Common Rail Pressure Control via Local Cylinder Modules
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Solution Overview
Problem
In common rail fuel injection systems, pressure control instability arises due to differences in pressure sensors and unsynchronized cylinder control modules, leading to uneven fuel distribution and reduced engine operating life.
Innovation Solution
A method and apparatus that form an internal pressure reference value by subtracting a portion from the set pressure reference value, dependent on control signal data, to stabilize pressure control signals and ensure consistent fuel flow across engine cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If pressure data is transmitted from a central main control module to multiple cylinder control modules, then centralized pressure monitoring is achieved, but communication failures and data inconsistency occur between modules
Solution Approach 1:
Each cylinder control module is equipped with its own pressure sensor and uses local pressure measurement data to generate control signals, rather than relying on centralized data transmission. This localizes the control function to each module, eliminating communication dependency and ensuring each module has accurate, real-time pressure information for its specific cylinder group.
Solution Approach 2:
The pressure control system is divided into independent segments: each cylinder control module operates autonomously with its own pressure sensor and control logic. This segmentation breaks the centralized control architecture into distributed independent units, so that a failure in one module does not affect others, and each module maintains reliable pressure control locally.
2Ease of operation
If different pressure reference values are used by different cylinder control modules, then local pressure control is optimized, but uneven fuel distribution occurs across cylinders
Solution Approach 1:
Each cylinder control module continuously measures local pressure with its own sensor and uses this feedback to dynamically adjust its control signals. The control module compares measured pressure against a reference value and modifies fuel injection timing and quantity to maintain optimal pressure, ensuring uniform fuel distribution while allowing local optimization.
Solution Approach 2:
The system dynamically changes pressure reference values and control parameters based on real-time operating conditions. Each module can adjust its local pressure target within a range, and the control algorithm modifies injection parameters (timing, duration, quantity) to achieve both local optimization and overall uniformity across all cylinders.
3Speed
If control units are completely open or closed due to unstable pressure control, then immediate pressure adjustments are made, but the operating life of control units is shortened
Solution Approach 1:
The control system uses dynamic, graduated adjustments rather than extreme on/off control. Each cylinder control module continuously modulates its control signals based on real-time pressure feedback, making smooth incremental changes to fuel injection parameters. This dynamic control avoids the mechanical stress and wear associated with complete opening or closing of control units, extending their operating life while maintaining fast pressure response.
Data Source
Figure 1~2
Figure 3~4B
Figure 5
AI summary
The apparatus according to the invention comprises a controller (7) to form a control signal, which controller is arranged to receive pressure data of the CR system (51). The apparatus also comprises a module (52) to form an internal pressure reference value based on a set pressure reference value when forming the control signal (53).