Method for managing the integrity of a fuel heating system applicable to combustion engines powered by at least one fuel

Description

1 / 15 Descriptive Report of the Invention Patent for a METHOD FOR MANAGING THE INTEGRITY OF A FUEL HEATING SYSTEM APPLICABLE TO COMBUSTION ENGINES POWERED BY AT LEAST ONE FUEL.

[0001] The present invention relates to a method for managing the integrity of a fuel heating system applicable to combustion engines powered by at least one fuel that employ fuel heating systems, preferably used in engines employed in vehicles. STATE OF THE ART

[0002] In recent years, problems with the amount of pollutants emitted (HC, CO, CO2 and particulates, among others), mainly by car engines, have been a major problem for large cities. Therefore, new technologies have been developed to help reduce pollutants emitted by internal combustion engines.

[0003] In order to mitigate greenhouse gas emissions from automobiles and reduce dependence on fossil fuels, several alternatives to replacing the internal combustion engine are available. However, the best solution to this dilemma must take into account the geographical and socioeconomic characteristics of the country, its energy matrix, its emissions legislation, and the environmental impact of the fuel's carbon emissions throughout its life cycle.

[0004] Brazil has a strong reputation for its fleet of flex-fuel vehicles, long experience in the use of ethanol fuel, and its distribution network. This sets it apart from other global markets and justifies a unique approach to reducing aldehyde emissions, for example. Petition 870230023890, dated 03 / 21 / 2023, page 6 / 34 2 / 15

[0005] However, some limitations are observed in the use of dual-fuel engines (popularly known as "flex" engines). To meet the demand for using two fuels in a single tank, the sizing of a flex-fuel engine tends to be intermediate, since the sizing of single-fuel engines is different depending on whether the fuel is ethanol or gasoline. This is because the vast majority of dual-fuel engines tend to have a single geometric compression ratio, which represents the ratio between the aspirated volume plus the combustion chamber volume in relation to the combustion chamber volume).

[0006] During its stroke, the piston reaches a higher point and a lower point in its displacement, called respectively top dead center (TDC) and bottom dead center (BDC).

[0007] Usually, the operation of a passenger vehicle engine has four strokes: Admission Compression Combustion Exhaust

[0008] The effect of the compression ratio becomes evident in the second stroke - the intake valves close after the injection of the air / fuel mixture, and this mixture is compressed so that the combustion process can begin. In this way, the geometric compression ratio of the engine is obtained: the ratio between the volume of the combustion chamber of the piston at its bottom dead center BDC (largest volume) and its top dead center TDC (smallest volume).

[0009] Gasoline engines typically use lower compression ratios (usually between 8:1 and 12:1), while ethanol-powered engines perform better with higher ratios (12:1 or even 14:1). No Petition 870230023890, dated 03 / 21 / 2023, page 7 / 34 3 / 15 However, before the fuel reaches the combustion chamber, it travels a path from the vehicle's tank. This fuel is moved by a fuel pump and flows through ducts that transport the fuel - first, a hose and, subsequently, a more rigid and branched duct called a rail. The branches carry the fuel to be injected into the respective cylinders, and it is at the outlet of these branches that the fuel injectors are positioned.

[0010] In addition, fuel impingement on the piston surface or intake duct walls can contribute to increased particulate matter emissions. Furthermore, fuel condensation in cold engine zones can result in incomplete combustion, generating hydrocarbons and carbon monoxide (HC and CO).

[0011] When discussing engines that employ the Otto cycle (engines traditionally used in automobiles), both those using Port Fuel Injection (PFI) and those operating with direct injection (DI) emit particulate matter above permitted limits. Therefore, the use of a particulate filter for gasoline engines (whose acronym is GPF, as it comes from the English Gasoline Particulate Filter) has been recommended to comply with the new particulate emission regulations that have come into effect.

[0012] However, even with the use of GPF, engines can still generate particulate matter above the limits set by official health agencies, since pollutant emissions also depend on driver behavior regarding how they drive and proper vehicle maintenance.

[0013] That being said, one of the most effective techniques for achieving more accurate fuel combustion is to deliver it to the combustion chamber preheated.

[0014] Fuel heating is carried out by means of Petition 870230023890, dated 03 / 21 / 2023, page 8 / 34 4 / 15 heaters positioned as close as possible to each fuel injector (most efficient method), either integrated into it or mounted immediately before the injector, in order to deliver the fuel flowing through the rail to said injector properly heated.

[0015] Heating must be equal for all engine injectors, so that all injectors receive fuel at the same temperature so that fuel combustion occurs homogeneously in all cylinders, regardless of configurations: from injection systems that use one injector to individually feed each cylinder or multiple injectors per cylinder.

[0016] However, heating systems have physical, electrical, and thermal limitations that prevent them from fully heating the fuel to be injected. In extreme situations of immense temperature ranges (difference between the initial temperature of the fuel before and after heating for injection), the heater may not deliver all the thermal energy necessary for the fuel to reach the desired target temperature (for example, when the ambient temperature is very low).

[0017] For the delivery to be carried out correctly, the fuel heating system must be in complete integrity and fully functional; otherwise, the fuel will not be heated properly and, as a consequence, atomization will be more deficient, resulting in more polluting gases being emitted.

[0018] In order to check the integrity of the heating system and fuel heaters, it is necessary to have a way of knowing if the components involved in the entire process necessary for fuel heating (systems, subsystems and devices) are in perfect condition so that the function of heating the fuel is fully performed. Petition 870230023890, dated 03 / 21 / 2023, page 9 / 34 5 / 15

[0019] For this, there must be a method that manages some steps prior to the heating itself and that checks, for example, the resistance of the heater (if there have been no malfunctions in the heater, such as carbon buildup), if the battery has sufficient voltage for the heater to be able to convert voltage into sufficient power to heat the fuel and / or if the working pressure of the fuel line is adequate.

[0020] Known state-of-the-art solutions can be observed, for example, in patent document BR102020 024417 and also in patent documents BR102020024436, BR102020020172, BR102019027845, BR102019027843 and BR102018 077109. These are fuel heating system management techniques with the clear objective of properly dosing and applying electrical power to heaters, but they are completely silent regarding any possibilities or techniques for carrying out steps to diagnose possible failures in heating systems and related components, which would lead to a completely deficient supply of heat to the fuel.

[0021] In this sense, a solution is sought that provides more efficient heating, capable of delivering the necessary power to heat the fuel and, consequently, better fuel atomization in all injectors.

[0022] Thus, the present invention proposes to solve the problem of the state of the art in a very efficient way, aiming to diagnose faults in systems related to more efficient, balanced heating and, consequently, better fuel atomization in all injectors. OBJECTIVES OF THE INVENTION

[0023] The present invention aims to provide a method Petition 870230023890, dated 03 / 21 / 2023, page 10 / 34 6 / 15 of fuel heating system integrity management applicable to combustion engines powered by at least one fuel that operates simply and efficiently by verifying the condition and / or aging of systems related to fuel heating and that also allows combined use with various other heating systems from different manufacturers, including heated injectors, always in order to provide adequate and balanced heating between all injectors and, consequently, better fuel atomization. BRIEF DESCRIPTION OF THE INVENTION

[0024] Aiming to solve the technical problem presented and overcome the drawbacks of the prior art, the present invention aims to provide a method for managing the integrity of a fuel heating system applicable to combustion engines powered by at least one fuel equipped with at least one heating device; at least one control unit; at least one electrical power supply unit; at least one fuel line; in order to understand the steps involved in checking the condition of at least one electrical condition parameter at the current instant; perform an initial action; Check the condition of at least one parameter of the fuel line at the current moment; perform a second action; determine the power to be applied to the heating device to heat the fuel; Petition 870230023890, dated 03 / 21 / 2023, page 11 / 34 7 / 15 Compare the maximum power to be made available by the electrical power supply unit to the heating device with the power to be applied to the heating device to heat the fuel at the current instant; perform a third action; To perform a reading of at least one value of at least one electrical parameter of the heating device at a given instant and compare it with a reference value of the same parameter; perform a fourth action. BRIEF DESCRIPTION OF THE FIGURES

[0025] Figure 1 - Graph illustrating the correlation of the systems involved in fuel heating.

[0026] Figure 2 - Overview of the objective method of the present invention. DETAILED DESCRIPTION OF THE FIGURES

[0027] The fuel heating and heating management system is responsible for heating the fuel to be injected into the engine to a predetermined temperature. The purpose of heating the fuel is to improve the atomization of the injected fuel spray, reducing its droplet size, which means better preparation of the air-fuel mixture, leading to a more homogeneous mixture, which will result in a decrease in the amount of fuel injected and thus reduce the amount of gases and particulates emitted.

[0028] The heating system operates from the moment the engine starts. The system's management aims to maintain the injected fuel temperature at the target temperature. To achieve this, the system determines the amount of energy that must be supplied to the fuel, based on the fuel inlet temperature in the rail, the fuel flow rate, and the type of fuel. Petition 870230023890, dated 03 / 21 / 2023, page 12 / 34 8 / 15

[0029] When the fuel temperature management system accurately delivers fuel at the highest temperature, the measured or calculated temperature of the fuel exiting the heating chamber is the temperature for which the amount of energy was made available and supplied, thus avoiding energy waste. Furthermore, fuel atomization increases, improving combustion.

[0030] Thus, the integrity of the components of the heating and related systems (injection, pressure and electrical systems) is fundamental to achieving a completely efficient supply of heat to the fuel and is monitored by a method capable of diagnosing possible failures in each of these systems.

[0031] Thus, the present invention discloses a method for managing the integrity of a fuel heating system applicable to combustion engines powered by at least one fuel equipped with at least one heating device; at least one control unit; at least one electrical power supply unit; at least one fuel line; in order to understand the steps involved in checking the condition of at least one electrical condition parameter of the heating device at the current instant S1; execute a first action S2; Check the status of at least one parameter of the S3 electrical power supply unit; Check the condition of at least one fuel line condition parameter at the current time S4; Petition 870230023890, dated 03 / 21 / 2023, page 13 / 34 9 / 15 execute a second action S5; Determine the power to be applied to the heating device to heat fuel S6; Compare the maximum power to be made available by the electrical power supply unit to the heating device with the power to be applied to the heating device to heat the fuel at the current instant S7; execute a third action S8;

[0032] perform a reading of at least one value of at least one electrical parameter of the heating device at a given instant and compare it with a reference value of the same parameter S9; execute a fourth action S10.

[0033] As can be seen in figure 1, the graph merely illustrates the correlation between the physical quantities of resistance of the heating device, the electrical power supply unit and the condition of the fuel line at a current instant and at exemplary reference values, but which may perfectly vary according to the design of the heating element.

[0034] Combustion engines are understood to be powered by at least one fuel, preferably dual-fuel or flex-fuel engines powered by ethanol and gasoline, but not limited to dual-fuel engines or to only these two fuels.

[0035] A heating device is understood to be any device that heats fuel. Such a heating device may be any device that converts power into heat, preferably a heater, more preferably of the exposed filament type with a heating chamber, but configurations for glow plug, lance or fuel heating candle type heaters are permitted. Petition 870230023890, dated 03 / 21 / 2023, page 14 / 34 10 / 15

[0036] An electrical power supply unit is understood to be an electric battery or any other device that supplies electrical power to the vehicle.

[0037] A fuel line is understood to be a set of items and components that include ducts and / or pipes, pump, connections, devices for distributing fuel to injectors and cylinders (e.g., fuel rail) and fuel injectors. The injector device may be integrated into the injector, the fuel rail, or both simultaneously, or at any other point in the fuel line where it is most convenient.

[0038] The condition of the fuel line is understood to be the integrity of the line (whether it is fully functional or whether there is any discrepancy in its operation).

[0039] In one embodiment, the present invention describes a method for managing the integrity of a fuel heating system, where the step of executing a first action S2 comprises an action between interrupting the execution of subsequent steps and executing subsequent steps. Execution must be interrupted if the electrical operating limits of the heating element are outside the specified range. Additionally, the execution of this first action S2 may preferably, but not necessarily, include storing the reference parameter in a non-volatile memory of the control unit, but not limited to this type of memory, and may include storage in volatile memory.

[0040] In another embodiment, the present invention describes a method for managing the integrity of a fuel heating system, where the step of performing a second action S5 comprises an action between interrupting the execution of subsequent steps and executing subsequent steps. This second action S5 must be interrupted if the integrity of the fuel line is not Petition 870230023890, dated 03 / 21 / 2023, page 15 / 34 11 / 15 for validation.

[0041] In a further embodiment, the present invention describes a method for managing the integrity of a fuel heating system, wherein the step of performing a third action S8 comprises an action between interrupting the execution of subsequent steps and executing subsequent steps. The interruption should occur when the state of charge of the electrical power supply unit (battery) is outside the control parameters (for example, if the available supply voltage is outside 12 Volts).

[0042] In a further embodiment, the present invention describes a method for managing the integrity of a fuel heating system, wherein the step of performing a fourth action S10 comprises an action between enabling the fuel heating system and disabling the fuel heating system.This step may include reporting the degradation status of the heating element as a desirable characteristic, but it is not mandatory for this step to be completed.

[0043] In an alternative embodiment, this invention describes a method for managing the integrity of a fuel heating system, where the action of interrupting the execution of subsequent steps comprises at least one action among the actions of finalizing the integrity management of the S12 fuel heating system; Disable the S13 heating system; issue at least one S14 alert; generate at least one S15 fault identification code.

[0044] In an alternative embodiment, this invention describes a method for managing the integrity of a fuel heating system, where the step of performing a fourth action S10 Petition 870230023890, dated 03 / 21 / 2023, page 16 / 34 12 / 15 includes at least one action among the actions to enable the S11 heating system; Disable the S13 heating system; issue at least one S14 alert; generate at least one S15 fault identification code.

[0045] A fault identification code is understood to be any type of alphanumeric code or message that identifies the type, the failed component and / or the severity of the fault.

[0046] In yet another alternative embodiment, the present invention discloses a method for managing the integrity of a fuel heating system, such that the step of checking the condition of at least one electrical condition parameter at the current instant S1 comprises verifying the integrity of the heating device S1.1; verify the integrity of the S1.2 control unit; verify the integrity of the electrical power supply unit S1.3.

[0047] Additionally, said system may include at least one safety element, such as a reverse polarity relay, which may or may not be integrated within the control unit, or even a fuse as a safety device, since it is integrated into the wiring harness. In this sense, the step of checking the condition of at least one electrical condition parameter at the current instant includes a step of verifying the integrity of at least one safety element.

[0048] Preferably, the action of verifying is understood as comparing the state of each of the components (pass / fail), however, concretizations are admitted where the verification includes an evaluation of whether the system as a whole can still function. Petition 870230023890, dated 03 / 21 / 2023, page 17 / 34 13 / 15 adjusting certain compensatory parameters so that the fuel heating is carried out satisfactorily.

[0049] The present invention further discloses a method for managing the integrity of a fuel heating system, wherein the step of verifying the integrity of the electrical power supply unit S1.3 comprises verifying and evaluating the amount of voltage available in the electrical power supply unit.

[0050] The present invention also discloses a method for managing the integrity of a fuel heating system in which the step of checking the condition of at least one fuel line condition parameter at the current instant S4 comprises measuring the working pressure of the fuel line at the current instant. The working pressure is directly related to the operation of the fuel pump and the presence (or absence) of possible leaks.

[0051] The present invention also includes a method for managing the integrity of a fuel heating system in which the step of determining the power to be applied to the heating device to heat the fuel S6 comprises calculating the power to be applied to the heating device to heat the fuel.

[0052] The present invention also discloses a method for managing the integrity of a fuel heating system in which a value of an electrical parameter of the heating device comprises a resistance value measured in at least one heating device.

[0053] Additionally, the present invention also discloses a method for managing the integrity of a fuel heating system in which a value of an electrical parameter of the heating device comprises a value of electrical current measured in at least one heating device. Petition 870230023890, dated 03 / 21 / 2023, page 18 / 34 14 / 15

[0054] In an alternative embodiment, the present invention also discloses a method for managing the integrity of a fuel heating system, where the action of issuing at least one S14 alert comprises issuing at least one audible alert.

[0055] In yet another alternative embodiment, the present invention also discloses a method for managing the integrity of a fuel heating system, where the action of issuing at least one S14 alert comprises issuing at least one visual alert.

[0056] In another alternative embodiment, the present invention also discloses a method for managing the integrity of a fuel heating system, where the steps of performing a first action S2, performing a second action S5, performing a third action S8, and performing a fourth action S10 include an action of transmitting at least one fault information to at least one generic device. A generic device is understood to be a local processing unit, a cloud, or a device connected via cable or wirelessly such as a laptop, computer, or notebook.

[0057] The control of the heaters, that is, the determination of the amount of energy required for the fuel to reach a target temperature value, must be carried out by a vehicle parameter processing control unit, which is primarily responsible for the overall intelligence of the engine. This control unit may comprise either the ECU (Electronic Control Unit - responsible for electronically managing all engine operation) already present in the vehicle, or it may comprise a dedicated unit (HCU - Heating Control Unit) exclusively for the fuel heating system.

[0058] The objective method of the present invention is performed by the control unit, which can be either the ECU or the HCU.

[0059] Thus, it can be noted that, as described above, Petition 870230023890, dated 03 / 21 / 2023, page 19 / 34 15 / 15 The present invention achieves the objective of providing a method for managing the integrity of fuel heating systems applicable to combustion engines powered by at least one fuel, which operates simply and efficiently by verifying the status of systems related to fuel heating and which also allows for combined use with various other heating systems from different manufacturers, including heated injectors, always in order to provide adequate and balanced heating between all injectors and, consequently, better fuel atomization.

[0060] Thus, the present invention also fulfills the role of enabling an increase in the power extracted from the engine associated with lower fuel consumption and a consequent reduction in polluting gases from the engines. Petition 870230023890, dated 03 / 21 / 2023, page 20 / 34

Claims

1 / 4 CLAIMS 1. Fuel heating system integrity management method applicable to combustion engines powered by at least one fuel equipped with: • at least one heating device; • at least one control unit; • at least one electrical power supply unit; • at least one fuel line; characterized in that it comprises the steps of: • checking the condition of at least one electrical condition parameter of the heating device at the current instant (S1); • performing a first action (S2); • checking the condition of at least one condition parameter of the fuel line at the current instant (S3); • checking the condition of at least one condition parameter of the fuel line at the current instant (S4); • performing a second action (S5); • determining the power to be applied to the heating device to heat the fuel (S6);• Compare the maximum power to be made available by the electrical power supply unit to the heating device with the power to be applied to the heating device to heat the fuel at the current instant (S7); • Perform a third action (S8); • Read at least one value of at least one electrical parameter of the heating device at a current instant and compare it with a reference value of the same parameter (S9); • Perform a fourth action (S10). Petition 870230023890, dated 03 / 21 / 2023, page 21 / 34 2 / 4; 2. Fuel heating system integrity management method according to claim 1, characterized in that the step of performing a first action (S2) comprises an action between interrupting the execution of subsequent steps (I2) and executing the subsequent steps.

3. Fuel heating system integrity management method according to claim 1, characterized in that the step of performing a second action (S5) comprises an action between interrupting the execution of subsequent steps (I5) and executing the subsequent steps.

4. Fuel heating system integrity management method according to claim 1, characterized in that the step of performing a third action (S8) comprises an action between interrupting the execution of subsequent steps (I8) and executing subsequent steps.

5. Fuel heating system integrity management method, according to any one of claims 2, 3 and 4, characterized in that the action of interrupting the execution of subsequent steps (I2, I5, I8) comprises at least one action among the actions of • finalizing fuel heating system integrity management (S12); • disabling the heating system (S13); • issuing at least one alert (S14); • generating at least one fault identification code (S14).

6. Fuel heating system integrity management method, according to claim 1, characterized in that the step of performing a fourth action (S10) comprises at least one action among the actions of Petition 870230023890, dated 03 / 21 / 2023, page 22 / 34 3 / 4 • enable the heating system (S11); • disable the heating system (S13); • issue at least one alert (S14); • generate at least one fault identification code (S14).

7. Fuel heating system integrity management method according to claim 1, characterized in that the step of checking the condition of at least one electrical condition parameter at the current instant (S1) comprises: • checking the integrity of the heating device; • checking the integrity of the control unit; • checking the integrity of the electrical power supply unit.

8. Fuel heating system integrity management method according to claim 7, characterized in that the step of verifying the integrity of the electrical power supply unit comprises verifying and evaluating the amount of voltage available in the electrical power supply unit.

9. Fuel heating system integrity management method according to claim 1, characterized in that the step of checking the condition of at least one fuel line condition parameter at the current instant (S3) comprises measuring the working pressure of the fuel line at the current instant.

10. Fuel heating system integrity management method according to claim 1, characterized in that the step of determining the power to be applied to the heating device to heat the fuel (S6) comprises calculating the power to be applied to the heating device to heat the fuel.

11. A method for managing the integrity of a fuel heating system, according to claim 1, characterized in that a value of an electrical parameter of the heating device comprises a resistance value measured in at least one heating device.

12. Fuel heating system integrity management method according to claim 1, characterized in that a value of an electrical parameter of the heating device comprises a value of electrical current measured in at least one heating device.

13. Fuel heating system integrity management method according to claim 5, characterized in that the action of issuing at least one alert comprises issuing at least one audible alert.

14. Fuel heating system integrity management method according to claim 5, characterized in that the action of issuing at least one alert comprises issuing at least one visual alert.

15. Fuel heating system integrity management method according to claim 5, characterized in that the steps of performing a first action (S2), performing a second action (S5), performing a third action (S8), and performing a fourth action (S10) include an action of transmitting at least one fault information to at least one generic device. Petition 870230023890, dated 03 / 21 / 2023, p. 24 / 34

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