This application is a U.S. National Stage Application of International Application No. PCT/EP2014/071638 filed Oct. 9, 2014, which designates the United States of America, and claims priority to EP Application No. 13187995.9 filed Oct. 10, 2013, the contents of which are hereby incorporated by reference in their entirety.
The present disclosure relates in general to injectors and more specifically to an injector for a combustion engine.
Injectors are in widespread use, in particular for internal combustion engines, where they may be arranged in order to dose the fluid into an intake manifold of the internal combustion engine or directly into the combustion chamber of a cylinder of the internal combustion engine. These injectors ought to have a high reliability over their lifetime and very exact injection volume.
The object of the invention is to create an injector which allows for an exact dosage of the fluid volume to be injected. The given fluid is, for example, gasoline or diesel.
In some embodiments, an injector for a combustion engine comprising an injection valve housing has an injection valve cavity. The injection valve housing defines a longitudinal axis. The injector further comprises a valve needle axially movable within the injection valve cavity and with respect to the injection valve housing. The injector further comprises an electromagnetic actuator assembly. The actuator assembly may be configured to actuate the valve needle. The electromagnetic actuator assembly comprises a pole piece being fixedly coupled with respect to the injection valve housing—for example in the injection valve cavity—and an armature being axially movable within the injection valve cavity for actuating the valve needle. The armature can be mechanically fixed to the valve needle.
In some embodiments, the armature is axially displaceable with respect to the valve needle. The valve needle is only movable within certain limits with respect to the pole piece. The valve needle is operable to seal a valve of the injector in a closing position. The valve needle is axially displaceable away from the closing position for opening the valve. The armature may be operable to mechanically interact with the valve needle for displacing the valve needle away from the closing position.
The injector further comprises a damping element which is arranged and configured to mechanically interact with the valve needle and the pole piece during movement of the valve needle with respect to the pole piece. By the provision of the damping element, a very exact volume of fluid can be injected by the injector in a controllable way. Particularly catalyst heating processes during an operation of the combustion engine may require, e.g., at a cold start of the engine, an accurate injection of a low volume or mass flow of fluid, in order to comply with future requirements of injectors.
In some embodiments, the damping element is arranged inside the injection valve cavity, wherein the damping element is disposed to abut a stop face of the pole piece. This embodiment provides a stop or reference which may be required for the damping element during its mechanical interaction with the valve needle and the pole piece.
In some embodiments, the stop face is disposed at an inner surface of the pole piece. The valve needle and the damping element can be arranged or disposed near the inner side of the pole piece or inside of the pole piece.
In some embodiments, the damping element is arranged axially between the stop face of the pole piece and the valve needle. The damping element may interact with the valve needle and the pole piece during a relative axial movement of the valve needle with respect to the pole piece, for example.
For example, the pole piece has a central recess which extends axially through the pole piece. The recess comprises a step so that it has a first portion and a second portion, which first portion has a larger cross-sectional area than the second portion.
The stop face is a radially extending surface of the step which also represents a bottom surface of the first portion. The valve needle is received in the first portion so that the first portion in particular guides the valve needle in axial direction.
For example, the valve needle has an armature retainer in an axial end region of the valve needle. The armature is in particular operable to interact mechanically with the valve needle by means of the armature retainer for displacing the valve needle. The armature retainer may be partially or completely be positioned in the first portion of the central recess of the pole piece. The damping element is preferably arranged between the step of the recess and the armature retainer.
In some embodiments, the damping element is axially fixed with respect to the pole piece. The damping element may be disposed such that it only mechanically interacts with the valve needle during a final movement of the valve needle with respect to the pole piece. Said final movement relates to the opening movement of the injector or the valve needle. In other words, the damping element may be axially spaced apart from the valve needle when the valve needle is in the closing position. The damping element may be arranged in such fashion that the valve needle approaches the damping element, comes into contact with the damping element and subsequently compresses the damping element axially when the armature is operated to displace the valve needle away from the closing position.
In some embodiments, the damping element is configured to provide damping, for example mass damping, during movement of the valve needle towards the stop face of the pole piece. Mass damping shall mean that kinetic energy of the valve needle is received by the damping element during movement of the valve needle towards the stop face of the pole piece.
In these embodiments, a mechanical interaction between the valve needle and the pole piece may be rendered more controllable during an operation of the injector.
In some embodiments, the damping, in particular the mass damping, is provided for more than the final 20 μm of movement of the valve needle towards the stop face of the pole piece. The damping element may account or compensate for tolerances or inaccuracies, e.g., of the valve needle or the pole piece during a fabrication of the injector.
For example, the injector is dimensioned such that the armature is displaceable by at least 20 μm towards the pole piece while the valve needle and/or the armature retainer abuts the damping element. The armature is displaceable with respect to the valve needle and is configured to couple to the armature retainer for displacing the valve needle away from the closing position after an initial idle stroke. The idle stroke may also be called a blind lift or free lift.
Injectors having such a free lift can be operated at particularly high pressures due to the comparatively large initial impulse transfer to the needle when the accelerated armature hits the armature retainer at the end of the idle stroke. However, there is a risk that the impact of the armature on the needle leads to an unpredictable movement of the valve needle with respect to the armature immediately after the impact. When the injector is operated in a so-called ballistic mode in which the actuator assembly is de-energized before the armature comes to a rest after hitting the pole piece, said unpredictable movement of the valve needle may lead to unintended variation of the fluid quantity dispensed by the injector. In some embodiments, the dampening element dampens the movement of the valve needle in a particularly large axial range even in the ballistic operation mode. Thus, a particular precise dosing of fluid is achievable.
In some embodiments, the electromagnetic actuator assembly is configured such that an armature movement towards the pole piece within the injection valve cavity is transferred to the valve needle during an operation of the injector.
In some embodiments, the movement of the valve needle towards the stop face of the pole piece relates to an opening of the injector. According to this embodiment, sticking of the valve needle at the stop face of the pole piece, which may, e.g., be caused by hydraulic damping between the valve needle and the pole piece and effect an unintended increase of the mass flow of fluid during operation of the injector, can advantageously be prevented.
In some embodiments, the damping element comprises a viscoelastic material such as a rubber compound.
In some embodiments, the damping element is an O-ring.
In some embodiments, the armature retainer comprises a spring seat for a valve spring. The valve spring is operable to bias the valve needle towards the closing position. The valve spring may extend axially through the damping element.
In some embodiments, the damping element is mounted to the injector in a pre-compressed state. The elastic or damping properties of the damping element may be adjusted to the respective requirements of the injector.
In some embodiments, the material of the damping element is adapted for a temperature range between −40° C. and +150° C.
In some embodiments, an injector for a combustion engine comprises an injection valve housing with an injection valve cavity, a valve needle being axially movable within the injection valve cavity, an electromagnetic actuator assembly and a damping element. Each of these is in particular in accordance with one of the embodiments described above.
The electromagnetic actuator assembly comprises the pole piece being fixedly coupled with respect to the injection valve housing in the injection valve cavity and the armature being axially movable within the injection valve cavity. The pole piece has a central recess which extends axially through the pole piece and has a step so that it has a first portion and a second portion, the first portion having a larger cross-sectional area than the second portion. The pole piece has a stop surface which is a radially extending surface of the step. The valve needle has an armature retainer which is partially or completely positioned in the first portion of the central recess of the pole piece. The armature is axially displaceable with respect to the valve needle and is operable to interact mechanically with the valve needle by means of the armature retainer for actuating the valve needle. The damping element is arranged axially between the stop surface and the armature retainer to mechanically interact with the valve needle and the pole piece—in particular via the stop surface and the armature retainer—during movement of the valve needle with respect to the pole piece. In some embodiments, the damping element is in form-fit connection with the stop surface and a surface of the armature retainer facing towards the stop surface.
Features which are described herein above and below in conjunction with different aspects or embodiments, may also apply for other aspects and embodiments. Further features and advantageous embodiments of the subject-matter of the disclosure will become apparent from the following description of the exemplary embodiment in conjunction with the figures, in which:
Like elements, elements of the same kind and identically acting elements may be provided with the same reference numerals in the figures. Additionally, the figures may be not true to scale. Rather, certain features may be depicted in an exaggerated fashion for better illustration of important principles.
The injector further comprises a valve seat 13, on which the needle ball 14 of the valve needle 5 rests in a closed position and from which the valve needle 5 is lifted for an open position. The closed position may also be denoted as closing position.
The injector further comprises a spring element 12 being designed and arranged to exert a force on the valve needle 5 acting to urge the valve needle 5 in the closed position. The armature retainer acts as a spring seat for the spring element 12. In the closed position of the valve needle 5, the valve needle 5 sealingly rests on the valve seat 13, by this preventing fluid flow through at least one injection nozzle. The injection nozzle may be, for example, an injector hole. However, it may also be of some other type suitable for dosing fluid.
The injector further comprises an electromagnetic actuator assembly, which is designed to actuate the valve needle 5. The electromagnetic actuator assembly, comprises a coil, in particular a solenoid 10. It further comprises a pole piece 1 which is fixedly coupled to the injection valve housing 11. The electromagnetic actuator assembly further comprises an armature 2 which is axially movable within the injection valve cavity by an activation of the electromagnetic actuator assembly.
The armature 2 is mechanically coupled or decoupled with the valve needle 5, preferably movable with respect thereto only within certain limits. In other words, the armature 2 can be positionally fixed with respect to the valve needle 5 or axially displaceable with respect to the valve needle 5, as in the present embodiment.
Axial displacement of the armature 2 with respect to the valve needle 5 in direction towards the pole piece 1 is limited by the armature retainer 15. The valve needle 5 further comprises a stop element 3 which is welded on a shaft 4 of the valve needle 5. The stop element 3 is operable to limit axial displacement of the armature 2 relative to the valve needle in direction away from the pole piece 1.
The injector applies a concept in which the armature momentum is used to generate an opening of the injector or the valve needle 5, or a movement of the valve needle 5 towards the stop face 8 of the pole piece 1 (“kick” see below). During this movement, a hydraulic load on a valve seat 13 is to be overcome.
The valve needle 5 prevents a fluid flow through a fluid outlet portion and the injection valve housing 11 in the closed position of the valve needle 5. Outside of the closed position of the valve needle 5, the valve needle 5 enables the fluid flow through the fuel outlet portion.
In case that the electromagnetic actuator assembly with the coil gets energized, the electromagnetic actuator assembly may affect an electromagnetic force on the armature 2. The armature 2 is thus displaced towards the pole piece 1. For example, it may move in a direction away from the fuel outlet portion, in particular upstream of a fluid flow, due to the electromagnetic force acting on the armature. Due to the mechanical coupling with the valve needle 5, the armature 2 may take the valve needle 5 with it, such that the valve needle 5 moves in axial direction out of the closed position. Outside of the closed position of the valve needle 5 a gap between the injection valve housing 11 and the valve needle 5 at an axial end of the valve needle 5 facing away from the electromagnetic actuator assembly forms a fluid path and fluid can pass through the injection nozzle.
In the case when the electromagnetic actuator assembly is de-energized, the spring element 12 may force the valve needle 5 to move in axial direction in its closed position. It is dependent on the force balance between the forces on the valve needle 5—including at least the force caused by the electromagnetic actuator assembly with the coil 10 and the force on the valve needle 5 caused by the spring element 12—whether the valve needle 5 is in its closed position or not.
The minimum injection of fluid, such as gasoline or diesel dispensed from the injector may relate at each injection pulse to the mass of 1.5 mg at pressures from e.g. 200 to 500 bar.
The damping element 7 is axially fixed with respect to the pole piece 1. The damping element 7 is arranged axially between the stop face 8 of the pole piece 1 and the armature retainer 15 of the valve needle 5. The damping element 7 is further disposed at an inner surface 9 of the pole piece 1.
The damping element 7 is arranged axially above, the valve needle 5, here at a position relative to the valve needle 5 facing axially away from the injector outlet or nozzle. The damping element 7 further abuts a stop face 8 of the pole piece 1 (cf.
More specifically, the pole piece 1 has a central recess 22,24 which is defined by the inner surface 9. The central recess 22,24 has a step 20 so that it is separated in a first portion 22 having a surface of the step 20 as a bottom surface and a second portion 24 upstream of the first portion 22. The bottom surface of the first portion represents the stop face 8. The second portion 24 has a smaller cross-sectional area than the first portion 22. The armature retainer 15 is arranged in the first portion 22 of the recess 22,24 of the pole piece 1 and axially guided by the first portion 22.
The spring element 12 extends from a spring seat in the second portion to the armature retainer 15 in the first portion. The armature retainer 15 acts as a further spring seat for the spring element 12.
The damping element 7 is preferably mounted to the injector 100 in a pre-compressed state, preferably the damping element 7 is pre-compressed by 1 to 2 N.
The damping element 7 may be an O-ring. In the present embodiment, the spring element 12 extends through the central opening of the O-ring.
Furthermore, the damping element 7 may comprise a viscoelastic material such as a rubber compound. The damping element 7 preferably, provides for a mass damping of the valve needle 5, when the valve needle 5 is moved towards the stop face 8 of the pole piece 1. Preferably, the mass damping is provided for more than the final 20 μm of movement of the valve needle 5 towards the stop face 8 of the pole piece 1.
In
The injector 100 may further comprise a further damping arrangement which provides for a hydraulic damping during movement of the valve needle away from the stop face 8 of the pole piece 1, for example during a closing of the injector. The damping arrangement may be represented mating surfaces of the armature 2 and the pole piece 1 which cooperate to provide hydraulic damping when the spring element 12 moves the valve needle towards the closed position—and, thus, the armature 2 out of contact with the pole piece 1 by means of mechanical interaction via the armature retainer 15. In addition, an additional damping arrangement may be provided for damping the movement of the armature 2 relative to the valve needle 5 when the armature 2 moves into contact with the stop element 3 of the valve needle 5.
In
As mentioned above, when the electromagnetic actuator assembly is activated or energized, the armature 2 is axially movable for an initial idle stroke until it contacts the armature retainer 15 of the valve needle 5 to generate the momentum and the above mentioned “kick” on the valve needle 5. Then, the armature 2 takes the valve needle 5 for about 80 to 90 μm with it on its travel towards the pole piece 1 (opening of the valve or so-called working stroke) such that the total movable distance of the armature 2 may relate to about 120 μm or 130 μm. The overall force Ftot of the armature effected by the electromagnetic actuator assembly provides the momentum for the opening of the valve needle (cf. “kick” of the valve needle as described above). The momentum is given by the following equation:
∫0TFtot(t)dt=mA*vT,
wherein mA is the armature mass and vT is the speed of the valve needle 5 at the event T of the contact of the valve needle 5 and the armature 2. The damping effect generated by the damping element to reduce the speed of the valve needle and to improve the controllability of the position and consequently the minimum flow rate is described by the following damping equations:
F(t)=mN{umlaut over (z)}+Dż+kz,
z(t=T)∝∫0TFtot(t)dt,
wherein mN is the needle mass, D is the introduced damping constant of the damping element 7 and k is the spring constant of the spring element 12.
The scope of protection is not limited to the examples given herein above. The invention is embodied in each novel characteristic and each combination of characteristics, which particularly includes every combination of any features which are stated in the claims, even if this feature or this combination of features is not explicitly stated in the claims or in the examples.
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13187995 | Oct 2013 | EP | regional |
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PCT/EP2014/071638 | 10/9/2014 | WO | 00 |
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WO2015/052281 | 4/16/2015 | WO | A |
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