GDI fuel injector electromagnet high-temperature dry grinding durability testing device and method

Abstract

The invention provides a GDI fuel injector electromagnet high-temperature dry grinding durability testing device and method, and belongs to the field of engine devices. The at least one ECU module is connected with the upper computer through a CAN (Controller Area Network) communication line; under the control of the upper computer, the ECU module can continuously drive the GDI fuel injector electromagnet according to a driving time sequence; a program is burnt in the ECU module and is calibrated in advance, and a test current for driving the electromagnet of the GDI fuel injector can be generated; the power supply is connected with a serial port of the upper computer; the GDI fuel injector electromagnet is located in a cavity of the high-low temperature box and used for providing a high-temperature environment for the GDI fuel injector electromagnet; the ECU module is connected with a GDI fuel injector electromagnet through a Teflon cable. And the non-contact Hall current sensor is connected with the upper computer through the data acquisition card and is used for monitoring a current waveform generated by the electromagnet of the GDI oil sprayer under the action of the test current. The device and the method can be used for testing the electromagnet of the GDI fuel injector in a high-temperature environment.

Description

Technical Field

[0001] The invention belongs to the field of engine devices, and in particular relates to a device and method for testing the high-temperature dry wear durability of a GDI injector electromagnet. Background Art

[0002] The engine nozzle needle (also known as the injector needle) is a core precision component of the fuel injector (fuel injector nozzle). The GDI injector solenoid, acting as the actuator that controls the nozzle needle's movement, plays a decisive role in its accuracy, which in turn directly impacts engine performance and fuel economy. Therefore, conducting dry-wear durability testing of GDI injector solenoids in high-temperature environments is essential to ensure their stable operation within the fuel system.

[0003] However, in the existing technical system, there is no special device and method for testing the high-temperature dry wear durability performance of GDI injector electromagnets. Therefore, there is a clear practical need and value in developing a device and method for testing the high-temperature dry wear durability of GDI injector electromagnets. Summary of the Invention

[0004] In order to overcome the deficiencies in the prior art, the present invention provides a device and method for testing the high-temperature dry wear durability of a GDI injector electromagnet.

[0005] In order to achieve the above object, the present invention proposes the following technical solution: a GDI injector electromagnet high temperature dry wear durability test device, comprising:

[0006] Host computer;

[0007] At least one ECU module is connected to a host computer via a CAN communication line; under the control of the host computer, the ECU module can continuously drive the GDI fuel injector electromagnet according to a drive timing; the host computer can count or reset the number of times the ECU module is driven; the ECU module is programmed and pre-calibrated, and when powered on, the ECU module can generate a test current for driving the GDI fuel injector electromagnet;

[0008] The power supply is connected to the serial port of the host computer. Under the control of the host computer, the power supply is on or off. When the power supply is on, the ECU module is immediately powered on and drives the GDI injector electromagnet. When the power supply is off, the ECU module immediately stops driving the GDI injector electromagnet.

[0009] The high and low temperature box, in which the GDI injector electromagnet is located, is used to provide a high temperature environment for the GDI injector electromagnet; the ECU module is connected to the GDI injector electromagnet through a Teflon cable;

[0010] The non-contact Hall current sensor is connected to the host computer through a data acquisition card and is used to monitor the current waveform generated by the GDI injector electromagnet under the action of the test current.

[0011] Furthermore, a temperature sensor armored probe rod is installed on the panel of the high and low temperature box. The temperature sensor armored probe rod is connected to the host computer and extends into the interior of the high and low temperature box cavity for monitoring the temperature inside the high and low temperature box.

[0012] Furthermore, the test current corresponds to five actuations of the GDI injector solenoid, the five actuations including pilot injection 1, pilot injection 2, main injection, post injection 1, and post injection 2;

[0013] In the time-current coordinate system, the test current includes BOOST current, PEAK current, BYPASS current, and HOLD current;

[0014] The BOOST current lasts from time 0 to time t1, and includes a current waveform in which the current rises from 0 to A1 with a slope K1.

[0015] The peak current waveform lasts from time t1 to time t3 and includes two segments. The first segment lasts from time t1 to time t2, with the current decreasing from A1 to A2 at a slope of K2. The second segment lasts from t2 to t3 and is a triangular sawtooth waveform parallel to the time axis, consisting of N rising segments and N-1 falling segments. The peak current of the second segment is A3, and the valley current is A2. The peak current off-time is defined as the duration of the second falling segment of the triangular sawtooth waveform along the time axis.

[0016] The BYPASS current lasts from time t3 to time t4 and includes a current waveform in which the current decreases from A3 to A4 at a slope K3;

[0017] The HOLD current lasts from time t4 to time t5, and includes a current waveform. In this current waveform, it is triangular sawtooth-shaped in a direction parallel to the time axis, including N rising trajectories and N-1 falling trajectories. The peak current of the current waveform is A5. The off-time of the HOLD current is defined as: the duration of the second falling trajectory in the triangular sawtooth waveform along the time axis; where A1 ≥ A3 > A2 > A5 > A4.

[0018] Furthermore, a 5A fuse is connected in series between the output of the ECU module and the GDI injector electromagnet.

[0019] Furthermore, each ECU module is connected to 6 GDI injector electromagnets, and the ECU module drives the 6 GDI injector electromagnets in sequence according to the driving sequence; the driving frequency of the ECU module is 30 Hz.

[0020] Furthermore, S1: equipped with a GDI injector electromagnet high temperature dry wear durability test device;

[0021] S2: Turn on the high and low temperature chamber. When the temperature sensor's armored probe detects that the chamber temperature has reached 150°C, the host computer receives a "turn-on signal." Then, under the control of the host computer, the power is turned on, and the ECU module is immediately powered on and drives the GDI injector electromagnet. The ECU module generates the test current required to drive the GDI injector electromagnet according to the programmed program and pre-calibration in time steps.

[0022] S3: The GDI injector electromagnet under test generates a corresponding current waveform under the test current generated by the above-mentioned ECU module. The non-contact Hall current sensor collects the current waveform and transmits it to the host computer.

[0023] S4: Determine whether the GDI injector solenoid is abnormal;

[0024] The judgment conditions are as follows:

[0025] (1) Based on the collected actual waveforms of each GDI injector electromagnet under test, check whether the current duration of each injection, i.e., the time period from 0 to t5, is within the ±200μs deviation range of the set value;

[0026] (2) Based on the collected actual waveforms of each tested GDI injector electromagnet, detect whether the peak value of the triangular sawtooth portion of the PEAK current of each injection round, that is, A3, is within the ±2A deviation range of the set value;

[0027] (3) Based on the collected actual waveforms of each tested GDI injector electromagnet, check whether the valley value of the triangular sawtooth portion of the peak current of each injection round, that is, A2, is within the ±2A deviation range of the set value;

[0028] (4) Based on the collected actual waveforms of each GDI injector solenoid under test, check whether the peak current time of each injection, i.e., the time period from 0 to t3, is within the ±200 μs deviation range of the set value;

[0029] (5) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the peak value of the triangular sawtooth portion of the HOLD current of each injection round, that is, A5, is within the ±2A deviation range of the set value;

[0030] (6) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the valley value of the triangular sawtooth portion of the HOLD current for each injection round, i.e., A4, is within the ±2A deviation range of the set value;

[0031] (7) Calculate the effective value of the current waveform of the entire three rounds according to the set driving frequency, and check whether the effective value is within the ±0.5A deviation range of the initial value of the test;

[0032] If any of the above conditions is not met, the GDI injector is considered abnormal;

[0033] The above technical solutions can achieve the following beneficial effects:

[0034] 1. Set up a high and low temperature box and place the GDI injector electromagnet in a high temperature environment. Generate a test current through the burned program to make the GDI injector electromagnet generate corresponding drives (pre-injection 1, pre-injection 2, main injection, post-injection 1 and post-injection 2). Then, by comparing the time interval and the low value (the valley value of the triangular sawtooth), it is known whether the GDI injector electromagnet is abnormal.

[0035] 2. Under the control of the controller, the ECU module continuously emits test current at the same frequency as the cam, 30Hz, to simulate the real environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is the overall structural module diagram of the test device;

[0037] Figure 2 It is the current waveform generated by the ECU module;

[0038] Figure 3 It is the current waveform generated by the GDI injector solenoid under the ECU module current;

[0039] Figure 4 This is the driving timing diagram of the ECU module.

[0040] 1. Host computer; 2. ECU module; 3. High and low temperature chamber; 4. Armored probe of temperature sensor; 5. GDI injector electromagnet. DETAILED DESCRIPTION

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0042] Example 1: A high-temperature dry wear durability test device for a GDI injector electromagnet, comprising:

[0043] Host computer 1 (industrial computer);

[0044] At least one ECU module 2 is connected to a host computer via a CAN communication line. The host computer sends count commands or count reset commands to the ECU module 2 via the CAN communication line. The ECU module 2 is powered by an ITECH IT6512A power supply with a maximum voltage of 80V, a maximum current of 60A, and a maximum power of 1200W. In this embodiment, eight ECU modules are connected to the host computer, powered by two ITECH IT6512A power supplies, each of which supplies power to four of the ECU modules 2. The ITECH IT6512A power supply is connected to the serial port of host computer 1. Host computer 1 controls the ON and OFF of the ITECH IT6512A power supply. When the power supply is ON, ECU module 2 is immediately powered on and drives the GDI injector electromagnet 5. When the power supply is OFF, ECU module 2 is powered off and stops driving the GDI injector electromagnet 5. In addition, the voltage of the ITECH IT6512A power supply is also set by host computer 1. For example, the voltage of each power supply is set to 24V.

[0045] The host computer 1 and ECU modules 2 are located outside the chamber 3. The GDI injector electromagnets are located within the chamber 3. Each ECU module 2 is connected to six GDI injector electromagnets via 200°C Teflon cables, meaning one ECU module 2 tests six GDI injector electromagnets. A 5A fuse is connected in series between the ECU module 2 output and each GDI injector electromagnet to prevent damage to the ECU module 2 due to short circuits during testing.

[0046] The temperature sensor's armored probe 4 is mounted on the panel of the temperature chamber 3 and connected to the host computer 1 via a transmitter. The 50cm-long probe extends into the chamber 3, with a measurement range of -50°C to 200°C. When the chamber temperature rises to 150°C, the host computer's control power is turned on, energizing the ECU module and driving the GDI injector electromagnet 5 for a high-temperature dry-run test. When the chamber temperature drops to 140°C, the host computer's control power is turned off, de-energizing the ECU module and stopping driving the GDI injector electromagnet 5.

[0047] Multiple non-contact Hall current sensors are used to monitor the current waveforms of the corresponding GDI injector electromagnets. The non-contact Hall current sensors are connected to a data acquisition card, which is connected to a host computer so that the host computer can obtain the current waveforms of each tested GDI injector electromagnet.

[0048] Example 2: A method for testing the high-temperature dry wear durability of a GDI injector electromagnet, comprising the following steps:

[0049] S1: Build a high-temperature dry wear durability test device for GDI injector electromagnet;

[0050] S2: Turn on the high and low temperature box. When the temperature sensor armored probe detects that the temperature of the high and low temperature box reaches 150℃, the host computer receives the "open signal". After that, under the control of the host computer, the power is turned on, the ECU module is immediately powered on and drives the GDI injector electromagnet;

[0051] The program is burned into the ECU module and pre-calibrated. The meaning of calibration is that the various parameters involved in the ECU program have been systematically debugged, optimized and set, and it can generate the test current required to drive the GDI injector electromagnet according to the time step; the time and current waveform of the test current are as follows: Figure 2 This current waveform corresponds to the GDI injector's pilot injection 1, pilot injection 2, main injection, post-injection 1, and post-injection 2, driving the GDI injector's electromagnet five times. The duration of these cycles coincides with the timing of pilot injection 1, pilot injection 2, main injection, post-injection 1, and post-injection 2.

[0052] See Figure 2 ,For the convenience of expression, the above current waveform ,in time steps includes BOOST current, PEAK current, BYPASS current, and HOLD current;

[0053] The BOOST current lasts from time 0 to time t1. In the time-current coordinate system, it includes a current waveform. In the current waveform, the current rises from 0 to A1 with a slope K1.

[0054] The peak current waveform lasts from time t1 to time t3. In the time-current coordinate system, it consists of two current waveform segments. The first segment, from time t1 to time t2, decreases from A1 to A2 at a slope of K2. The second segment, from t2 to t3, presents a triangular sawtooth pattern parallel to the time axis, consisting of N rising segments and N-1 falling segments. The peak current of the second segment is A3, and the valley current is A2. The peak current off-time is defined as the duration of the second falling segment of the triangular sawtooth waveform along the time axis.

[0055] The BYPASS current lasts from time t3 to time t4 and includes a current waveform in the time-current coordinate system. In the current waveform, the current decreases from A3 to A4 with a slope K3.

[0056] The HOLD current lasts from time t4 to time t5. In the time-current coordinate system, this current waveform comprises a triangular sawtooth pattern parallel to the time axis, consisting of N rising segments and N-1 falling segments. The peak current of the current waveform is A5. The HOLD current off-time is defined as the duration of the second falling segment of the triangular sawtooth waveform along the time axis. The numerical relationship between A1 and A5 is: A1 ≥ A3 > A2 > A5 > A4. Figure 2 A1~A5 are all adjustable. Generally, A1 and A3 are 24A, A2 is 11A, A5 is 10A, and A4 is 7A.

[0057] S3: The GDI injector electromagnet under test generates a corresponding current waveform under the current generated by the above-mentioned ECU module. The non-contact Hall current sensor collects the current waveform and transmits it to the host computer.

[0058] S4: Determine whether the GDI injector solenoid is abnormal.

[0059] Figure 3 This is a section of the waveform of the GDI injector solenoid under test.

[0060] The judgment conditions are as follows:

[0061] (1) Based on the collected actual waveforms of each GDI injector electromagnet under test, check whether the current duration of each injection, i.e., the time period from 0 to t5, is within the ±200μs deviation range of the set value;

[0062] (2) Based on the collected actual waveforms of each tested GDI injector electromagnet, detect whether the peak value of the triangular sawtooth portion of the PEAK current of each injection round, that is, A3, is within the ±2A deviation range of the set value;

[0063] (3) Based on the collected actual waveforms of each tested GDI injector electromagnet, check whether the valley value of the triangular sawtooth portion of the peak current of each injection round, that is, A2, is within the ±2A deviation range of the set value;

[0064] (4) Based on the collected actual waveforms of each GDI injector solenoid under test, check whether the peak current time of each injection, i.e., the time period from 0 to t3, is within the ±200 μs deviation range of the set value;

[0065] (5) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the peak value of the triangular sawtooth portion of the HOLD current of each injection round, that is, A5, is within the ±2A deviation range of the set value;

[0066] (6) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the valley value of the triangular sawtooth portion of the HOLD current for each injection round, i.e., A4, is within the ±2A deviation range of the set value;

[0067] (7) Calculate the effective value of the current of the entire three rounds of current waveform according to the set driving frequency (for example, if the driving frequency is set to 30Hz, it is necessary to calculate the effective value within 3×33.33ms, that is, 100ms), and check whether the effective value is within the ±0.5A deviation range of the test initial value (4A).

[0068] If any of the above conditions is not met, the GDI injector is considered abnormal.

[0069] Since each ECU module is connected to 6 GDI injector electromagnets, the ECU module drives the 6 GDI injector electromagnets in a cycle according to the driving sequence. The driving sequence diagram is shown in Figure 4 For a single GDI injector electromagnet, the ECU module continuously drives each GDI injector electromagnet at a frequency of 30Hz, that is, the driving time for each wheel is 33.33ms (the time interval between the start point of the current wheel drive and the start point of the next wheel drive). Figure 4 The maximum frequency can also be adjusted to 40 Hz, continuously driving each GDI injector solenoid at a maximum frequency of 40 Hz.

[0070] S5: Turn off the high and low temperature box. When the temperature sensor armored probe detects that the temperature of the high and low temperature box has dropped to 140°C, the power supply is turned off under the control of the host computer, and the ECU module is immediately powered off and stops driving the electromagnet.

[0071] With the above-described preferred embodiments of the present invention as a guide, and with reference to the above description, relevant personnel are fully capable of making various changes and modifications without departing from the technical scope of this invention. The technical scope of this invention is not limited to the contents of the specification and must be determined according to the scope of the claims.

Claims

1. A GDI injector electromagnet high temperature dry wear durability test device, characterized in that: include: Host computer; At least one ECU module is connected to a host computer via a CAN communication line; under the control of the host computer, the ECU module can continuously drive the GDI fuel injector electromagnet according to a drive timing; the host computer can count or reset the number of times the ECU module is driven; the ECU module is programmed and pre-calibrated, and when powered on, the ECU module can generate a test current for driving the GDI fuel injector electromagnet; The power supply is connected to the serial port of the host computer. Under the control of the host computer, the power supply is on or off. When the power supply is on, the ECU module is immediately powered on and drives the GDI injector electromagnet. When the power supply is off, the ECU module immediately stops driving the GDI injector electromagnet. The high and low temperature box, in which the GDI injector electromagnet is located, is used to provide a high temperature environment for the GDI injector electromagnet; the ECU module is connected to the GDI injector electromagnet through a Teflon cable; The non-contact Hall current sensor is connected to the host computer through a data acquisition card and is used to monitor the current waveform generated by the GDI injector electromagnet under the action of the test current.

2. A GDI fuel injector electromagnet high temperature dry wear durability testing device according to claim 1, characterized in that: A temperature sensor armored probe rod is installed on the panel of the high and low temperature box. The temperature sensor armored probe rod is connected to the host computer and extends into the interior of the high and low temperature box cavity for monitoring the temperature inside the high and low temperature box.

3. A GDI fuel injector electromagnet high temperature dry wear durability testing device according to claim 1, characterized in that: The test current corresponds to five actuations of the GDI injector solenoid, including pilot injection 1, pilot injection 2, main injection, post injection 1, and post injection 2. In the time-current coordinate system, the test current includes BOOST current, PEAK current, BYPASS current, and HOLD current; The BOOST current lasts from time 0 to time t1, and includes a current waveform in which the current rises from 0 to A1 with a slope K1. The peak current waveform lasts from time t1 to time t3 and includes two segments. The first segment lasts from time t1 to time t2, with the current decreasing from A1 to A2 at a slope of K2. The second segment lasts from t2 to t3 and is a triangular sawtooth waveform parallel to the time axis, consisting of N rising segments and N-1 falling segments. The peak current of the second segment is A3, and the valley current is A2. The peak current off-time is defined as the duration of the second falling segment of the triangular sawtooth waveform along the time axis. The BYPASS current lasts from time t3 to time t4 and includes a current waveform in which the current decreases from A3 to A4 at a slope K3; The HOLD current lasts from time t4 to time t5, and includes a current waveform. In this current waveform, it is triangular sawtooth-shaped in a direction parallel to the time axis, including N rising trajectories and N-1 falling trajectories. The peak current of the current waveform is A5. The off-time of the HOLD current is defined as: the duration of the second falling trajectory in the triangular sawtooth waveform along the time axis; where A1 ≥ A3 > A2 > A5 > A4.

4. A GDI fuel injector electromagnet high temperature dry wear durability testing device according to claim 1, characterized in that: A 5A fuse is connected in series between the output of the ECU module and the GDI injector electromagnet.

5. The GDI injector electromagnet high temperature dry wear durability testing device according to claim 1, characterized in that: Each ECU module is connected to 6 GDI injector electromagnets, and the ECU module drives the 6 GDI injector electromagnets in sequence according to the driving timing; the driving frequency of the ECU module is 30Hz.

6. A high-temperature dry-abrasion durability test method for a GDI fuel injector electromagnet, based on the high-temperature dry-abrasion durability test device for a GDI fuel injector electromagnet according to claim 3, characterized in that: The following steps are involved: S1: Equipped with a GDI injector electromagnet high temperature dry wear durability test device; S2: The temperature chamber is turned on. When the temperature sensor's armored probe detects that the chamber temperature has reached 150°C, the host computer receives a "turn-on signal." Then, under the host computer's control, the power is turned on, and the ECU module immediately powers on and drives the GDI injector electromagnet. The ECU module generates the test current required to drive the GDI injector electromagnet in a timed manner, according to the pre-calibrated and programmed program. S3: The GDI injector electromagnet under test generates a corresponding current waveform under the test current generated by the above-mentioned ECU module. The non-contact Hall current sensor collects the current waveform and transmits it to the host computer. S4: Determine whether the GDI injector solenoid is abnormal; The judgment conditions are as follows: (1) Based on the collected actual waveforms of each GDI injector electromagnet under test, check whether the current duration of each injection, i.e., the time period from 0 to t5, is within the ±200μs deviation range of the set value; (2) Based on the collected actual waveforms of each tested GDI injector electromagnet, detect whether the peak value of the triangular sawtooth portion of the PEAK current of each injection round, that is, A3, is within the ±2A deviation range of the set value; (3) Based on the collected actual waveforms of each tested GDI injector electromagnet, check whether the valley value of the triangular sawtooth portion of the peak current of each injection round, that is, A2, is within the ±2A deviation range of the set value; (4) Based on the collected actual waveforms of each GDI injector solenoid under test, check whether the peak current time of each injection, i.e., the time period from 0 to t3, is within the ±200 μs deviation range of the set value; (5) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the peak value of the triangular sawtooth portion of the HOLD current of each injection round, that is, A5, is within the ±2A deviation range of the set value; (6) Based on the collected actual waveforms of each tested GDI injector solenoid, detect whether the valley value of the triangular sawtooth portion of the HOLD current for each injection round, i.e., A4, is within the ±2A deviation range of the set value; (7) Calculate the effective value of the current waveform of the entire three rounds according to the set driving frequency, and check whether the effective value is within the ±0.5A deviation range of the initial value of the test; If any of the above conditions is not met, the GDI injector is considered abnormal; S5: Turn off the high and low temperature box. When the temperature sensor armored probe detects that the temperature of the high and low temperature box drops to 140℃, under the control of the host computer, the power is turned OFF, the ECU module is immediately powered off and stops driving the electromagnet.

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