Efficient grinding of key components in the engine "heart"

For details of the article, please purchase the 4th issue of Modern Parts in 2007 or the PDF file at the bottom of the download page.

The fuel injection pump is an important part of the diesel engine and is the most important component of the fuel supply system, so it is called the "heart" of the engine. The function of the fuel injection pump is to raise the pressure of the fuel to a certain value. According to the working sequence of the engine and the magnitude of the load, the fuel is delivered to the cylinder through the injector periodically and quantitatively for combustion. This function of the fuel injection pump is realized by driving the cam to rotate and driving the plunger to reciprocate in the plunger sleeve. Therefore, the quality of the plunger processing directly affects the performance of the engine. If the precision of the plunger processing is insufficient and the geometry is out of tolerance, the engine power may be degraded, the rotation speed may be unstable, black smoke, flameout or traveling phenomenon may occur, and a serious accident may occur. Therefore, the dimensional accuracy and shape error of the plunger must be strictly controlled during the machining process.

Since the specifications of the plunger are numerous, the common feature is that the shape and structure are basically the same. In order to improve the plunger process capability, meet the requirements of mass production, save the number of special fixtures and the cost of manufacturing management, a liquid plastic fixture for efficiently grinding the end face of the plunger has been designed, which has been effectively applied in our company.

Structural principle of the fixture

To grind the end face of the plunger shown in Figure 1, our company designed the fixture shown in Figure 2.

Figure 1 Plunger outline drawing Figure 2 Grinding plunger end face fixture outline drawing The specific process size requirements of the plunger are shown in Figure 3.

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Use <br> <br> clamp the plunger 32 in turn is mounted to both side surfaces of the V-groove of the V shaped body, the plunger against the bottom end surface of the small boss, pushing against the platen 2 with the left hand a compact V On the outer cylinder line of each side of the plunger, the handle is pulled by the handle to drive the pressure plate 1 to press on the outer circle of each plunger on the other side of the V-shaped body, and then the locking shaft is rotated clockwise around the stable pin, when the switch is turned to the pressure plate 2 When the gap is in the middle, the handle is pushed clockwise. At this time, the pressure plates on both sides are closed by the increase of the radius of rotation of the eccentric wheel, and the liquid plastic uniformly transmits the pressure to the respective compression shafts like a liquid, and the pressing shaft acts. After the plungers are reached, the clamping of the workpiece is achieved. After the machining is completed, push the handlebar counterclockwise with the right hand. When the eccentric wheel is turned to a smaller radius, the eccentric wheel is separated from the pressing part, and the pulling lock shaft is driven by the hand to rotate the pressure plate 1 counterclockwise around the stable pin, so that two The pressure plate is separated from the clamping portion and the workpiece is taken out. By using a hex nut to adjust the length of the two shafts extending out of the V-shaped body and increasing or decreasing the number of spacers at the eccentric wheel, the distance between the two V-shaped bodies can be adjusted to meet the processing of plungers of different specifications.

The formulation of liquid plastic and the role of each component (1) 59% dipotassium phosphite, making polyvinyl chloride elastic.

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Preparation and pouring of liquid plastic

After mixing the four materials according to the above respective contents, they were cooled at room temperature for 24 hours, then slowly heated, and continuously stirred with a metal bar. When a yellow-red gelatinous liquid is present, it is necessary to leave the heat source, and if the color becomes dark, the plastic is easily aged. At 130 ~ 150 ° C, it should be kept for 30 minutes to remove the bubbles, and then remove a small amount of dross before pouring. Before pouring, install all the pressure shafts in the corresponding holes of the pressure plate, and adjust the length of the pressure shaft to extend the pressure plate to be equal, then tighten the top wire. Note that the pressure plate must be preheated to 130-150 ° C, so that the liquid plastic slowly cools in the pressure plate. When pouring, the pressure plate should be inclined at an angle to the vertical direction, and the liquid plastic is cooled to form a solid shape conforming to the inner cavity of the pressure plate. To prevent shrinkage after cooling, a small amount of liquid plastic should continue to be compensated at the gate before it is completely cooled. Since dibutyl phosphobenzene dipotassium is easily volatile, flammable, and toxic, it must be equipped with an exhaust device and fire prevention facilities.

Features of the fixture (1) Since the liquid plastic pouring channel is cooled, a gel-like solid plastic is formed, and no leakage occurs. It is not in contact with air or grinding fluid. It is not prone to deterioration and aging for a long time, and has low toxicity and stable performance.

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Effect and promotion

The above-mentioned jig has the advantages of simple structure, convenient operation, large number of clamping, high processing efficiency, low manufacturing cost, strong versatility, good consistency of parts after processing and high process capability, and is well received by the production site. With the continuous use of the field, according to the above design principle, the plunger grinding chute fixture is designed. Since the amount of oil injected by the fuel injection pump depends on the length of the effective stroke of the plunger, the fuel supply of the fuel injection pump can be changed depending on the operating conditions of the engine, and the effective stroke of the plunger must be changed, and the plunger The effective stroke is realized by changing the relative position of the plunger chute and the oil hole of the plunger sleeve. Therefore, the machining precision of the plunger chute must be effectively controlled during the machining process, and the plunger grinding chute fixture designed for this purpose is also With the advantages of the above-mentioned jig, the production efficiency is greatly improved, and the user's requirements can be fully satisfied.

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