Patent Grant
12326129
The present disclosure relates generally to fuel systems and, more particularly, to a rotatable bypass assembly for use with a high-pressure fuel pump. The rotatable bypass assembly that is the subject of the present disclosure relates to protecting a diesel fuel system from damage caused by contaminants and contaminated fuel in the event of a mechanical failure of a high-pressure fuel pump, without regard to the specific vehicle or engine application in which the high-pressure fuel pump is installed and without the need for an application specific or vehicle specific bypass block. In that regard, the present disclosure relates to a universal rotatable bypass assembly for use with a high-pressure diesel fuel system.
Certain internal combustion engines can utilize fuel systems which deliver fuel under high pressures to the engine combustion chambers. For example, internal combustion engines can utilize direct fuel injection systems which require that fuel be delivered at high pressures (e.g., approximately 2000 bar or 29,000 psi or more) to the combustion chambers of the engine. The use of high-pressure fuel systems on internal combustion engines can have advantages such as increased fuel efficiency, increased engine power output, reduction of emissions, and/or facilitate a more efficient combustion process. Delivery of clean and uncontaminated fuel is important for proper operation and longevity of high-pressure fuel systems and proper performance of an engine utilizing a high-pressure fuel system.
In some applications, e.g. diesel engines, high-pressure common rail fuel systems can be used. Common rail systems distribute diesel fuel, under high pressures, to engine combustion chambers using one or more fuel injectors. Diesel fuel is distributed, under high pressure, to the fuel injectors through a high-pressure accumulator or rail. Diesel fuel is placed under high-pressure and is supplied to the fuel rail by a high-pressure fuel pump. A high-pressure fuel pump can be constructed using various designs. For instance, a high-pressure fuel pump can consist of a pump camshaft, which is driven by a belt, chain, cogwheel or gear. The camshaft can move other mechanical components, such as a pump piston, to pump fuel and generate or place the fuel under the required high pressure.
Drawbacks exist with respect to high-pressure fuel systems and high-pressure fuel pumps. More specifically, in a high-pressure fuel system, the fuel (e.g., diesel fuel) may not be routed only or directly between a fuel supply (e.g., fuel tank) and the common rail or fuel injectors. Rather, the diesel fuel may be used to lubricate and cool certain mechanical components of the high-pressure fuel pump (e.g., the cam shaft, piston, roller tappet), and then the diesel fuel can be fed into other portions of the fuel system (e.g., common rail and injectors) and the engine. Drawbacks in this fuel system design exist because mechanical components (e.g. a pump camshaft, roller tappet, pump piston) or other components of a high-pressure fuel pump can become worn, deteriorate, or suffer catastrophic failure which can cause metal particles or other materials to contaminate the high-pressure fuel pump, contaminate the fuel within the high-pressure fuel pump (e.g., the fuel present within the pump, which is being used to lubricate and/or cool the pump), contaminate other components of the high-pressure fuel system, and/or contaminate or damage components of the internal combustion engine or vehicle in or on which the high-pressure fuel system is installed. After contaminants resulting from the failure or deterioration of any component of a high-pressure fuel pump are present in the fuel within the high-pressure fuel system, the contaminants and contaminated fuel can be distributed (i.e., pumped) throughout the fuel system and can damage some or all of the components of the fuel system and/or cause extensive damage to the internal combustion engine. Damage arising from a failed high-pressure fuel pump can partially or completely disable an engine or vehicle and necessitate costly repairs, such as the replacement of some or all aspects of the fuel system. For example, many modern pickup trucks fitted with diesel engines using common rail diesel fuel systems can cost more than $10,000 to repair after the failure of a high-pressure fuel pump and require many hours of labor to repair. Wear, deterioration, or failure of a high-pressure fuel pump, and/or contamination of a fuel system, may not be detectable by an owner or operator of a vehicle or engine until a catastrophic failure of the high-pressure fuel pump occurs and/or after severe damage has been caused to other vehicle or engine components, such as fuel lines, fuel injectors, and fuel rails, among others.
A filtration system can be added or retrofitted on to a fuel system to filter, clean out, or trap contaminants that enter a fuel system. A filtration system can reduce the potential for, or in some instances prevent, damage that may result from a high-pressure fuel pump failure. However, it is not practical to filter fuel that is under high pressure. Existing approaches to filtration systems for fuel systems, particularly add-on or retrofit systems, can present certain challenges. For example, high pressure fuel systems are used in a wide range of applications, including a wide variety of vehicles or machines (e.g., passenger vehicles, light duty trucks, boats, and construction equipment), or in a wide variety of engines (e.g., gasoline or diesel). Therefore, application specific (e.g., vehicle specific, engine specific or fuel pump specific) filtration systems must be designed and manufactured for each application. The use of application specific filtration systems results in drawbacks such as manufacturing inefficiencies, higher costs, and in some cases, the absence of filtration systems for uncommon applications (e.g., old, or rare vehicles or engines).
For these reasons, it would be advantageous to have a filtration system for high-pressure diesel fuel systems, which includes a bypass assembly that is universal or readily adaptable across many applications, including many vehicles and/or engine applications. It would be advantageous to have a bypass assembly for a fuel filtration system that is not limited to or directed to only a single application (e.g., limited to only a specific vehicle, a specific engine, a specific fuel system or a specific high pressure fuel pump).
Aspects and advantages of embodiments of the present disclosure will be set forth in part in the following description, or may be learned from the description, or may be learned through practice of the embodiments.
Variations and modifications can be made to these example aspects of the present disclosure. These and other features, aspects and advantages of various embodiments will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the related principles.
A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure.
Reference now will be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary.
The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. As used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a five percent margin of error.
Aspects of the present disclosure are directed to a rotatable bypass assembly for use with a high-pressure fuel pump (sometimes referred to herein as the “HPFP”) or high-pressure fuel system. The rotatable bypass assembly of the present disclosure can be used to block the existing fuel supply passage of a high-pressure fuel pump. The fuel supply passage of a high-pressure fuel pump is a fluid passage that is part of and/or located within a fuel pump that supplies fuel to or permits a flow of fuel to a pumping chamber and then to a common rail and/or fuel injectors of a high-pressure fuel system, after said fuel has first passed through the case of the HPFP which contains the movable mechanical components (e.g., the cam shaft, piston, roller tappet), and/or come into fluid communication with said mechanical components, driving a pumping element of the HPFP. Fuel supplied to the pumping chamber of the HPFP is placed under high pressure in said pumping chamber and then delivered to the combustion chamber(s) of the engine by way of a common rail and/or fuel injectors.
When the bypass block of the rotatable bypass assembly of the present disclosure is not used with a high-pressure fuel pump (e.g., attached to or otherwise in fluid communication with the fuel supply passage of a HPFP), the fuel supply passage of a HPFP is in fluid communication with, at least, the pumping chamber, the common rail of the high-pressure fuel system and/or in fluid communication with certain movable mechanical components located within the case of the high-pressure fuel pump (e.g., the cam shaft, piston, roller tappet). In this way, fuel is first in fluid communication with the movable mechanical components located within the case of the high-pressure fuel pump (e.g., the cam shaft, piston, roller tappet), and acts as a lubricant for or provides lubrication to said movable mechanical components of the high-pressure fuel pump, before the said fuel enters, is in fluid communication with, or is delivered to the pumping chamber.
The bypass block of the rotatable bypass assembly of the present disclosure can block or obstruct the existing fuel supply passage of a high-pressure fuel pump (e.g., a Bosch® CP4 pump) or otherwise stop, break, or interrupt the fluid communication existing between the fuel supply passage of a high-pressure fuel pump and, at least, the pumping chamber of the HPFP and/or the common rail of the high-pressure fuel system. In this way, the bypass block of the rotatable bypass assembly of the present disclosure can be used avoid, stop, block, or prevent combustion fuel (e.g., fuel being supplied to the pumping chamber and, in turn, the internal combustion engine through a common rail and fuel injectors) from mixing with, being in fluid communication with and/or being contaminated by the lubricating fuel (e.g., fuel being used to lubricate and/or cool certain movable mechanical components located within the case of the high-pressure fuel pump such as the cam shaft, piston, and roller tappet, of the HPFP), without said lubricating fuel first being filtered by or passed through one or more filters.
The bypass block of the rotatable bypass assembly of the present disclosure can be used to facilitate the supply of combustion fuel to an internal combustion engine from a fuel tank, without said combustion fuel being in fluid communication with the lubricating fuel at or within the HPFP, without or before said lubricating fuel is filtered by or passed through one or more fluid filters. The rotatable bypass assembly of the present disclosure can also be used to facilitate filtration of the lubricating fuel, by preventing said lubricating fuel from mixing with the combustion fuel or said lubricating fuel returning to the fuel tank (via a return fuel line), without said lubricating fuel first being routed through or filtered by a fuel filter or other fluid filter. In this way, the rotatable bypass assembly of the present disclosure avoids or prevents the mixing of unfiltered lubricating fuel with or otherwise being in fluid communication with filtered fuel, combustion fuel, and/or fuel stored within a fuel tank.
Aspects of the present disclosure are directed to a rotatable bypass assembly for use with a high-pressure fuel pump. The rotatable bypass assembly includes a bypass block and a collar. The collar can be mechanically attached to the high-pressure fuel pump by or through one or more mounting points. However, in some embodiments, the collar does not comprise or require mechanical fasteners or threading to secure the rotatable bypass assembly to the high-pressure fuel pump, that is separate the mechanical fasteners or threading used to attach a fuel contact actuator to a high-pressure fuel pump, when the rotatable bypass assembly is not present. Each of the one or more mounting points includes one or more stop faces. The bypass block of the rotatable bypass assembly is rotatable relative to the collar. The bypass block can be turned or rotated, on an axis extending in a vertical direction through the center of the bypass block. In this way the fuel supply passage of the bypass block can be placed or angled in a plurality of locations between the stop faces of the mounting points of the collar. In this way, the rotatable bypass block allows for use of the rotatable bypass assembly on a plurality of applications, including a plurality of high-pressure fuel pumps, vehicles, engines, and fuel systems. In this way, the bypass block of the rotatable bypass assembly of the present disclosure can be used to prevent delivery of unfiltered fuel (i.e., diesel fuel) directly to the common rail and fuel injectors without regard to the specific vehicle or application in which the high-pressure fuel system is located.
Aspects of the present disclosure are directed to a rotatable bypass assembly for use with a high-pressure fuel pump. The rotatable bypass assembly can include a collar with a first mounting point. The first mounting point can include a first stop face and a second stop face. The rotatable bypass assembly can also include a bypass block with a fuel barb. The fuel barb of the bypass block is rotatable between, at least, the first stop face and the second stop face. The bypass block and fuel barb of the rotatable bypass assembly can be integrally formed.
The rotatable bypass assembly can also include a second mounting point including a first stop face and a second stop face. The rotatable bypass assembly and/or collar can include a front edge and a rear edge. The fuel barb can be rotatable along the front edge between the first stop face of the first mounting point and the first stop face of the second mounting point, and the fuel barb can also be rotatable along the rear edge between the second stop face of the first mounting point and the second stop face of the second mounting point.
The first mounting point and second mounting point can be directly or approximately opposed from one another across collar, based on a centerline which divides the collar into half. The collar can include a collar alignment surface and the bypass block can include a block alignment surface. The collar alignment surface and block alignment surface can be in rotatable contact. The bypass block can include a top surface and the first mounting point and second mounting point each form protrusions extending from collar and said first mounting point and second mounting point include a top. The top surface of bypass block is level with the top of, at least, one of the first mounting point or second mounting point when the block alignment surface and collar alignment surface are in rotatable contact.
The collar can also include a bottom and a mounting protrusion extending from said bottom. The rotatable bypass assembly can also include a fuel delivery nozzle in fluid communication with a fuel reception chamber located within the rotatable bypass block and the fuel delivery nozzle includes a barrier wall located or positioned above a sealing groove. The barrier wall includes a surface that is operable to or configured to form a liquid-tight seal against a case of a high-pressure fuel pump and obstruct an internal fuel supply passage located with the high-pressure fuel pump. The rotatable bypass assembly can also include a fuel delivery nozzle in fluid communication with a fuel reception chamber located within the rotatable bypass block and the fuel delivery nozzle can include a barrier wall located or positioned above a sealing groove. The rotatable bypass assembly can have a bypass block mounting protrusion extending from block alignment surface and the bypass block mounting protrusion is aligned with or level with collar mounting protrusion when the block alignment surface and collar alignment surface are in rotatable contact. The first mounting point can also include a cutout. The cutout can extend from the first stop face of the first mounting point into a mounting aperture located within the first mounting point.
Aspects of the present disclosure are also directed to a rotatable bypass block for use with a high-pressure fuel pump. The rotatable bypass block includes a body including a top surface, a block alignment surface and an outer wall extending from top surface to block alignment surface. The bypass block also includes a fuel reception chamber within the body, a fuel barb including a combustion fuel supply passage, wherein said combustion fuel supply passage is in fluid communication with said fuel reception chamber and a fuel delivery nozzle in fluid communication with the fuel reception chamber, wherein the fuel delivery nozzle includes a barrier wall located or positioned above a sealing groove.
The barrier wall includes a surface operable to or configured to form a liquid-tight seal against a case of a high-pressure fuel pump and obstruct an internal fuel supply passage located with the high-pressure fuel pump. The body of bypass block, the fuel barb, and the fuel delivery nozzle are integrally formed. The fuel reception chamber is a void which can receive or is configured to receive a valve end of a fuel control actuator. The bypass block body forms a cylinder. The rotatable bypass block may also include a bypass block mounting protrusion extending from block alignment surface.
Referring now to the figures, example aspects of the present disclosure will be discussed in greater detail.
Referring generally to
The rotatable bypass assembly 100 includes a bypass block 102 and a collar 104. The bypass block 102 can be integrally formed or machined from a single piece of material, such as a billet of aluminum. In other embodiments bypass block 102 can be comprised of multiple or separable components which are joined together or affixed through welding, press fit, gluing, or other known method of assembly or attachment. Bypass block 102 and/or collar 104 can be formed or machined from metal, such as aluminum or steel, or formed from any other material which can be exposed to or come in contact with fuel without failure or degradation.
Rotatable bypass assembly 100, can include one or more mounting points such a first mounting point 106A and second mounting point 106B. Mounting points 106A and 106B are attached to or integrally formed with collar 104. One or both the mounting points 106A and 106B include a mounting aperture 310. As shown in
Each of the mounting points 106A and 106B includes a first stop face 108A and a second stop face 108B. In some embodiments, the mounting points 106A and 106B may include a cut-out 150 (or scallop) in the first stop face 108A and/or second stop face 108B to provide additional clearance for certain applications or fluid hose connections. In some embodiments, cut-out 150 may extend from the first stop face 108A and/or second stop face 108B into the mounting aperture 310 of mounting points 106A and 106B.
Bypass block 102 can include an integrally formed fuel barb 112. Because the bypass block 102 is rotatable relative to the collar 104, the fuel barb 112 can be oriented or placed in a plurality of locations between each of the mounting points 106A and 106B, allowing the fitment in nearly any engine bay configuration. This ability to orient/clock the fuel barb 112 for various engine configurations makes the rotatable bypass assembly 100 of the present disclosure nearly universal, readily adaptable across many applications and not limited to or directed to only a single application, a specific vehicle or a specific fuel system.
Because the bypass block 102 is rotatable relative to the collar 104, the fuel barb 112 (and combustion fuel supply passage 110 contained therein) of the bypass block 102 can be placed, rotated, or angled in any location or between the one or more stop faces (e.g., first stop face 108A and second stop faces 108B) located on the collar 104. In this way, the rotation of the bypass block 102 allows for use of the rotatable bypass assembly 100 of the present disclosure on a plurality of applications, including a plurality of high-pressure fuel pumps, vehicles, engines, and fuel systems. For instance, the exemplary embodiment of the rotatable bypass assembly 100 depicted in
Bypass block 102 of the rotatable bypass assembly 100 is rotatable relative to the collar 104. Bypass block 102 can be turned or rotated within or relative to collar 104, on or about an axis 148. Axis 148 extends in a vertical direction V through the center of both bypass block 102 and collar 104. Bypass block 102 may be rotated, relative to collar 104, about axis 148 until at least a portion of the fuel barb 112 comes into physical contact with the first stop face 108A or the second stop face 108B of one of the mounting points 106A or 106B. Because the bypass block 102 and collar 104 are not immovably affixed or joined to the other, bypass block 102 can be rotated, relative to collar 104, such that the fuel barb 112 rotates along the perimeter of the front edge 152 of the collar 104, between first stop face 108A of first mounting point 106A and first stop face 108A of second mounting point 106B. Similarly, because the bypass block 102 and collar 104 are not immovably affixed or joined to the other, bypass block 102 can be rotated, relative to collar 104, such that the fuel barb 112 rotates along the perimeter of the rear edge 154 of the collar 104, between second stop face 108B of first mounting point 106A and second stop face 108B of second mounting point 106B.
It should be appreciated that first mounting point 106A and second mounting point 106B are depicted in
In another exemplary embodiment of the present disclosure, collar 104 can include only a first mounting point 106A. In such an exemplary embodiment, because the bypass block 102 and collar 104 are not immovably affixed or joined to the other, bypass block 102 can be rotated, relative to collar 104, such that the fuel barb 112 rotates along the perimeter of the front edge 152 and the rear edge 154 of the collar 104, between first stop face 108A of first mounting point 106A and second stop face 108B of first mounting point 106A. In such an embodiment, the angle of rotation of fuel barb 112 along the perimeter of the rear edge 154 of the collar 104 and along the front edge 152 of the collar 104 is about 360 degrees. Because the bypass block 102 is rotatable relative to the collar 104, the combustion fuel supply passage 110 of the bypass block 102 can be placed, rotated, or angled in or between a plurality of locations, and the rotatable bypass assembly 100 can be used to prevent delivery of lubrication fuel or other unfiltered fuel (i.e., diesel fuel) to the pumping chamber of the HPFP, the common rail and/or fuel injectors of a high pressure fuel system without regard to the specific vehicle or application in which the high-pressure fuel system is located.
Referring again, generally, to
Bypass block 102 includes a fuel reception chamber 122 and fuel delivery nozzle 140. Fuel delivery nozzle 140 includes a sealing groove 142. Sealing groove 142 is a depression within fuel delivery nozzle 140. Sealing groove 142 can accommodate or hold an O-ring or other seal to create a fluid-tight connection or seal between fuel delivery nozzle 140 and the case of the high-pressure fuel pump (not shown) upon which the rotatable bypass assembly 100 is installed. Fuel delivery nozzle 140 also includes a fuel outlet passage 144, which allows combustion fuel to travel from fuel reception chamber 122 to the pumping chamber of the HPFP (not shown), common rail and/or injectors of the fuel system upon which the rotatable bypass assembly 100 is installed and/or being used. Fuel outlet passage 144 is a void, channel, or fluid passageway located within fuel delivery nozzle 140. Fuel outlet passage 144 extends, in a vertical direction V along axis 148, from inner chamber floor 124 to the nozzle outlet surface 146 of fuel delivery nozzle 140.
Fuel delivery nozzle 140 includes a barrier wall 147, which is located above, in a vertical direction V, sealing groove 142. Barrier wall 147 may be a cylinder surrounding fuel outlet passage 144. Barrier wall 147 can be a smooth surface which can form a liquid-tight seal against the case of the HPFP to block or obstruct the existing fuel supply passage (not shown and which is often an internal passageway within a HPFP, such as within the case of the HPFP) of a high-pressure fuel pump (e.g., a Bosch® CP4 pump) or otherwise stop, break, or interrupt the fluid communication existing between the fuel supply passage of a high-pressure fuel pump and, at least, the pumping chamber of the HPFP and/or the common rail of the high-pressure fuel system. In this way, the bypass block 102 of the present disclosure can be used avoid, stop, block, or prevent combustion fuel from mixing, being in fluid communication with and/or being contaminated by the lubricating fuel, without said lubricating fuel first being filtered by or passed through one or more filters.
It should be appreciated that in other exemplary embodiments of the present disclosure, it should be appreciated that other portions of the rotatable bypass assembly 100 of the present disclosure can form a liquid-tight seal against the case of the HPFP to block or obstruct the existing fuel supply passage (not shown and which is often an internal passageway within a HPFP, such as within the case of the HPFP) of a high-pressure fuel pump (e.g., a Bosch® CP4 pump) or otherwise stop, break, or interrupt the fluid communication existing between the fuel supply passage of a high-pressure fuel pump and, at least, the pumping chamber of the HPFP and/or the common rail of the high-pressure fuel system. This could include the collar 104, nozzle outlet surface 146, collar mounting protrusions 502 or block mounting protrusion 504.
The fuel reception chamber 122 is a void or cavity formed within the body 103 of bypass block 102, said void being defined by a top surface 116, an inner chamber wall 120 and an inner chamber floor 124 (shown
Referring now to
Collar 104 also includes one or more collar mounting protrusions 502 at the bottom of the one or more mounting points 106A and 106B. Collar mounting protrusions 502 extend, in a downward vertical direction V, from the bottom surface 312 of collar 104. Collar mounting protrusions 502 correspond with one or more depressions (not shown) existing in a high-pressure fuel pump to prevent the collar 104 from moving about axis 148 relative to the high-pressure fuel pump.
Bypass block 102 includes a block mounting protrusion 504 which extends downward, in vertical direction V, from block alignment surface 302. Height of block mounting protrusion 504 is based, at least in part, on the height of collar mounting protrusions 502, the collar alignment surface 304 and block alignment surface 302. More specifically, the height of block mounting protrusion 504 is such that when bypass block 102 is placed within collar 104, and the block alignment surface 302 comes into rotatable physical contact with and rests on collar alignment surface 304, collar mounting protrusions 502 are level, in a vertical direction V, horizontal direction H and transverse direction T, with the block mounting protrusion 504.
Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing can be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples for the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 10280876 | Lee | May 2019 | B2 |
| 20020148509 | Tine, Jr. | Oct 2002 | A1 |
| Number | Date | Country |
|---|---|---|
| 107110091 | Aug 2017 | CN |
| 0171878 | Feb 1986 | EP |
