Boost Controller for Fuel Injection Valves Managing Regenerative Current
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Solution Overview
Problem
The existing injection control devices for fuel injection valves face issues with inappropriate timing of boost control, leading to voltage floating and excessive current due to regenerative currents, which can result in insufficient voltage accumulation and exceeding the rated current of the boost capacitor.
Innovation Solution
The proposed solution involves a boost controller that temporarily stops boost control during a predetermined period to prevent voltage from exceeding the full-charge threshold and to manage regenerative currents, ensuring appropriate boost control timing and preventing excessive current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the boost controller continues boost control when regenerative current flows, then the boosted voltage may temporarily exceed the full-charge threshold due to ESR effect, but the boost control should be maintained to ensure sufficient voltage accumulation
Solution Approach 1:
The control unit detects regenerative current flow before it causes harmful effects. When regenerative current is detected, the control unit temporarily stops boost control in advance to prevent voltage from exceeding the full-charge threshold, thereby avoiding voltage floating and excessive current issues while maintaining proper voltage accumulation when needed
2Object-affected harmful factors
If the boost controller stops boost control when regenerative current flows, then voltage floating and excessive current are prevented, but the boosted voltage may not be sufficiently accumulated
Solution Approach 1:
The boost control operation is made dynamic rather than static. The control unit continuously monitors the boosted voltage and regenerative current, and adjusts the boost control operation in real-time - stopping when regenerative current is detected to prevent harmful effects, and resuming when conditions are safe to ensure sufficient voltage accumulation. This dynamic adjustment resolves the contradiction between preventing harmful effects and maintaining voltage accumulation reliability
3Reliability
If regenerative current and boost control current add up, then the rated current of the boost capacitor may be exceeded, but the regenerative current should be utilized to accumulate voltage
Solution Approach 1:
The control unit detects regenerative current flow before it combines with boost control current to exceed the rated current limit. When regenerative current is detected, the control unit temporarily stops boost control in advance to prevent the combined current from exceeding the rated current of the boost capacitor, while still allowing voltage accumulation through regenerative current alone
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively suppresses voltage floating and prevents excessive current, ensuring the boosted voltage is maintained near the full-charge threshold, thereby efficiently accumulating voltage and managing regenerative currents within safe limits.
Implementation Method 1
a floating voltage occurs due to the effect of an equivalent series resistor (ESR) of the boost capacitor
Data Source
AI summary
An injection control device includes a boost controller performing boost control of a boosted voltage generated by a booster circuit until a boosted voltage, which is generated in a boost capacitor, rises to a full-charge threshold when the boosted voltage falls below a charge start threshold. When a power interruption controller interrupts electric current supplied to the fuel injection valve by the drive unit, a regeneration unit regenerates electric current generated in the fuel injection valve to the boost capacitor of the booster circuit. The boost controller stops the boost control of the booster circuit when at least the electric current is regenerated by the regeneration unit to the boost capacitor of the booster circuit after the interruption control by the power interruption controller.