Dual-Valve Fuel Injection Unit for Large Engine Efficiency
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Solution Overview
Problem
Conventional fuel injection systems for large internal combustion engines are complex, prone to wear, and inefficient, especially at low loads, leading to increased emissions and maintenance challenges, particularly in dual-fuel engines where additional components and systems complicate the cylinder head space and operations.
Innovation Solution
A fuel injection unit with a single high-pressure fuel accumulator and two fuel injection valves, one smaller and one larger, where the smaller valve is used for low-load operations and the larger for full-load operations, simplifying the system by reducing components and enabling efficient fuel injection control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional fuel injection system with individual injection pumps for each cylinder is used, then fuel can be injected into each cylinder, but the system becomes complex and the injection pressure varies between cylinders leading to inconsistent fuel amounts
Solution Approach 1:
The patent combines multiple injection functions into a single common rail system that supplies all cylinders. Instead of having separate injection pumps for each cylinder, a single high-pressure pump feeds a common rail that distributes fuel to all injection valves, simplifying the system while maintaining consistent injection pressure across all cylinders.
Solution Approach 2:
The common rail system serves as a universal fuel supply for all cylinders, providing consistent high-pressure fuel to multiple injection valves. The single common rail structure performs the function of multiple individual pumps, reducing system complexity while ensuring uniform injection conditions across all cylinders.
2Adaptability or versatility
If hydromechanical injection nozzles with predetermined opening pressure are used, then the injection system is simple, but the injection timing and duration cannot be adjusted to account for component wear during engine operation
Solution Approach 1:
The patent replaces hydromechanical injection nozzles with electronically controlled injection valves. Instead of relying on predetermined mechanical opening pressures, the electronic control system can precisely regulate injection timing and duration, allowing adaptation to component wear and varying operating conditions while maintaining simple nozzle structures.
Solution Approach 2:
The injection system transitions from static, predetermined opening pressures to dynamic, electronically controlled injection timing and duration. The electronic control allows real-time adjustment of injection parameters to compensate for component wear and optimize performance across different operating conditions.
3Measurement precision
If a common rail fuel system with electronically controlled injection valves is used, then injection timing and duration can be precisely controlled, but the system complexity increases and costs rise
Solution Approach 1:
The patent segments the injection control into modular electronic control units for each cylinder, allowing precise independent control of each injection valve while using a shared common rail system. This segmentation enables precise timing control without requiring complete system redesign, managing complexity through modular architecture.
4Adaptability or versatility
If additional components are added to dual-fuel engines to handle both gas and liquid fuel, then the engine can operate in multiple fuel modes, but the cylinder head space becomes crowded and maintenance becomes difficult
Solution Approach 1:
The common rail system serves as a universal fuel supply for both gas and liquid fuel modes in dual-fuel engines. By using a single high-pressure fuel system that can supply both injection valves, the patent reduces the number of separate fuel systems needed, freeing up cylinder head space and improving maintenance accessibility while maintaining multi-fuel capability.
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 configuration simplifies the fuel system, reduces emissions and maintenance, minimizes component failure risks, and lowers costs by eliminating redundant components, while improving injection precision and reducing pressure loss and sac volume, thereby enhancing overall engine performance.
Implementation Method 1
a high pressure fuel accumulator (8) for providing said first and second fuel injection valves with fuel
Implementation Method 2
electronic control, for instance by means of a solenoid or piezoelectric valve
Implementation Method 3
fuel is injected by means of a fuel injection valve or an injector directly into the cylinders of an engine
Data Source
AI summary
A novel fuel injection unit for a large internal combustion engine includes a common rail fuel system. The fuel injection unit of the invention is constructed of at least a high pressure fuel accumulator specific for the fuel injection unit, a flow fuse, a first fuel injection valve with a control valve, and a second fuel injection valve with a control valve. The first fuel injection valve is a smaller one used for injecting at most 30% of the fuel required in full load operation of a diesel mode.