Method of manufacturing an injector for injecting fluid and injector for injecting fluid

Abstract

A valve assembly is provided with a valve body, a valve needle and an armature. An actuator assembly surrounds the valve assembly. The actuator assembly includes a housing and a coil. The coil can be energized so as to induce a force for axially displacing the armature. A flow characteristic of fluid to be injected by the injector is adjusted by axially shifting the valve assembly and the actuator assembly relative to one another.

Claims

1. A method of manufacturing an injector for injecting fluid, the method comprising: providing a valve assembly having a valve body, a valve needle and an armature, the valve body defining a longitudinal axis and being formed with a cavity configured to receive therein the valve needle and the armature, the valve needle and the armature being mounted for axial movement relative to the valve body and being operable to control a flow rate of injected fluid from the cavity to an exterior of the injector; providing an actuator assembly surrounding the valve assembly, the actuator assembly including a housing and a magnetic coil, the coil being energizeable to induce a force for axially displacing the armature; providing a further magnetic element disposed axially next to the magnetic coil along the longitudinal axis and radially surrounding the valve assembly in a position between the housing and the magnetic coil, the further magnetic element being a permanent magnet or an electromagnet; and adjusting a flow characteristic of the fluid to be injected by the injector by axially shifting the valve body and the actuator assembly relative to one another.

2. The method according to claim 1, wherein the further magnetic element is operable to induce a force for axially displacing the armature.

3. The method according to claim 1, which further comprises: providing a physical model having an input parameter; operating the injector for determining a value of the input parameter; determining a shifting value by using the physical model with the determined value of the input parameter; and axially shifting the valve assembly and the actuator assembly relative to one another depending on the shifting value thus determined.

4. The method according to claim 1, which further comprises a step of fixedly coupling the valve assembly and the actuator assembly to one another after the adjusting step.

5. The method according to claim 4, which comprises welding the valve assembly and the actuator assembly to one another.

6. The method according to claim 1, wherein the fluid is a gas.

7. The method according to claim 6, wherein the fluid is air or nitrogen.

8. The method according to claim 1, wherein the fluid is a liquid.

9. The method according to claim 8, wherein the fluid is N-heptane.

10. An injector for injecting fluid, the injector comprising: a valve assembly having a valve body, a valve needle and an armature, said valve body defining a longitudinal axis and being formed with a cavity configured to receive therein said valve needle and said armature, said valve needle and said armature being mounted for axial movement relative to said valve body and being operable to control a flow rate of injected fluid from the cavity to an exterior of said injector; an actuator assembly surrounding said valve assembly, said actuator assembly having a housing and a magnetic coil, said magnetic coil being energizeable to induce a force for axially displacing the armature; a further magnetic element disposed axially next to said magnetic coil along the longitudinal axis and radially surrounding said valve assembly in a position between said housing and said magnetic coil, said further magnetic element being a permanent magnet or an electromagnet; and wherein said valve assembly and said actuator assembly are shaped and disposed to enable an adjustment of a flow characteristic of fluid to be injected by the injector by axially shifting said valve body and said actuator assembly relative to one another during an assembly of the injector.

11. The injector according to the claim 10, wherein said valve assembly and said actuator assembly are friction-locked to one another, but said valve assembly and said actuator assembly are not positively engaged so as to block a relative axial movement of said valve assembly and said actuator assembly.

12. The injector according to the claim 10, wherein said valve assembly comprises a valve spring disposed to axially bias said valve needle, said valve spring being received in said cavity and having a stiffness equal to 25 N/mm or higher.

13. The injector according to the claim 10, wherein a rigid connection is established between said valve assembly and said actuator assembly.

14. The injector according to the claim 13, wherein said rigid connection is a welded connection.

15. The injector according to the claim 10, wherein said further magnetic element is arranged with poles thereof oriented radially with respect to the longitudinal axis.

16. The injector according to the claim 10, wherein said magnetic coil and said further magnetic element are disposed in said housing.

17. The injector according to the claim 10, wherein said further magnetic element is oriented radially with respect to the longitudinal axis with both magnetic poles thereof in a plane that is orthogonal to the longitudinal axis.

18. An injector for injecting fluid, the injector comprising: a valve assembly having a valve body, a valve needle and an armature, said valve body defining a longitudinal axis and being formed with a cavity configured to receive therein said valve needle and said armature, said valve needle and said armature being mounted for axial movement relative to said valve body and being operable to control a flow rate of injected fluid from the cavity to an exterior of said injector; an actuator assembly surrounding said valve assembly, said actuator assembly having a housing and a magnetic coil, said magnetic coil being energizeable to induce a force for axially displacing the armature, said actuator assembly does not laterally overlap any portion of said valve assembly which said actuator assembly overlaps axially; a further magnetic element disposed axially next to said magnetic coil along the longitudinal axis and radially surrounding said valve assembly, said further magnetic element being a permanent magnet or an electromagnet; and wherein said valve assembly and said actuator assembly are shaped and disposed to enable an adjustment of a flow characteristic of fluid to be injected by the injector by axially shifting said valve assembly and said actuator assembly relative to one another during an assembly of the injector.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) FIG. 1 is a longitudinal section through an embodiment of an injector according to the invention;

(2) FIG. 2 shows an enlarged longitudinal section view of the injector according to FIG. 1;

(3) FIG. 3 shows a first enlarged longitudinal section view of a valve assembly and an actuator assembly of the injector according to FIG. 1;

(4) FIG. 4 shows a second enlarged longitudinal section view a valve assembly and an actuator assembly of the injector according to FIG. 1;

(5) FIG. 5 shows a graph of a force applied on an armature of the injector according to FIG. 1 over an axial displacement of its valve assembly and its actuator assembly relative to each other; and

(6) FIG. 6 shows a flow chart of a method for manufacturing the injector according to FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(7) Referring now to the figures of the drawing in detail and first, particularly, to FIGS. 1 and 2 thereof, there is shown an exemplary embodiment of an injector 1 with a valve assembly 3 and an electromagnetic actuator assembly 5. The injector of the present embodiment is a fuel injector which is configured for injecting fuel, such as gasoline, directly into a combustion chamber of an internal combustion engine.

(8) The valve assembly 3 comprises a valve body 7, a valve needle 9 and an armature 11. The valve body 7 has a longitudinal axis 13 and has a cavity 15 formed therein with a valve seat 17.

(9) The valve needle 9 is received in the cavity 15 and is axially movable relative to the valve body 7. In a closing position, in which the valve needle 9 is seated on the valve seat 17, the valve needle 9 is operable to prevent an injection of fluid from the cavity 15 outwardly out of the injector 1. In the present embodiment, the fluid is injected into the combustion chamber. The valve needle 9 is further operable to enable the injection of fluid when it is axially displaced away from the closing position.

(10) The armature 11 is mechanically coupled to the valve needle 9in particular the armature 11 is operable to establish a form-fit connection with the valve needle 9for axially displacing the valve needle 9 away from the closing position. It has an axial play relative to the valve needle 9. The injector 1 may comprise a first spring 19 for biasing the armature 11 in mechanical contact with the valve needle 9.

(11) The electromagnetic actuator assembly 5 comprises a magnetic coil 21, in particular solenoid, positioned in a metallic housing 23. The housing 23 circumferentially surrounds a portion of the valve body 7. The magnetic coil 21, the housing 23, the valve body 7, a pole piece which is fixed inside the valve body 7, and the armature 11 form a magnetic circuit. When the magnetic coil 21 is energized, it generates a magnetic field which attracts the armature 11 towards the pole piece.

(12) Due to the mechanic coupling of the armature 11 with the valve needle 9, the electromagnetic actuator assembly 5 is thus operable to exert a force for influencing a position of the valve needle 9. Particularly, the valve needle 9 may be axially displaced by the electromagnetic actuator assembly 5 relative to the valve body 7 away from the closing position against the spring force of a valve spring 27.

(13) The valve spring 27 is arranged and preloaded for biasing the valve needle 9 towards the closing position, in particular in order to contribute to a leak-tightness of the injector 1. A calibration element 29, in particular a calibration tube, may be received in the cavity 15 and press-fitted into the valve body 7 or into another part of the injector 1 which is positionally fixed relative to the valve body 7. The calibration element 29 axially abuts the valve spring 27. In particular, the valve spring 27 is seated on the calibration element 29 at one axial end and on the valve needle 9 at its opposite axial end.

(14) The actuator assembly 5 may further comprise a magnetic element 25 (cf. e.g. FIG. 2). In this embodiment, the magnetic element 25 is a permanent magnet. In other embodiments, the magnetic element 25 may be an electromagnet.

(15) Particularly, the magnetic element 25 is received in a recess of the housing 23. The magnetic element 25 exerts a force for influencing the position of the valve needle 9. In particular, the valve needle 9 may be subjected to a force of the magnetic element 25 and the coil 21, when the coil 21 is energized.

(16) Referring now to FIG. 3, there is shown a first enlarged longitudinal section view of the injector 1, wherein the valve assembly 3 and the actuator assembly 5 are assembled together, comprising a first axial displacement d1 relative to each other with respect to predetermined reference positions.

(17) A magnetic field of the coil 21 and the magnetic element 25, when the coil 21 is energized, is visualized by first field lines B1.

(18) FIG. 4 shows a second enlarged longitudinal section view of the injector 1, wherein the valve assembly 3 and the actuator assembly 5 are assembled together, comprising a second axial displacement d2 relative to each other with respect to the predetermined reference positions.

(19) The magnetic field of the coil 21 and the magnetic element 25, when the coil 21 is energized, is visualized by second field lines B2.

(20) A force F induced by the magnetic field of the coil 21 and the magnetic element 25, when the coil 21 is energized, is dependent on an axial displacement d of the valve assembly 3 and the actuator assembly 5 relative to each other with respect to the predetermined reference positions (FIG. 5). The force F substantially increases with decreasing axial displacement d. The magnetic element 25 may enhance this dependency of the force F on the axial displacement d, as well as a magnitude of the force F. In particular by means of the magnetic element 25, a gradient of the force F is achieved which has, for example, a value between 10 N/mm inclusive and 14 N/mm inclusive, allowing for precise adjustment of the flow characteristic of fluid.

(21) In this context, the magnetic element 25 is, in particular, radially oriented with respect to the longitudinal axis 13, that is, a plane in which both magnetic poles of the magnetic element 25 are located is arranged perpendicular to the longitudinal axis 13. In other words, the magnetic poles of the magnetic element 25 are arranged in radially subsequent fashion.

(22) The valve spring 27 may have a stiffness of 18 N/mm or higher. Particularly, the valve spring 27 has a predetermined stiffness, in particular 25 N/mm or higher. This contributes to a prevention of bouncing of the valve needle during the operation of the injector.

(23) In one embodiment, the calibration element 29 may be operable to adjust a bias of the valve spring 27 in order to adjust a flow characteristic of fluid to be injected by the injector 1. In this embodiment however, the valve spring 27 is solely seated on the calibration element 29, the bias of the valve spring 27 being substantially constant.

(24) In the following, one embodiment of a method for manufacturing the injector 1 is described with the aid of the flow chart of FIG. 6.

(25) In step S1, the valve assembly 3 and the actuator assembly 5 are provided. Particularly, the valve assembly 3 and the actuator assembly 5 are provided in a way that the actuator assembly 5 surrounds the valve assembly 3 such that the actuator assembly 5 is operable to influence an axial displacement of the valve needle 9. For example, the actuator assembly 5 and the valve assembly 3 are axially shifted relative to one another until they are in the predetermined reference positions.

(26) The valve spring 27 may be pre-loaded to a predetermined preload, in particular before shifting the actuator assembly 5 over the valve assembly 3.

(27) The valve assembly 3 and the actuator assembly 5 may be releasably coupled together in order to allow for operation of the injector 1 as well as its adjustment. In this context, the valve assembly 3 and the actuator assembly 5 are particularly friction-locked. The valve assembly 3 and the actuator assembly 5 may particularly be preassembled, for example by coupling the valve assembly 3 and the actuator assembly 5 within an engagement area 31 (see FIG. 2).

(28) Only in order to make the friction lock visible, the housing 23 is depicted to overlap the valve body 7 in radial inward direction in the engagement area 31 in FIG. 2. However, the valve assembly 3 and the actuator assembly 5 are in fact not in a form-fit engagement. Rather, the actuator assembly 5 is displaceable in both axial directions along the valve body 7. For example, the actuator assembly 5 has a central axial opening which is delimited by a cylindrical inner surface and the valve assembly 3 has a cylindrical outer surface which extends over complete axial length of the cylindrical inner surface of the actuator assembly 5, axially projects beyond the cylindrical inner surface on both sides. The cylindrical outer surface of the valve assembly 3 in particular contacts the cylindrical inner surface of the actuator assembly 5 at least in places for establishing the friction lock.

(29) In step S3, a value of a parameter which is representative for the flow characteristic of fluid to be injected by the injector 1 is determined under predetermined conditions. In this embodiment, the injector 1 is operated and an amount of injected fluid from the cavity 15 to outside the injector 1 is measured. Additionally or alternatively, the amount of injected fluid within a given time window is measured, that is, a flow rate of injected fluid is determined. Particularly in case of the fluid being nitrogen, an instantaneous flow rate may be determined.

(30) In other embodiments, values of an additional and/or alternative parameter may be determined, representing the flow characteristic of fluid to be injected, for example the force F exerted on the valve needle 9, the axial displacement d of the valve assembly 3 and the actuator assembly 5 relative to each other and in particular with respect to the predetermined positions, a magnetic field, or a so called feedback closing signal. The feedback closing signal is in particular a voltage change due to a velocity change of the valve needle 9 during the axial movement of the valve needle 9 for closing the valve, in particular when the valve needle 9 hits the valve seat 17.

(31) The fluid to be injected during operation of the injector 1 for calibrating the flow characteristic when manufacturing the injector 1 may be a gas such as nitrogen or air. Alternatively, the fluid may be a liquid such as N-Heptane, particularly corresponding with its injection related properties to those of fuel.

(32) When determining the flow characteristic of fluid to be injected, the injector 1 may be arranged in an environment with known border conditions such as temperature and/or fluid pressure of fluid to be injected, particularly in order to ensure reproducibility.

(33) Additionally and/or alternatively, the injector 1 may be supplied with fluid under predetermined border conditions, that is, for example, the injector is supplied with fluid at a predetermined fluid pressure and/or a predetermined temperature.

(34) In step S5, the parameter value determined in step S3 is compared to a predetermined value, a so-called application target of the flow characteristic of fluid. If a deviation of the determined parameter value from the predetermined value exceeds a predetermined error value, the method is continued in step S7. Otherwise, the method is continued in step 9.

(35) In step S7, a physical model is provided, the physical model having at least one input parameter. The input parameter may, for example, be the parameter determined in step S3. Moreover, border conditions may be provided as respective and in particular additional input parameters to the physical model.

(36) The physical model particularly relates the flow characteristic of fluid to the axial displacement d of the valve assembly 3 and the actuator assembly 5 relative to each other with respect to the predetermined positions.

(37) In one embodiment, a first data set corresponding to the graph of FIG. 5 may be provided, mapping the force F exerted on the armature 11 to the axial displacement d. In this case, for example, a further data set is provided, mapping the measured parameter which is representative for the flow characteristic of fluid to the force F of the first data set. Hence, depending on the flow characteristic of fluid, the axial displacement d of the valve assembly 3 and the actuator assembly 5 relative to each other with respect to the predetermined positions can be determined.

(38) Dependent on the determined value of the input parameter, a shifting value is determined using the physical model. The valve assembly 3 and the actuator assembly 5 are subsequently axially shifted relative to each other by the shifting value. In this embodiment, particularly in case of iterative adjustment of the flow characteristic of fluid, the method is continued in step 3. In other embodiments, the method may be continued in step S9.

(39) In step S9, the valve assembly 3 and the actuator assembly 5 are fixedly coupled together, particularly long-lasting. In this embodiment, the valve assembly 3 and the actuator assembly 5 are welded together at the engagement area 31 (see FIG. 2). Particularly in case that the valve assembly 3 and the actuator assembly 5 are friction-locked, step S9 is optional but may improve long-term stability of the flow characteristic and reduce the risk that the flow characteristic is changed, for instance due to mechanical vibrations and/or shocks.