The present invention relates to a high-pressure fuel injection pump assembly, and in particular to a returnless high-pressure (HP) fuel pump assembly that is configured for inhibiting propagation of a pressure pulsation from a pump bushing to a low-pressure fuel line, the pressure pulsation resulting from a pressurization stroke or phase of the HP fuel pump assembly.
Fuel pumps for vehicles rapidly pressurize an amount of fuel delivered or drawn from a low-pressure fuel supply, such as a tank or reservoir, to a fuel delivery system for an internal combustion engine. Depending on the type of fuel delivery system used, i.e. a carburetor, a throttle body injection system, a port injection system, or a direct fuel injection system, the fuel may be delivered to or directed into the engine under relatively low- or high-pressure. For example, a fuel injection system typically requires fuel to be delivered at much higher pressures than does a carburetor. High-pressure (HP) fuel pump assemblies used with Spark Ignition Direct Injection (SIDI) engines in particular typically utilize fuel rail pressures of approximately 150 to 200 bar,
Combustible fuel may be pressurized to a sufficiently high level of pressure using a high-pressure (HP) fuel pump system or assembly. Such a HP fuel pump assembly typically operates as a demand-style pump assembly, i.e. a pump assembly having an output pressure and flow rate that vary in accordance with certain engine operating parameters such as load, speed, and/or temperature. Demand-style pump assemblies may be configured as either a “return” or a “returnless” design, depending on the respective presence or absence of a dedicated or separate fuel return line. That is, a returnless fuel pump assembly is characterized by the presence of a fuel feed line for delivering fuel to a portion of a pumping chamber within a pump bushing, and also by the absence of a dedicated fuel return line for returning an amount of unused fuel from the pumping cavity back to the tank/reservoir.
Accordingly, a returnless fuel pump assembly is provided having a plunger and a pump bushing, which together define a dual-chambered pumping cavity that is in fluid communication with a low-pressure supply of fluid. A fluid channel connects the two chambers of the pumping cavity to allow unused fluid to shuttle between the two chambers, thereby isolating a pressure pulsation occurring during a pressurization stroke of the fuel pump assembly. The fuel pump assembly has a plurality of fluid control valves, at least one of which is a check valve for containing the pressure pulsation within the pump bushing.
In one aspect of the invention, the fluid control valves include a check valve having an inlet side that is in fluid communication with the supply of fluid, and an outlet side that is in fluid communication with the dual-chambered pumping cavity.
In another aspect of the invention, a pressure relief valve is in fluid communication with an outlet port of the pump bushing and an inlet side of the check valve, with the pressure relief valve configured for opening in response to a threshold pressure of approximately, but not limited to, 200 to 225 bar in one embodiment.
In another aspect of the invention, the fuel pump assembly includes a second pressure relief valve having a flow path that is parallel to a flow path of the check valve.
In another aspect of the invention, the fuel pump assembly includes a control orifice of approximately, but not limited to, 0.4 to 0.6 millimeters in one embodiment, and having a flow path that is parallel to a flow path of the check valve.
In another aspect of the invention, a double-acting, returnless fuel pump assembly includes a pump bushing defining a dual-chambered pumping cavity, and a plunger having a primary axis. The plunger moves within the pumping cavity in response to a motion of an engine component, with movement of the plunger in one direction admitting an amount of low-pressure fuel from a reservoir into a first chamber of the pumping cavity, and movement of the plunger in another direction pressurizing the admitted fuel. A controllable solenoid valve admits the low-pressure fuel into the first chamber. An inlet side of a first check valve is in fluid communication with an outlet port of the pump bushing, and is configured as a pressure relief valve. An inlet side of a second check valve is in fluid communication with the reservoir, and an outlet side of the second check valve is in fluid communication with an inlet side of the controllable solenoid valve.
In another aspect of the invention, an outlet side of the first check valve is in fluid communication with one of an outlet side of the controllable solenoid valve and an inlet side of the second check valve.
In another aspect of the invention, a third check valve is positioned in parallel with the second check valve, and has an outlet side that is in fluid communication with the reservoir, as well as an inlet side that is in fluid communication with an inlet side of the controllable solenoid valve.
In another aspect of the invention, the second check valve and the third check valve are positioned at least partially externally to the pump bushing.
In another aspect of the invention, a control orifice is positioned in parallel with the second check valve, between the reservoir and an inlet side of the controllable solenoid valve.
In another aspect of the invention, a vehicle includes a transmission, an engine connected to the transmission for combusting a pressurized supply of fuel for powering the vehicle, and a high-pressure fuel rail for injecting the pressurized supply of fuel into the engine. The vehicle also includes a HP fuel pump assembly for pressurizing an amount of low-pressure fuel, the HP fuel pump assembly having a plunger and an inlet control valve. A low-pressure fuel line is in fluid communication with an inlet side of the inlet control valve and a low-pressure fuel supply, with the HP fuel pump assembly inhibiting a pressure pulsation from a pressurization stroke of the plunger from propagating through the low-pressure fuel line.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, and beginning with
The vehicle 10 includes a low-pressure fuel supply, reservoir, or tank 15 containing a low-pressure amount of combustible fuel 19L, with the character “L” representing relatively low-pressure throughout the various Figures. A supply pump 22, also labeled “L” in
The HP fuel pump assembly 24 is operable for rapidly pressurizing the fuel 19L to at least approximately 150 to 200 bar in one embodiment, although lower pressures are usable within the scope of the invention, and for delivering the pressurized fuel 19H to a fuel rail 16 through a high-pressure fuel line 11H, and ultimately to a fuel delivery device, such as a plurality of fuel injectors 16A. The pressurized fuel 19H is directly injected into various combustion chambers (not shown) of the engine 12 via the fuel injectors 16A, with the fuel rail 16 having at least one pressure sensor 18 operatively connected thereto and configured for sensing a fuel pressure at or in proximity to the fuel rail 16. An electronic control unit or controller 17 is in electronic communication with the engine 12, the fuel rail 16, the supply pump 22, and the HP fuel pump assembly 24, and enables the control and/or synchronization of the various fuel delivery components described herein.
Referring now to
The HP fuel pump assembly 24A includes an electro-mechanical solenoid device or a solenoid 56 operatively connected to and selectively controllable by controller 17. The solenoid 56 is a normally-open device, although a normally-closed solenoid or other controllable electro-mechanical device is also usable within the scope of the invention. The HP pump assembly 24A is thus operable for discharging an amount of pressurized fuel 19H into a respective fuel rail and injector 16 and 16A (see
The HP fuel pump assembly 24A includes a cylinder or pump bushing 50. The HP fuel pump assembly 24A further includes a piston or plunger 48, a plunger shaft 46, a cam follower 44, and various interconnecting fluid channels, as will be described hereinbelow. The HP fuel pump assembly 24A is shown schematically in the various figures for clarity, and therefore the interconnected fluid channels described herein may be sized and/or routed with respect to the pump bushing 50 as needed in order to make the most efficient use of available material space within the HP fuel pump assembly 24A.
The pump bushing 50 may be constructed of a high-strength material, such as stainless steel or another suitable metal or alloy, and has a continuous cylindrical inner wall 59 at least partially defining an upper pumping or pressure chamber 51A. The plunger 48 is cylindrical in shape, and is disposed within the cylindrical inner wall 59 of the pump bushing 50. The plunger 48 slides or moves in the direction of arrows A in response to a force applied by an engine component, such as a cam portion 42, with motion in the direction of arrow A describing a pressurization stroke or “upstroke” of the HP fuel pump assembly 24A. Motion in the direction of arrow B is provided by a return spring 89 disposed between a lower portion 31 of the pump bushing 50 and a floor 74 of the cam follower 44, which will be described later hereinbelow. Sealing of the plunger 48 within the pump bushing 50 relies on a high precision fit, i.e. approximately 2-3 microns of clearance, such that no additional seals are required for that purpose.
The plunger 48 may be operatively connected to or formed integrally with the plunger shaft 46, which is positioned concentrically within and passes through an opening 63 formed in lower portion 31 of the pump bushing 50. A seal 60, such as an o-ring or other suitable fluid seal, is positioned to prevent fluid bypass through the opening 63. The HP fuel pump assembly 24A is configured as a returnless pump, as described previously hereinabove, and may be configured as either a single-action pump or a double-action pump, with the double-action pump version shown in phantom.
The plunger shaft 46 is operatively connected to, or in continuous contact or engagement with, the cam follower 44. A wheel, drum, or roller 44A is operatively connected to cam follower 44 using a connecting pin or rod 61. The cam follower 44 is generally cylindrical piece of metal or other sufficiently rugged material in continuous rolling contact with an external surface 42A of a cam portion 42. Cam portion 42 has an upper cavity 77A positioned opposite a lower cavity 77B, with the floor 74 positioned therebetween to separate the two cavities 77A, 77B. The plunger 48 is positioned at least partially within the upper cavity 77A, with the roller 44A positioned at least partially within the lower cavity 77B.
The cam portion 42 may be a 1, 2, 3, or 4 lobe configuration, with each lobe either symmetrically or asymmetrically configured to provide a desired stroke of the plunger 48. As shown in
The HP pump assembly 24A is in fluid communication with the tank 15 (see
Pressurized fuel 19H passing through the outlet valve 71 enters the high-pressure fuel line 11H, which is in fluid communication with the fuel rail 16 and, ultimately, the fuel injectors 16A (see
A double-action configuration is shown in phantom in
As the HP fuel pump assembly 24A does not utilize a separate return line back to the tank 15 (see
Still referring to
Closing of the inlet valve 72 may occur anywhere from a bottom position, i.e. a bottom dead center (BDC) position, of the plunger 48, to any point along the upstroke path in the direction of arrow A during a pressurization stroke. The closing point of the inlet valve 72 is also known as the “delivery angle” or “cam angle”. For the three-lobe cam as shown in
However, at delivery angles less than 60°, pressure development within upper pressure chamber 51A becomes very rapid. For example, in less than 1 millisecond the pressure formed in the upper pressure chamber 51A can rapidly increase to approximately 150 bar or higher. As the delivery angle is lowered from 60° during periods of reduced fuel demand, inlet pulsations (arrows E) may progressively increase. Such pressure pulsations arise from the increasing quantity of “wasted” or unused pressurized fuel 19H from the pressurization phase, which must then flow backward through the open inlet valve 72 and toward the tank 15 (see
Referring to
In this manner, any “wasted”, unused, or uncompressed fuel will exchange or shuttle internally between the upper and lower chambers 51A and 51B, respectively, as represented by the arrow F of
Referring to
The snubber device 90 includes a check valve 75 as described above disposed within an upper fluid channel 91, and a high-pressure relief valve 78 disposed within a lower fluid channel 92, with the fluid channels 91 and 92 positioned in parallel as shown in
Referring to
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
This application claims priority to U.S. Provisional Patent Application No. 60/970,572, filed on Sep. 7, 2007, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
---|---|---|---|
60970572 | Sep 2007 | US |