Control Valve Coil Temperature Controller for Diesel Injectors
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Solution Overview
Problem
Spool valves in diesel fuel injectors become sluggish or stick during cold starts, delaying engine cranking and potentially causing overheating issues once the engine is running.
Innovation Solution
Implementing a coil temperature measurement and heating system that provides short heating pulses to spool valves before and during engine cranking, ensuring the coil remains operational and within a safe temperature range, and adjusting power delivery based on engine oil temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If heating pulses are applied to the coil before and during engine cranking, then the spool valve responsiveness is improved, but the risk of coil overheating increases
Solution Approach 1:
The patent applies periodic heating pulses to the coil rather than continuous heating. The controller delivers short-duration heating pulses at specific intervals before and during engine cranking, allowing the coil to reach adequate operating temperature for valve responsiveness while preventing excessive temperature buildup that would cause overheating.
Solution Approach 2:
The patent incorporates temperature sensing feedback to monitor coil temperature in real-time. The controller receives temperature signals from sensors and uses this feedback to dynamically adjust the heating pulse delivery, reducing or stopping heating when the coil reaches safe temperature thresholds, thus preventing overheating while maintaining valve responsiveness.
2Reliability
If the engine cranking is delayed to allow spool valve heating, then the valve sticking is prevented, but the engine starting time increases
Solution Approach 1:
The patent applies preliminary heating action to the coil before engine cranking begins. The controller detects cold conditions and delivers heating pulses in advance of the cranking event, preparing the spool valve for immediate operation without requiring a delay in the engine starting sequence.
Solution Approach 2:
The patent maintains continuous useful action by delivering heating pulses both before and during the cranking process. Rather than stopping the cranking to heat the valve, the heating continues concurrently with the cranking operation, ensuring the valve remains responsive throughout the starting sequence without extending the overall starting time.
3Speed
If high current is applied to the coil for valve actuation, then the valve response speed is improved, but the energy consumption increases
Solution Approach 1:
The patent uses periodic pulsed current delivery to the coil instead of continuous high current. The controller applies short-duration high-current pulses only when needed for valve actuation or heating, separated by intervals of reduced or zero current, thereby maintaining fast valve response capability while significantly reducing overall energy consumption during idle or steady-state operation.
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
Ensures smooth engine starting by preventing valve sticking and overheating, maintaining efficient operation by dynamically managing coil temperature and reducing the risk of catastrophic failures in cold conditions.
Implementation Method 1
The coil temperature measurement circuit measures the resistance of the control valve coil between its terminals
Implementation Method 2
provides short heating pulses to spool valves before and during engine cranking
Data Source
AI summary
A method of actuator coil temperature control for actuators that are not continuously operated, wherein when an actuation current is not being applied to the actuator coil, a) sensing a parameter indicative of the resistance of the actuator coil as an indication of the temperature of the actuator coil, b) if the sensed parameter indicates the temperature of the actuator coil is below a first predetermined limit, then initiating a series of successive actuation current pulses to the actuator coil, each actuation current pulse being terminated before actuation of the actuator occurs, and c) periodically repeating a) and b).