Dual Nozzle Fuel Injection Unit for Load-Dependent Emission Control
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Solution Overview
Problem
Large compression ignition internal combustion engines face challenges with smoke formation at low loads due to suboptimal fuel injector performance, which also leads to higher fuel consumption and increased NOx, CO, and hydrocarbon emissions when optimized for high loads.
Innovation Solution
A fuel injection unit with two fuel galleries and nozzles, along with a control valve and injector needles, allows for optimized fuel delivery at varying engine loads by selecting the appropriate nozzle for different conditions, reducing emissions and fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the fuel injector is optimized for high loads, then the fuel delivery performance at maximum power is improved, but smoke formation increases at low loads
Solution Approach 1:
The fuel injection system is segmented into two separate fuel injection nozzles with different flow areas. The first nozzle has a larger flow area optimized for high-load conditions, while the second nozzle has a smaller flow area optimized for low-load conditions. This segmentation allows each nozzle to be specifically tuned for its operating range, eliminating the compromise required by a single nozzle design.
Solution Approach 2:
The system dynamically selects which nozzle to use based on the current engine load conditions. A control mechanism switches between the first and second nozzles depending on whether the engine is operating at high or low load, ensuring optimal fuel delivery performance across the entire operating range rather than being fixed for a single condition.
2Object-generated harmful factors
If the injector performance at low loads is improved, then smoke formation is reduced, but fuel consumption increases at high loads
Solution Approach 1:
The fuel injection system is segmented into two separate fuel injection nozzles with different flow areas. The first nozzle has a larger flow area optimized for high-load conditions, while the second nozzle has a smaller flow area optimized for low-load conditions. This segmentation allows each nozzle to be specifically tuned for its operating range, eliminating the compromise required by a single nozzle design.
Solution Approach 2:
The system dynamically selects which nozzle to use based on the current engine load conditions. A control mechanism switches between the first and second nozzles depending on whether the engine is operating at high or low load, ensuring optimal fuel delivery performance across the entire operating range rather than being fixed for a single condition.
3Device complexity
If a single fuel injection nozzle is used, then the device complexity is reduced, but the adaptability to different operating conditions deteriorates
Solution Approach 1:
The fuel injection system is segmented into two separate fuel injection nozzles with different flow areas. The first nozzle has a larger flow area optimized for high-load conditions, while the second nozzle has a smaller flow area optimized for low-load conditions. This segmentation allows each nozzle to be specifically tuned for its operating range, eliminating the compromise required by a single nozzle design.
Solution Approach 2:
The fuel injection unit achieves multi-functionality by incorporating two nozzles that can handle different operating conditions. The system can universally adapt to both high-load and low-load conditions by selecting the appropriate nozzle, making a single injection unit capable of performing multiple functions that would otherwise require separate systems.
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
The solution enables reduced fuel consumption and lower emissions of NOx, CO, and hydrocarbons while minimizing smoke formation by using the appropriate fuel injection nozzle based on engine load, improving overall engine efficiency.
Implementation Method 1
a first injector needle for opening and closing flow communication between the first fuel gallery and the first fuel injection nozzle, and a second injector needle for opening and closing flow communication between the second fuel gallery and the second fuel injection nozzle
Implementation Method 2
the control valve comprises a valve member having at least a first position where fuel flow from an inlet port of the control valve to the first fuel gallery is allowed and fuel flow from the inlet port to the second fuel gallery is prevented, and a second position where fuel flow from the inlet port to the second fuel gallery is allowed and fuel flow from the inlet port to the first fuel gallery is prevented
Data Source
Figure 1~2
Figure 3~5
AI summary
The fuel injection unit (1) for an internal combustion engine comprises a body (29), a first fuel gallery (31) and a second fuel gallery (32), a first fuel injection nozzle (3) and a second fuel injection nozzle (4), a first injector needle (7) for opening and closing flow communication between the first fuel gallery (31) and the first fuel injection nozzle (3), and a second injector needle (8) for opening and closing flow communication between the second fuel gallery (32) and the second fuel injection nozzle (4). The invention also concerns a fuel injection system.