DE102016210391A1 - Compressed component and method for its production - Google Patents

Abstract

The present invention relates to a pressure-loaded component (1), in particular in the formation of a high-pressure fuel rail (Rail), comprising an integrally formed base body (2), which at least two in a cutting region (S) intersecting channels (3, 4) for performing a Fluid through the base body (2), wherein in the base body (2) at least in the intersection region (S) of the channels (3, 4) on the through the channels (3, 4) limited inner wall (6) of the base body (2) connected (7), open support structure (5) for supporting the base body (2) against internal or external pressure loads of the base body (2) is provided at least in the cutting area (S). Furthermore, the present invention relates to a method for producing the pressure-loaded component (1) according to the invention.

Description

The present invention relates to a pressure-loaded component having an integrally formed main body and at least two channels intersecting in a cutting region for passing a fluid through the main body.

Pressurized or highly loaded pressure-carrying components are known from the prior art, for example in the formation of a high-pressure fuel accumulator (rail) for a common rail fuel injection system of an internal combustion engine. In addition, fluid-carrying components or bodies are used for different tasks that are often exposed to the environment an internal and / or external pressure. Fluids may be air or other gases, liquids such as water, fuel and the like. Often, these components are exposed to widely varying pressures. As a result, the components are loaded according statically and / or cyclically. High pressure differences can lead to spontaneous failure of the components due to the load. A failure after a certain number of cycles (cycles) can occur.

In order to counteract this, it is known from the prior art to increase the tolerable pressure level or to increase the number of sustainable cycles (cycles) by appropriate reinforcements from the outside or by a so-called autofrettage treatment. This requires additional components and / or complex production steps. The use of high-strength materials is conceivable, which may lead to significantly higher component costs under certain circumstances. The DE 102 47 524 A1 also proposes to round off the edges at the transition from radial bores to the pressure accumulator in a fuel distributor produced by casting.

It is therefore an object of the present invention to provide pressure-loaded components in a simple manner, which are designed for a high sustainable pressure level or for a high number of sustainable load cycles.

This object is solved by the subject matter of the independent claims. The dependent claims further form the central idea of the present invention in a particularly advantageous manner.

According to a first aspect, the present invention relates to a pressure-loaded component, in particular in the formation of a high-pressure fuel rail, comprising an integrally formed base body, which has at least two channels intersecting in a cutting area for passing a fluid through the base body, wherein in the base body at least in the intersection region of the channels, an open support structure connected to the inner wall of the base body delimited by the channels is provided for supporting the base body against (inner and / or outer) pressure loads of the base body at least in the intersection region.

Especially in the transition region of intersecting channels in an integrally formed, hollow base body, the loads are particularly high in internal or external pressure load of the body and especially in flowing fluids, so that by providing a correspondingly connected to the inner wall of the body open support structure and these pressure loads without (substantial) influencing the flow path can be safely absorbed or supported. Consequently, the sustainable pressure level or the number of sustainable load cycles and thus the life of the component can be significantly increased. In addition to be provided components (eg reinforcements), an additional component treatment (eg. Autofrettage treatment) or the use of high-strength materials can be dispensed with.

By means of the support structure according to the invention it is possible not only to be applied to internal pressure-acted components / body advantageous effect, but in particular also in those which are acted upon by external pressure. For example, pressurized pipes or containers can be provided, which due to the inner, stiffening 'support structure endure increased damage-free or life-prolonging tolerable internal pressures or external pressures than comparable components without this structure. By providing the support structure, in particular in the heavily stressed cutting region of the ducts, the tolerable pressures can be increased, for example in the areas of cable outlets, and / or the service life of the component can be extended until they fail.

In a preferred embodiment, the support structure is formed integrally with the base body, so that it can be provided on the one hand directly in the production of the base body and on the other hand is securely connected to the base body. In this way, the supporting effect of the support structure can be provided particularly effectively.

The support structure can preferably be designed to be optimized in terms of stress. Ideally, appropriate FEM (finite element method) calculation tools are used for the design and layout, which allow a local load-dependent design. The load-optimized Training is based in particular on FEM calculations for topology optimization and / or shape optimization of the component.

According to a preferred embodiment, the support structure has a regular geometric shape or any other design. For example, a bar structure, a grid structure, a matrix structure or matrix form, a mesh structure or a honeycomb structure are conceivable here. However, other embodiments are conceivable.

In a preferred embodiment, the support structure is formed by a plurality of elements. These elements may be struts and / or rods, for example. These can preferably be arranged homogeneously or even inhomogeneously distributed and / or dimensioned. Such embodiments are characterized in particular by a high load absorption in the direction of extension with a comparatively small geometric dimension. In addition, the distribution and / or dimensioning of the elements of the support structure enables a stress-optimized design of the same with minimum use of material.

In a preferred embodiment, the elements forming the support structure may be at least partially connected to each other or formed integrally with each other. In this case, the connecting regions of the elements are preferably rounded. The present invention thus allows, with appropriate design and design of the inner support structure to local load peaks due to the operating loads (pressurization) by local expression / adaptation of, for example, number, thickness and design of the elements and their connection (rounding) of these elements or structures react.

In a comparable manner, the connection of the support structure to the base body, in particular for stress reduction, can also be designed to be rounded.

For the connection as well as for the connection areas of the elements, it applies in the same way that not only radii but also any (load-adapted) geometrical configurations can be provided for them.

The support structure, in particular its elements, can be formed uniformly or unevenly. The latter can be achieved, for example, with defined material accumulation, in particular in regions of relatively higher load on the support structure. Thus, the design (the elements) of the support structure, a load-optimized design of the same with minimal use of material can be achieved.

The support structure may be connected to the base body distributed over at least one part, preferably at least at opposite regions and particularly preferably over the entire inner wall region of the base body delimiting the cutting region. In this way, a load-adapted support structure can be provided with as uniform and large-area distribution of the support load. In a preferred embodiment, a corresponding connection of the support structure to the base body is provided substantially opposite to any connection of the support structure to the base body.

The open support structure may define or include in its interior cavities which are uniformly or non-uniformly formed and / or evenly or non-uniformly distributed in the support structure. Thus, a load-optimized design of the same with minimal use of material (also) on the dimensioning and / or distribution of the cavities in the support structure can be achieved.

The cutting region may preferably have a stress-reducing geometric shape. For this purpose, the cutting region may for example be at least partially rounded and particularly preferably at least partially spherical. In principle, however, any free, load-adapted design of the basic structure of the cutting area or of the main body of the pressure-loaded component is conceivable. In combination with the support structure according to the invention thus the interception of load peaks can be further improved supported.

The pressure-loaded component is preferably made of metal or plastic. However, the invention is not limited thereto and can be applied in principle to all types of pressure-loaded components made of any materials.

In a preferred embodiment, the pressure-loaded component is provided in the form or in the form of a high-pressure fuel accumulator (rail). One of the channels of the base body is preferably designed as a longitudinal cavity, into which at least one further channel opens into the cutting region or the cutting region.

The pressure-loaded component is preferably provided by means of primary molding or generative manufacturing processes. Thus, the present invention further relates to a method for producing a pressure-loaded member according to the present invention by means of a primary molding method or a generative manufacturing process. In particular, by generative manufacturing methods, any and especially by means of FEM calculation load-optimized support structure can be implemented in any form. By generative manufacturing, for example, designs of the component and the support structure can be made, which close to classical manufacturing processes. For example, in accordance coarsely selected structures, it is also possible that pressure-loaded component in the usual way by Urformverfahren - ie, for example, casting process - produce.

Further embodiments and advantages of the present invention will be described with reference to the figures of the accompanying drawings. Show it:

1 1 is a detail cross-sectional view of a pressure-loaded component according to a first exemplary embodiment of the present invention,

2 1 is a detail cross-sectional view of a pressure-loaded component according to a second embodiment of the present invention;

3a and 3b Detail cross-sectional views of a pressure-loaded component according to a third embodiment of the present invention,

4a and 4b Detail cross-sectional views of a pressure-loaded component according to a fourth embodiment of the present invention,

5 to 7 three further geometric embodiments for a support structure according to the present invention,

8th a schematic detail view of another geometric embodiment of a support structure according to the present invention,

9a a detailed cross-sectional view of a pressure-loaded component without support structure,

9b a detailed view of the 9a with illustrated voltage curves at internal pressure load,

10a a detailed cross-sectional view of a pressure-loaded member according to another embodiment of the present invention without supporting structure with load-adapted cutting area, and

10b a detailed view of the 10a with illustrated voltage curves at internal pressure load.

The 1 to 4 All show different embodiments of a pressure-loaded component according to the invention 1 , The illustrated pressure-loaded components 1 are in the formation of a high-pressure fuel rail (rail) for a common rail fuel injection system of an internal combustion engine before. However, the present invention is not limited thereto but, in principle, can be applied to all types of pressure-loaded members having channel structure for passing a fluid (for example, pressure-carrying bodies, conduits, etc.).

The pressure-loaded component 1 has an integrally formed base body 2 on. "Integrally formed" means in the context of the invention that the basic body is made in one piece from a material; for example by means of a generative manufacturing process or a primary molding process. In principle, other production methods such as machining production methods are conceivable.

The basic body 2 has at least two intersecting in a cutting area S channels 3 . 4 for passing a fluid through the parent body 2 on. In the context of the present invention, "cut area" is understood to mean the area in which there are at least two channels which are preferably not rectilinear but, for example, angled away from one another in the base body 2 extend, meet or converge. In the illustrated embodiment, as is often the case with high-pressure fuel storage, are the two channels shown 3 . 4 at a right angle to each other. However, the invention is not limited thereto.

With reference to the 9a and 9b For example, it is conceivable that the cutting region S by two here, for example, by means of cylindrical holes introduced, intersecting channels 3 . 4 is formed. This results in a - as from 9b apparent - highly stressed transition between the two channels 3 . 4 , which is exposed to high voltages under pressure, in particular 9b can be seen. In this section region S, as described below, a support structure according to the invention can then be provided 5 be provided.

With reference to the 10a and 10b However, it is also conceivable that the cutting area S itself has a voltage-reducing geometric shape. It can be a free, load-adapted design of the basic body 2 act. In a particularly preferred The sectional region S is at least partially rounded off and, with particular preference, at least partially spherical or spherical, as shown in particular 10 as well as the 1 to 4 is apparent. Due to the rounded transitions in the section area S of the channels 3 . 4 can thus already a significant reduction in stress of the pressure-loaded component 1 especially in the highly stressed area of the intersecting channels 3 . 4 (ie in the intersection S) can be achieved. In this thus configured cutting area S can then be a support structure according to the invention 5 , as described below, be provided.

In the main body 2 is according to the present invention, at least in the sectional area S of the channels 3 . 4 the aforementioned open support structure 5 for supporting the basic body 2 against internal and / or external pressure loads of the main body 2 provided at least in the cutting area S. Under "open" is with respect to the support structure 5 in the context of the invention understood that the support structure 5 a flow through a fluid through the body 2 without (substantial) influencing of the flow path and the flow rate allowed; Thus, therefore, without (substantial) impairment of the flow characteristics of a comparable component without support structure 5 , In general, one can also speak of a 'hollow' support structure.

The open support structure 5 The present invention is characterized by passing through the channels 3 . 4 limited interior wall 6 of the basic body 2 connected (see connection 7 ). In the context of the present invention, "connected" is understood to mean that the support structure 5 with the inner wall 6 of the basic body 2 at least in the intersection region S is in communication to preferably receive the inner and / or outer compressive loads and thus the main body 2 relieve during operation.

The connection 7 the support structure 5 to the body 2 is preferably formed voltage-reducing. In a preferred embodiment, it is designed in particular rounded, as for example the 2 can be clearly seen. Also the connection 7 as in the 1 . 3 and 4 shown, is voltage-reducing - since slightly rounded - trained.

The support structure 5 is preferably integral with the main body 2 trained, as exemplified in the 1 to 4 is shown. The support structure 5 can be designed to be optimized in terms of load and is based, in particular, on FEM calculations, for example for topology optimization and / or shape optimization. Examples of such locally optimized adapted geometries based on FEM calculations, for example, in the 6 and 8th shown.

The support structure 5 can have any shape. For example, the support structure 5 also have a regular geometric shape, as for example in the 1 to 5 is shown. Preferred embodiments are rod structures (cf. 1 to 8th ), Lattice structures (cf. 3 to 8), matrix structures (cf. 4 . 5 and 7 ), Mesh structures or honeycomb structures (cf. 4 to 8th ). The support structure 5 may be preferred by multiple elements 8th be formed to distribute the pressure as much as possible. As elements 8th In particular, struts and / or rods come into question, as they in more or less regular or irregular design and arrangement in the 1 to 8th are shown. The Elements 8th can be distributed homogeneously, depending on requirements and in particular on the best possible load absorption (cf. 1 to 5 and 7 ) or inhomogeneously distributed (cf. 6 and 8th ) can be arranged. Likewise, the elements can 8th homogeneously dimensioned (cf. 1 to 5 and 7 ) or inhomogeneously dimensioned (cf. 6 and 8th ) be formed.

Beside the elements 8th in itself can also support structure 5 as a whole evenly (cf. 1 to 5 and 7 ; for example symmetrically) or unevenly (cf. 6 and 8th ) be formed. With reference to 8th is an example of a section of a load-optimized or locally optimized adapted geometry of a support structure 5 shown. As can be seen, is the support structure 5 as a whole and are the elements 8th in detail in the left area of the support structure 5 formed thicker or thicker than in a right area thereof, for example, there occurring higher loads in their assigned area of the component 1 or basic body 2 to record safely. Preferably, such a stress-optimized design of the support structure 5 or the individual elements 8th by defined material accumulations, in particular in areas of relatively higher load of the support structure 5 Or conversely by saving material in areas of relatively lower load on the support structure 5 - be achieved.

Preferably, the open support structure limits 5 in their interior cavities 10 or includes the same (cf. 1 to 8th ). Also these cavities 10 can, depending on the requirement and load profile of the component 1 evenly (cf. 1 to 5 and 7 ) or unevenly (cf. 6 and 8th ) be formed. Furthermore, the cavities 10 evenly (cf. 1 to 5 and 7 ) or unevenly (cf. 6 and 8th ) in the support structure 5 be arranged distributed. For example, with a renewed reference to 8th are the cavities shown there 10 formed larger in the left and right areas than those in the central area.

Due to the complex stress and load distribution in the pressure-loaded component 1 or basic body 2 in operation, such as the example 9b and 10b can be seen, depending on the requirements and load profile as well as complex load-optimized support structures 5 result. These are preferred in distribution and dimensioning of the elements 8th and cavities 10 designed (load-optimized).

The the support structure 5 forming elements 8th are preferably at least partially connected to each other or even integrally formed with each other, as for example from the 2 and 4 to 10 is apparent. The connection areas can be 9 of the elements 8th preferably designed stress-reducing and in particular rounded, as this is particularly clear the 2 . 4 and 8th can be seen.

To a particularly efficient support and thus pressure relief and voltage reduction of the pressure-loaded component 1 by means of the support structure 5 can achieve the support structure 5 at least over a part, preferably at least at opposite areas (cf. 1 to 4 ) and particularly preferably over the entire inner region of the base body delimiting the cutting region S. 2 distributed (see, for example 2 to 4 ) to the body 2 be connected. A particularly uniform support is achieved, when compared to any connection 7 the support structure 5 - that is the individual elements 8th the support structure 5 - on the body 2 a corresponding connection 7 the support structure 5 on the body 2 is provided.

The pressure-loaded component 1 can be made of any material. In particular, while offering metal or plastic. As a manufacturing process, especially in complex geometries of the pressure-loaded component 1 itself and in particular the support structure 5 Generative manufacturing processes conceivable. In principle, however, other methods such as primary molding or injection molding are conceivable. However, the invention is not limited to any manufacturing method, provided that a pressure-loaded component 1 with correspondingly provided support structure 5 can be provided. In principle, it is also conceivable that a corresponding support structure subsequently - ie after the production of the pressure-loaded component 1 - Is provided at least in the cutting area S / is. A connection 7 can then be made possible for example by means of cohesive methods or by gluing and the like.

As in particular the 1 to 4 it can be seen, is the pressure-loaded component 1 preferably a high-pressure fuel storage (rail). One of the channels 3 can be formed as a longitudinal cavity, then then, for example, the fuel is introduced into the rail. In this channel 3 then at least another channel opens 4 and thus forms the aforementioned cutting area S. This at least one more channel 4 serves to distribute the fuel to the respective injectors.

The present invention is not limited to the above-described embodiments insofar as it is encompassed by the subject matter of the following claims. In particular, while the support structure 5 in its geometric design and connection 7 to the body 2 not limited by the invention, provided that they with respect to internal and / or external pressure load of the body 2 provides support for this. Also, the invention is not limited to certain pressure-loaded components 1 limited. In principle, the present invention can be applied to all types of pressure-loaded components 1 use of any materials. Also, the geometric configuration of the cutting area S is not limited by the present invention. Likewise, the number of channels 3 . 4 and their orientation or angulation to each other is not limited by the present invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 10247524 A1 [0003]

Claims (15)

Pressurized component ( 1 ), in particular in the formation of a high-pressure fuel accumulator (rail), comprising an integrally formed main body ( 2 ), which has at least two channels (S) intersecting in a section (S) ( 3 . 4 ) for passing a fluid through the body ( 2 ), wherein in the base body ( 2 ) at least in the intersection region (S) of the channels ( 3 . 4 ) one at the through the channels ( 3 . 4 ) limited inner wall ( 6 ) of the basic body ( 2 ) ( 7 ), open support structure ( 5 ) for supporting the body ( 2 ) against internal or external pressure loads of the main body ( 2 ) is provided at least in the cutting area (S). Pressurized component ( 1 ) according to claim 1, wherein the support structure ( 5 ) integral with the main body ( 2 ) is trained. Pressurized component ( 1 ) according to claim 1 or 2, wherein the support structure ( 5 ) is optimized in terms of load, in particular based on FEM calculations for topology optimization and / or shape optimization. Pressurized component ( 1 ) according to any one of the preceding claims, wherein the support structure ( 5 ) has a regular geometric shape or any other configuration, for example a rod structure, lattice structure, matrix structure, mesh structure or honeycomb structure. Pressurized component ( 1 ) according to any one of the preceding claims, wherein the support structure ( 5 ) by several elements ( 8th ), in particular struts and / or rods, is formed, which are preferably arranged homogeneously or inhomogeneously distributed and / or dimensioned. Pressurized component ( 1 ) according to claim 5, wherein the support structure ( 5 ) forming elements ( 8th ) are at least partially connected to each other or formed integrally, wherein the connection areas ( 9 ) of the elements ( 8th ) are preferably voltage-reducing and in particular rounded. Pressurized component ( 1 ) according to any one of the preceding claims, wherein the support structure ( 5 ), in particular their elements ( 8th ), is formed uniformly or non-uniformly, preferably with a defined accumulation of material, in particular in regions of relatively higher loading of the support structure ( 5 ). Pressurized component ( 1 ) according to any one of the preceding claims, wherein the connection ( 7 ) of the support structure ( 5 ) to the main body ( 2 ) voltage-reducing and in particular rounded is formed. Pressurized component ( 1 ) according to any one of the preceding claims, wherein the support structure ( 5 ) at least over a part, preferably at least at opposite regions, particularly preferably over the entire inner region of the base body bounding the cutting region (S) ( 2 ) distributed on the base body ( 2 ) is attached. Pressurized component ( 1 ) according to one of the preceding claims, wherein substantially opposite to each connection ( 7 ) of the support structure ( 5 ) on the base body ( 2 ) a corresponding connection ( 7 ) of the support structure ( 5 ) on the base body ( 2 ) is provided. Pressurized component ( 1 ) according to one of the preceding claims, wherein the open support structure ( 5 ) in their interior cavities ( 10 ), which are evenly or irregularly formed and / or uniformly or non-uniformly in the support structure (FIG. 5 ) are arranged distributed. Pressurized component ( 1 ) according to one of the preceding claims, wherein the cutting region (S) has a stress-reducing geometric shape, preferably at least partially rounded and particularly preferably at least partially spherical. Pressurized component ( 1 ) according to one of the preceding claims, wherein the pressure-loaded component ( 1 ) is made of metal or plastic. Pressurized component ( 1 ) according to one of the preceding claims, wherein the pressure-loaded component ( 1 ) is a high-pressure fuel rail (Rail), wherein one of the channels ( 3 ) is formed as a longitudinal cavity into which at least one further channel ( 4 ) opens into the cutting area (S). Method for producing a pressure-loaded component ( 1 ) according to one of the preceding claims by means of a primary molding process or a generative manufacturing process.

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