Dual Injection Engine Control for Fuel Economy and Particulate Emissions

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Solution Overview

Problem

Controlling dual port-direct injection systems in internal combustion engines, combined with variable compression ratios and independent compression/expansion systems, is complex and requires new approaches to optimize fuel economy and maintain particulate emissions below a threshold.

Innovation Solution

A processor predicts settings for port fuel injection, direct injection, variable compression ratio, and independent compression/expansion systems to optimize fuel economy while ensuring particulate rates remain below a threshold, adjusting these settings based on load requests and using relative weights to prioritize their revision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If dual port-direct injection systems with variable compression ratios and independent compression/expansion systems are used, then fuel economy is optimized, but control complexity increases

Engineering Contradiction:

Improvefuel economyVSAvoidcontrol complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The control system segments the fuel injection into two separate systems: port fuel injection (PFI) and direct injection (DI). Each system has its own control parameters and injection timing, allowing independent optimization of fuel economy and emissions control without requiring complex integrated control of the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the compression ratio and independent compression/expansion rates based on operating conditions. The variable compression ratio mechanism and independent compression/expansion systems are controlled through adjustable linkages and timing mechanisms that respond to sensor feedback, enabling real-time optimization while managing complexity through adaptive control.

Inventive Principle:

Principle #15Dynamics

2Use of energy by moving object

If advanced engine systems with multiple injection systems are combined, then fuel economy is improved, but control difficulty increases

Engineering Contradiction:

Improvefuel economyVSAvoidcontrol difficulty

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The control system pre-calculates and stores optimal injection parameters, compression ratios, and timing settings for various operating conditions in lookup tables and control algorithms. This preliminary preparation allows the system to quickly select pre-determined optimal settings rather than calculating them in real-time, reducing control difficulty while maintaining fuel economy optimization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates sensors that monitor engine parameters such as intake manifold pressure, cylinder pressure, temperature, and emissions. This feedback is continuously processed by the control unit to adjust injection timing, duration, and quantity for both PFI and DI systems, as well as compression ratio settings, ensuring optimal performance while simplifying control through closed-loop regulation.

Inventive Principle:

Principle #23Feedback

3Productivity

If port fuel injection and direct injection are used simultaneously, then fuel mixing efficiency is improved, but system complexity increases

Engineering Contradiction:

Improvefuel mixing efficiencyVSAvoidinjection system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system merges PFI and DI into a unified dual injection architecture where both systems share common fuel rail infrastructure and control electronics. The PFI system provides initial fuel mixing in the intake manifold while the DI system delivers precise direct cylinder injection, creating a synergistic effect that improves overall fuel mixing efficiency while consolidating system components to manage complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses PFI for partial fuel delivery and mixing in the intake manifold, then supplements with DI for the remaining fuel quantity and precise timing control. This partial action approach allows the simpler PFI system to handle the bulk of fuel delivery while the more complex DI system focuses on precise metering and timing, optimizing the division of labor between the two injection systems.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11668259B1Port-direct injection engine methods and systems optimizing fuel economy with particulate control

Publication Date: 2023.06.06 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Methods and systems for optimizing fuel economy and maintaining particulate emissions below a threshold of an engine system in a vehicle. An engine system has port fuel injection, direct injection, variable compression ratio, and independent compression/expansion. A processor predicts settings for the four systems that optimize for a fuel economy that is maximized. A particulate rate of the engine system is computed based on the settings. A determination is made of whether the particulate rate is below a threshold. When the particulate rate is below the threshold, command signals are delivered to actuators of the systems to move to the settings. When the threshold is exceeded, the settings are revised to maintain the particulate below the threshold while optimizing for fuel economy.