tube; further comprising a seal connected to said pressure plate sealing said input line from one side of said pressure plate; and further comprising a stop made of nonmagnetic material disposed between said armature and said casing or head pole.
- 15. The fuel pressure regulator according to claim 12, in combination with an electronic control system comprising an electric power supply connected with said coil, a switching device connected with said coil, and a signal controlling said switching device.
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A |
6378500 |
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B1 |