The present invention concerns a fuel injector with balanced metering servovalve, for an internal combustion engine, in which the servovalve controls a control rod for the opening/closing of an injection nozzle.
Normally, the metering servovalve comprises a control chamber having a calibrated, pressurized fuel inlet hole. The control chamber is axially delimited by an end wall of the control rod on one side, and by the wall of the chamber on the other, fitted with an outlet or discharge hole. This outlet hole has a calibrated section and is opened/closed by a shutter to vary the pressure in the control chamber with a predetermined gradient. In particular, the shutter is axially movable under the action of an actuator and the axial thrust of a spring.
Injectors with a balanced-type metering servovalve have already been proposed, in which the shutter is subjected to substantially null axial pressure effects in the closed position, for which both the spring preloading and the actuator force can be reduced. In a known injector with balanced metering servovalve, the body of the valve is coupled with another body comprising an axial guide for the actuator anchor, through an intermediate element carrying an outlet hole with calibrated section, which communicates with a discharge passage carried by said other body. The discharge passage comprises an axial segment and a radial segment that exits through a lateral surface of the guide. In particular, the shutter is formed by a sleeve integral with the anchor and engaging in a fluid-tight manner with the axial guide, so as to obtain large fuel passage sections, without shutter rebound phenomena at the end of opening and closing travel.
This servovalve, although being satisfactory from the viewpoint of balancing pressure on the shutter, has the drawback of requiring three different parts to delimit the control chamber and to guide the anchor. Variations in the opening/closing behaviour of the injection nozzle with respect to that planned can be provoked due to the various couplings of these three parts and the flow conditions inside the injector at high fuel pressures.
An injector has also been proposed in which the valve body is in one piece with a shutter guide stem and carries an outlet passage comprising an axial segment and a radial segment. The latter has an accurately calibrated section and is opened and closed by the shutter, for which the servovalve is still of the “balanced” type.
This injector has a drawback due to the fact that the axial segment of outlet passage increases the volume of the control chamber. In order to achieve acceptable reactivity from the servovalve, it is necessary to reduce the diameter of the axial segment. Since the axial segment always has a very long length compared to the diameter, the drill bit needed to make it tends to flex, with high probability of breaking before arriving at the hole of the radial segment, which is why making it is difficult.
Furthermore, as it is necessary that the diameter of this axial segment is as small as possible, it follows that during the manufacture of the valve body, solid particles, such as machining chips for example, can remain trapped inside the blind part of the channel's axial segment. These solid particles, by having dimensions similar to those of the radial calibrated restriction, can even block it, endangering correct operation of the injector. Even a washing operation, with a liquid under high pressure for example, could be insufficient to remove these solid particles.
Since the calibrated section segment of the channel or restriction is radial, it must run onto a cylindrical surface and must match with the axial segment on the inside. Manufacturing of the valve body is therefore difficult and generates inaccuracies and a high reject percentage. In any case, due to the change in flow direction close to the calibrated section segment, disturbances are created in the fuel flow in output, which reduces reactivity.
Finally, due to the high pressure gradient that becomes established in correspondence to the calibrated restriction when the shutter is opened, vapour is formed immediately downstream of the same calibrated restriction. As this calibrated restriction is positioned close to the sealing surface of the shutter on the valve body, cavitation phenomena can arise that damage the sealing seat. In any case, the absence of fuel in the liquid phase in the zone of cavitation results in contact between the shutter and its seat without any form of damping. Both phenomena cause erosion and enormously shorten the life of the servovalve.
The object of the invention is that of embodying a fuel injector with a balanced servovalve for an internal combustion engine, which allows high servovalve reactivity to be achieved, eliminating the above-stated drawbacks in a simple and economic manner.
This object of the invention is achieved by a fuel injector with a balanced metering servovalve, for an internal combustion engine, as defined in the attached claims.
For a better understanding of the invention, some preferred embodiments will now be described, purely by way of non-limitative examples, with the aid of the attached drawings, in which:
With reference to
The casing 2 defines an axial cavity 6 in which a metering servovalve 5 is housed, comprising a valve body, indicated by reference numeral 7. The valve body 7 is in one piece with a tubular portion 8 that defines an axial hole 9, in which an injection control rod 10 can slide axially, sealed against pressurized fuel. The portion 8 has a cylindrical outer surface 11, from which a centering ridge 12 extends, coupled to an inner surface 13 of the body 2. The rod 10 is axially movable in the hole 9 to control, in the known manner, a shutter needle (not shown) that opens and closes the injection nozzle.
The casing 2 is fitted with another cavity 14, coaxial with cavity 6 and housing an actuator 15, comprising an electromagnet 16 able to operate a notched-disc anchor 17, which is integral with an axial sleeve 18. In particular, the electromagnet 16 comprises a magnetic core 19 that has a stop surface 20 for the anchor 17, perpendicular to the axis 3, and held in position by a support 21.
The actuator 15 has an axial cavity 22, in which a coil compression spring 23 is housed, preloaded to exert thrust on the anchor 17 in the opposite direction to the attraction exerted by the electromagnet 16. In particular, the spring 23 has one end resting against an internal shoulder of the support 21, and the other end acting on the anchor 17 through a washer 24.
The valve body 7 comprises a metering control chamber 26, which contains the volume delimited radially by the lateral surface of the hole 9 of the tubular portion 8, and axially by an end surface 25 of the rod 10 and by a bottom wall (or surface) 27 of the hole 9 itself. The control chamber 26 is in permanent communication with the inlet 4, through an inlet channel 28 made in portion 8, to receive pressurized fuel. The channel 28 is provided with a calibrated segment 29 that runs to the control chamber 26 in proximity to the bottom wall 27, for which the end surface 25 usefully has a truncated-cone shape. Instead, the inlet channel 28 runs to the outside, to an annular chamber 30, radially delimited by the surface 11 of portion 8 and by an annular groove 31 in the inner surface of the cavity 6. The annular chamber 30 is axially delimited on one side by the ridge 12 and on the other by a gasket 31a. Finally, a channel 32 made in the body 2 and in communication with the inlet 4 runs to the annular chamber 30.
Henceforth, the term “calibrated” applied to hole, channel, passage, segment or a restriction of these, is intended as indicating a diameter or a section and a length made with extreme precision, to exactly define a predetermined fluid flow rate with a given pressure difference between the associated inlet and the associated outlet. In particular, a so-called “calibrated” hole or restriction is subjected to precisely the operation of “calibration”, consisting in measuring the flow rate of a given fluid that passes through it when a predetermined pressure difference is applied between its upstream and downstream points.
The valve body 7 also comprises an intermediate axial portion, integral with the tubular portion 8, which forms an external flange 33, projecting radially with respect to the ridge 12, and housed in a portion 34 of the cavity 6 with enlarged diameter. The flange 33 is arranged axially in contact with a shoulder 35 inside the cavity 6, against which a threaded ring nut 36 is tightened, screwed into an internal thread 37 of portion 34, in order to guarantee fluid-tight sealing against the shoulder 35.
The valve body 7 also comprises a guide element for the anchor 17, composed of a stem 38 having a much smaller diameter than that of the flange 33. The stem 38 projects beyond the flange 33 itself, along the axis 3 in the opposite direction to the tubular portion 8, namely towards the cavity 22. The stem 38 is externally delimited by a lateral cylindrical surface 39 that guides the axial sliding of the sleeve 18. In particular, the sleeve 18 has an internal cylindrical surface 40, coupled to the lateral surface 39 of the stem 38 that is substantially fluid-tight, or rather via a coupling with opportune diameter play, 4 micron for example, or via the insertion of specific sealing elements.
The control chamber 26 also has a fuel outlet or discharge passage, indicated as a whole by reference numeral 42 and made entirely within the valve body 7. The passage 42 comprises a blind axial segment 43, made along the axis 3, partly in the flange 33 and partly in the stem 38. The passage 42 also comprises at least one radial segment 44 in communication with the axial segment 43. In the alternative of
The annular chamber 46 is obtained in an axial position adjacent to the flange 33 and is opened/closed by an end portion of the sleeve 18, which forms a shutter 47 for the outlet passage 42. The shutter 47 ends with a truncated-cone inner surface 48, which is able to engage a truncated-cone connecting surface 49 between the flange 33 and the stem 38.
In particular, the sleeve 18 is able to slide on the stem 38, together with the anchor 17, between an advanced end stop position and a retracted end stop position. In the advanced end stop position, the shutter 47 closes the annular chamber 46 and therefore also the outlet of the radial segment 44 of the passage 42. In the retracted end stop position, the shutter 47 sufficiently opens the annular chamber 46 to allow the radial segments 44 to discharge fuel from the control chamber 26, the outlet passage 42 and the annular chamber 46.
The advanced end stop position of the sleeve 18 is defined by the surface 48 of the shutter 47 hitting against the truncated-cone connection surface 49 between the intermediate portion 33 and the stem 38. Instead, the retracted end stop position of the sleeve 18 is defined by the anchor 17 axially hitting against the surface 20 of the core 19, with a nonmagnetic gap sheet 51 inserted in between. In the retracted end stop position, the anchor 17 places the annular chamber 46 in communication with a discharge channel of the injector (not shown), via an annular passage between the ring nut 36 and the sleeve 18, the notches in the anchor 17, the cavity 22 and an opening 52 on the support 21.
When the electromagnet 16 is energized, the anchor 17 moves towards the core 19, together with the sleeve 18, and hence the shutter 47 opens the annular chamber 46. The fuel is then discharged from the control chamber 26, the channel 42 and the annular chamber 46 itself. In this way, the fuel pressure in the control chamber 26 drops, causing an upward axial movement of the rod 10 and thus the opening of the injection nozzle.
Conversely, on de-energizing the electromagnet 16, the spring 23 returns the anchor 17, together with the shutter 47, to the advanced end stop position in
In order to control the velocity of pressure variation in the control chamber 26 on the opening and closing the shutter 47, the outlet passage 42 is fitted with a restriction or calibrated segment, generically indicated with reference numeral 53. As a rule, this calibrated segment 53 has a diameter between 150 and 300 micron. Instead, for technological reasons, the axial segment 43 of the passage 42 is at least five times the diameter of the calibrated segment 53.
According to the invention, in order to make the metering servovalve 5 more reactive, the calibrated segment 53 is arranged in the outlet passage 42 away from the annular chamber 46 and hence the shutter 47, and substantially close to the bottom wall 27 of the hole 9. In this way, the volume of fuel for which the pressure variation must be controlled is significantly reduced, being represented by just the volume of the hole 9 between the bottom wall 27 and the surface 25 of the rod 10, and by the possible portion of the passage 42 upstream of the calibrated segment 53.
Instead, the fuel volume of the passage 42 downstream of the calibrated segment 53, which can even be greater than the said volume of the hole 9, does not substantially affect the pressure variation in the control chamber 26. The axial segment 43 can usefully have a diameter at least eight times that of the calibrated segment 53. For technical reasons, the calibrated segment 53 is preferable arranged in a separate element of the valve body 7 and subsequently fixed in correspondence to the bottom wall 27 of the hole 9.
According to the alternative in
The bushing 54 has an external diameter such as to allow insertion by force, or rather interference fitting, into a seat 55 at the end of the axial segment 43 of the passage 42, in order to arrange it flush with the bottom wall 27 of the hole 9. Depending on the optimal volume required for the control chamber 26, the calibrated segment 53 can be arranged at the upper end of the bushing 54 as in
In any case, both the axial segment 43 and the radial segment 44 of the passage 42 are obtained in the valve body 7 via normal drill bits, without special precision. Instead, the calibrated segment 53 of the bushing 54 is made with high precision and the bushing 54 is subsequently implanted at the end of the axial segment 43, in any known manner.
According to the alternative in
According to the alternative in
As the end surface 25 of the rod 10 has a truncated-cone shape, the plate 56 can also have a considerably smaller diameter than that of the hole 9, as shown in
According to the embodiments in
According to the alternative in
In turn, the calibrated segment 53 is obtained in a bushing 61 of shorter length than that of the segment 58. The calibrated segment 53 extends for the entire length of the bushing 61, for which its manufacture becomes simpler. The bushing 61 is driven, or rather inserted by force, into a seat 60 having a diameter specially enlarged with respect to that of the axial segment 58 to facilitate this press fitting. The axial segment 58 can usefully have a diameter between 8 and 20 times that of the calibrated segment 53. In this way, when making the holes, the intersection of the same holes 59 with the end part of segment 58 is facilitated.
Furthermore, the radial segments 59 can be inclined with respect to the axis 3 by an angle between 30° and 45°. In this way, the length of the segment 58 is significantly reduced, and its manufacture and cleaning are facilitated. In addition, by ensuring that the end part of segment 58 is included in the external flange 33 of the valve body 7, the stem 38 has greater structural strength, the diameter of which can now even be reduced, with obvious benefits in limiting leaks in the pin/shutter dynamic seal.
According to the alternative in
The outlet passage 42 of the alternative in
In the alternatives in
The alternatives in
In particular, in the alternative in
The alternative in
Instead, mounting of the plate 69 is achieved via an insert formed by a sleeve 70, made of a relatively soft material to facilitate its press fitting. In fact, the valve body 7 is normally heat-treated to confer it with very high hardness; enough to reduce wear due to contact with the movable elements (control rod 10 and shutter 47).
Nevertheless, the plate 69 carrying the calibrated segment 53 must also be made of a very hard material, in order to resist wear phenomena caused by cavitation or erosion. As the press fitting of the plate 70 in a hard material into a seat of a very hard material can prove difficult to accomplish, it is useful to constrain the plate 69 carrying the calibrated segment 53 via the sleeve 70, made of a softer material and hence easy to press fit.
From what has been seen above, the advantages of the injector according to the invention with respect to injectors of known art are evident. First of all, even when the valve body 7, comprising both the tubular portion 8 and the guide stem 38 of the anchor 17, is obtained in a single piece, the calibrated segment 53, positioned away from the shutter 47 and close to the bottom wall 27 of the hole 9, allows the volume of the control chamber 26 to be reduced and improves the reactivity of the servovalve 5.
Having moved the calibrated segment 53 away from the truncated-cone surface 49 of the valve body 7, on which the sealing of the shutter 47 takes place, the risk of the sealing zone being subjected to cavitation wear phenomena is significantly reduced. In fact, as the diameter of this coaxial segment is much larger than that of the calibrated segment 53, the vapour formed immediately downstream of the calibrated segment 53 in the coaxial segment of the passage 42 is transformed back to the liquid phase again under the effect of expansion due to the increase in passage section.
Furthermore, it is possible to obtain both the axial segment and the radial segments of the outlet passage 42 via normal precision drilling. The calibrated segment 53 obtained in a bushing or a plate to be subsequently inserted in the specially provided seat allows a superior material, more suited to maximum precision machining, to be used. Alternatively, the calibrated segment 53 can be made in the bushing or plate using cheaper technologies, such as laser technology for example. Moreover, the abrasive calibration operation that, as already stated, consists in making a predefined flow rate of an abrasive fluid pass through this segment 53 to improve the velocity coefficient, is very simple and therefore of low cost.
Having increased the size of the diameter of the axial segment of the outlet passage 42, it is much easier to clean out chips during the various manufacturing phases. Since the press fitting of the element carrying the calibrated segment 53 is the last operation to be performed, the presence of particles that could jeopardize operation of the injector is avoided.
Finally, the alternatives in
The reduction of the seal diameter on the shutter 47 also allows the axial length of the sleeve 18 to be reduced.
In fact, the flow rate of fluid leakage is directly proportional to the circumference of the coupling zone between the inner cylindrical surface of the sleeve 18 and the outer cylindrical surface 39 of the stem 38, but inversely proportional to the axial length of this coupling zone: as the circumference of the coupling zone has decreased, for the same fluid leakage flow rate it is possible to reduce the axial length of the coupling zone and, consequently, the axial length of the sleeve 18.
The reduction of the seal diameter and, in consequence, the external diameter of the shutter 47 and the reduction in length of the sleeve 18 have the effect of reducing the mass of the sleeve 18 and, consequently, the response times of the metering servovalve 5.
Furthermore, the reduction in the seal diameter allows the load of the spring 23 to be reduced: in fact, for the same coupling play between the stem 38 and the shutter 47, the circumference of the seal between the stem 38 and the shutter 47 decreases and, consequently, also the axial force that acts on the shutter 47 due to the fuel pressure, which although minimal, is still present even if the metering servovalve is of the balanced tape. The ratio between the preloading of the spring 23 and the seal diameter or diameter of the coupling zone is usefully between 8 and 12 [N/mm].
The reduction in mass of the sleeve 18 and the reduction in load of the spring 23 have the effect of much smaller rebounds by the shutter 47 in the closure phase, and therefore better operating precision of the metering servovalve 5.
It is clear that other modifications and improvements can be made to the described alternatives of the injector 1 without leaving the scope of the invention. For example, the support for the calibrated segment 53 of the outlet channel 42 can have a different shape from those shown, and be fixed to the valve body 7 in a different manner, for example, via threaded elements.
Furthermore, the annular fuel inlet chamber 30 in the control chamber 26 can have a different shape and the seals between the tubular portion 8 and the hole 6, and between the flange 33 and the shoulder 35 can also be obtained with different means. In turn, the radial segments of the outlet passage 42 can be more than two and be arranged at equidistant angles.
Finally, the actuator 15 can be substituted by a piezoelectric actuator device.
Number | Date | Country | Kind |
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07425242 | Apr 2007 | EP | regional |
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6305355 | Hoffmann et al. | Oct 2001 | B1 |
6619617 | Ricco et al. | Sep 2003 | B2 |
6899069 | Mattes et al. | May 2005 | B2 |
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1 612 403 | Jun 2004 | EP |
1 621 764 | May 2005 | EP |
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Number | Date | Country | |
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20080257989 A1 | Oct 2008 | US |