Patent Application
20080041768
a is a schematic, partial cross sectional view of a first fuel injector nozzle defining a plurality of fuel injection holes;
b is a schematic, bottom view of the first fuel injector nozzle of
a is a schematic, partial cross sectional view of a second fuel injector nozzle defining a plurality of fuel injection holes;
b is a schematic, bottom view of the second fuel injector nozzle of
a is a schematic depiction of a sorting apparatus with the first fuel injector nozzle of
b is a schematic, elevational view of the screen of
c is a schematic, partial elevational view of the first fuel injector nozzle including a first identifier thereon;
a is a schematic depiction of the apparatus of
b is a schematic, elevational view of the screen of
c is a schematic, elevational view of the second fuel injector nozzle including a second identifier thereon.
Several exemplary embodiments and descriptions of sorting will be set forth below. These are exemplary only and intended to convey general principles to those of ordinary skill in the art. These embodiments and descriptions are not intended to limit or define the scope of patent protection. The scope of patent protection is intended to be defined in the attached set of claims.
The disclosure will be primarily described with reference to its application of sorting fuel injector tips. However, the disclosure is equally applicable to sorting other similar components or any component that may benefit therefrom.
Referring to
The tip 26A of the first fuel injector nozzle 10A defines a plurality of fuel injection holes 38A-H. The holes 38A-H extend from the conical portion 34 of the chamber 12 to the exterior of the fuel injector nozzle 10A. As understood by those of ordinary skill in this art, fuel under high pressure flows from the fuel chamber 12 into a combustion chamber (not shown) through the holes 38A-H during a fuel injection event.
The nozzle 10A is characterized by a first hole configuration. The first hole configuration includes eight holes. Each of the holes 38A-H is cylindrical, and is characterized by a diameter D1. Each of the holes 38A-H is characterized by an angular orientation; the centerline of each hole 38A-H forms angle α1 with the centerline C of the nozzle 10A. The first configuration is also characterized by the positions of the holes 38A-H, relative to the nozzle 10A and to each other, as shown in
Referring to
Those skilled in the art will recognize that the holes 38A-H and 42A-J of
The first and second hole configurations of nozzles 10A, 10B are exemplary. Hole configurations may include holes of any shape (e.g., oval, bugle shaped, etc.), size, orientation, quantity, position, etc. Further, although the holes of each nozzle 10A, 10B are shown identical in shape, size, and angular orientation, etc., it should be noted that a single nozzle may define holes of varying sizes, shapes, orientation, etc. One such example might be a showerhead nozzle used in some homogeneous charge compression ignition engines with holes of various orientations with respect to the nozzle centerline.
Referring to
The nozzle 10A is positioned within the fixture 52 such that light 60 from the light source 56 travels through the fuel chamber 12 and the holes 38A-H, and onto a light receiver 64, thereby to create a first light pattern (shown at 68A in
The light receiver 64 includes at least one of a screen 72 and a light sensor 76, such as a digital camera. In the embodiment depicted, the light receiver 64 includes both a screen 72 and a light sensor 76. Although the use of a screen 72 is optional, it is beneficial because a screen of a particular shape may intersect light 60 from the nozzle at close to a right angle so that the light is not distributed across a large surface area. The screen may have any geometric shape, such as hemispherical, cylindrical, planar, or any combination of shapes. The shape may be chosen to maximize sensitivity of sorting. For example, the screen 72 may define a concavity 80 that is open in the direction of the nozzle 10A, and, in the embodiment depicted, the screen 72 is hemispherical. In the embodiment depicted, the screen 72 is translucent, but not transparent, so that the light 60 diffuses as it passes through the screen 72, thereby making the light pattern more detectable by the light sensor 76. Light 60 from the holes 38A-H enters the screen 72 at a first surface 84 that defines the concavity 80, and exits the screen 72 from a second surface 88 that is opposite the first surface. The light sensor 76 is positioned to detect light 60 emitted from the second surface 88.
A “light pattern” is formed on a light receiver by the interaction of light from the nozzle 10A and the light receiver 64. Characteristics of a light pattern include the angle of incidence; the angle of refraction (if the light receiver is opaque or reflective); the manner in which light diffuses through the light receiver (if the light receiver is translucent); the area of illumination (i.e., the area of the light receiver receiving light), the intensity of the illumination (i.e., the electromagnetic flux at the surface of the light receiver); the distribution of light intensity over the surface of the light receiver; etc. As used herein, a light “pattern” does not imply any particular type or style of arrangement, configuration, or distribution of light on a light receiver, just light that can be detected in some way.
Referring to
A controller, i.e., a processor, 100 is operatively connected to the light sensor 76 to receive signals 96. In the context of the present disclosure, a “controller” or “processor” is any device or set of devices that are operative to perform the logical operations disclosed herein. A controller may be mechanical, electronic, etc. A typical electronic controller typically includes a microprocessor, ROM and RAM and appropriate input and output circuits of a known type for receiving various input signals and for outputting various control commands. An electronic controller may be programmable via software or have circuits physically dedicated to performing the logical operations described herein.
The controller 100 is programmed to process the signals 96 to sort the nozzle 10A into a first of a plurality of predetermined categories based on the light pattern 68A. For example, the controller 100 may sort one type of nozzle having holes in certain configuration from other types of nozzles having holes in other configurations. Or, the controller 100 may sort nozzles of the same type according to whether any of the holes are clogged, worn, damaged, etc. Or, the controller 100 may perform any combination of these types of sorting or other types of sorting. The controller 100 is operatively connected to a marker device 104 to cause the marker device 104 to mark the nozzle 10A with an identifier (shown at 108A in
The apparatus 48 may include an automatic feeder mechanism 112 that is configured to remove the nozzle 10A from the fixture 52, and to load another nozzle into the fixture for sorting. Referring to
In the fixture 52, the nozzle 10B is situated such that light 60 from the light source 56 travels through the fuel chamber 12, the holes 42A-J, and onto the screen 72 thereby to create a second light pattern (as shown at 68B in
More particularly, and with reference to
It may be desirable for the fixture 52, and therefore the nozzle contained therein, to be selectively rotatable via an actuator (not shown). The actuator may be controllable by the controller in order to selectively rotate the nozzle contained in the fixture and thereby arrange the light pattern on the screen for facilitated processing by the controller 100.
It may also be desirable for the screen 72 to be selectively movable such that the distance between the screen 72 and the nozzle 10A is selectively variable. As light departs the nozzle holes, it diffuses; accordingly, the size of the light pattern (and its component regions of locally intense illumination) on the screen 72 increases with increasing distance from the nozzle 10A. This increase in size is beneficial because it provides an enlarged projection of the hole configuration, facilitating both manual and automated hole configuration inspection. However, as the light diffuses, the light pattern generated becomes less distinct. Accordingly, the ability to vary the distance between the nozzle and the screen enables the controller or an operator to tune the apparatus to provide the optimum setting of light pattern size and light pattern distinctness.
It may also be desirable for the light sensor 76 to be selectively movable so that the distance between the screen 72 and the light sensor 76 is selectively variable in order to compensate for any movement of the screen so that the screen as perceived by the light sensor may remain constant.
In a preferred embodiment, the apparatus 48, including the light source 56, the fixture 52, the screen 72, and the light sensor 76, is contained inside a light-proof housing (not shown) to prevent ambient light from interacting with the screen 72 or the light sensor 76 and obscuring the light pattern formed by light from the nozzle. The interior surfaces of the container are configured to absorb light having the same wavelength of light from the light source to prevent stray light from the light source from obscuring the light pattern formed by light from the nozzle.
The sorting apparatus 48 may be advantageously used to sort nozzles without injecting fluid through the nozzles. Accordingly, the sorting apparatus 48 is simpler than prior art sorting systems because it does require a hydraulic circuit having a pump, a reservoir, etc. The sorting apparatus 48 also improves upon the prior art because passing light through a nozzle requires less time than injecting fuel or other liquid through the nozzle, thereby reducing the time required to sort a nozzle, and thus improving productivity. Furthermore, the apparatus 48 provides an enlarged image that corresponds to each unblocked nozzle hole, enabling more accurate and detailed sorting than is possible with merely visually observing fluid from the holes of a nozzle. The apparatus 48 also facilitates automated sorting of nozzles, because the enlarged images generated are more readily converted to digital or other electronic signals for processing by a controller than fluid sprayed from a nozzle.
The controller 100 may determine into which of the plurality of categories a nozzle is sorted based on one or more light pattern characteristics, which may include (1) the quantity of regions of locally intense illumination that are present in a light pattern, which corresponds to the quantity of unblocked holes in a nozzle; (2) the sizes of the regions of locally intense illumination that are present in a light pattern, which is determined, at least in part, by the sizes of the unblocked holes in a nozzle and their angles of orientation; (3) the intensity of illumination of the regions of locally intense illumination (or the total pattern), which is determined, at least in part, by sizes and angular orientations of the unblocked holes in a nozzle; (4) the relative positions of the regions of locally intense illumination, which corresponds to the relative positions of the unblocked holes of a nozzle; etc.
In order to program the controller for optimum sorting, it may be desirable to obtain and examine multiple characteristics of the light patterns produced by a sample of nozzles to be sorted, and to determine those characteristics that best differentiate nozzles in different categories. The controller 100 is preferably programmed to process the sensor signals 96 into one of the predetermined categories based on fewer than all of the light pattern characteristics obtained and examined, i.e., those characteristics that best differentiate the nozzles.
It should be noted that, in some circumstances, nozzles with different hole configurations may be functionally equivalent, and therefore should be sorted into the same category. In such a situation, it may be desirable for the controller to sort based on aggregated characteristics, such as the total or average light intensity of the screen, the combined surface area of the regions of locally intense illumination, etc.
Thus, the controller may sort by quantifying or qualifying characteristics of a light pattern, as perceived by the light sensor. It may be desirable to use commercially available machine vision software for analysis of light patterns. Those skilled in the art will recognize a variety of machine vision software that may be employed, such as “Vision Builder for Automated Inspection” available from National Instruments. Those skilled in the art will recognize a variety of other techniques that may be employed to sort a nozzle based on its light pattern. For example, the controller 100 may sort a nozzle by comparing the light pattern generated to one or more stored light patterns, each corresponding to a predetermined category, and sorting the nozzle based on which of the stored light patterns is most similar to, or substantially identical to, the generated light pattern.
In a first exemplary application of the sorting apparatus, nozzles are sorted after their manufacture to determine if they are within design specification, and the predetermined categories into which the nozzles are sorted will include a first category for nozzles that are within design specification, and a second category for nozzles that are not within design specification.
In a second exemplary application of the sorting apparatus, nozzles are sorted during remanufacturing to determine which of several hole configurations each nozzle has. The predetermined categories may include part numbers, an engine application for which the nozzle is suited, etc. The predetermined categories may also include a category for nozzles that are no longer serviceable, due to blocked holes, etc.
It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present invention in any way. Thus, those skilled in the art will appreciate that other aspects, objects, and advantages of the invention can be obtained from a study of the drawings, the disclosure and the appended claims. For example, the screen 72, if present, may be opaque, and the light sensor 76 positioned on the same side of the screen 72 as the nozzle 10A, 10B to detect the light pattern on the screen. The light receiver 64 may not include a light sensor 76, and the light pattern may be analyzed manually by a human. The light receiver may not include a screen 72, and the light sensor 76 may receive light 60 from the nozzle holes directly. The light sensor 76 may be positioned inside the fuel chamber 12, and the light source 62 may be positioned to transmit light into the chamber 12 through the holes 38A-H, 42A-J. The screen may be of any shape, including flat and cylindrical. Other nozzles, besides those used in fuel injection, may also be employed.
