Engine Controller Override for Warm-Up Emissions
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Solution Overview
Problem
Internal combustion engines (ICEs) face challenges in improving fuel efficiency and reducing emissions, particularly during engine warm-up phases, where existing fuel injection systems deliver fuel based on actual coolant temperatures, leading to suboptimal fuel delivery and increased emissions.
Innovation Solution
A controller system that overrides the coolant temperature sensor signal to simulate a higher coolant temperature of 250°F during engine warm-up, adjusting the fuel injector pulse width to deliver fuel as if the engine were at a lean-burn mode, thereby reducing hydrocarbon and carbon monoxide emissions without compromising power or fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the fuel injector delivers fuel based on actual coolant temperature during engine warm-up, then the fuel delivery matches the actual engine state, but emissions increase and fuel efficiency decreases
Solution Approach 1:
The system changes the temperature parameter input to the fuel injector control system. During engine warm-up, when the coolant temperature sensor detects temperatures between 120°F and 250°F, the controller overrides this reading and provides a simulated temperature signal corresponding to 250°F or higher. This parameter change causes the fuel injector to deliver less fuel than would normally be delivered at actual warm-up temperatures, thereby reducing hydrocarbon and carbon monoxide emissions while improving fuel efficiency without compromising engine power.
2Power
If the fuel injector delivers more fuel during warm-up to ensure proper combustion, then power is maintained, but emissions increase
Solution Approach 1:
The controller modifies the temperature parameter fed to the fuel injector control algorithm. By overriding the actual coolant temperature reading (120°F-250°F) with a simulated higher temperature (250°F or above), the system instructs the fuel injector to operate as if the engine were already warm. This results in reduced fuel delivery during warm-up, which lowers hydrocarbon and carbon monoxide emissions while the engine maintains adequate power through the controlled fuel reduction.
3Object-generated harmful factors
If the coolant temperature sensor signal is used directly for fuel injection control, then the system operates simply, but emissions cannot be optimized during warm-up
Solution Approach 1:
The controller acts as an intermediary between the coolant temperature sensor and the fuel injector control system. It receives the actual temperature signal from the sensor, processes it by comparing against predetermined thresholds (120°F and 250°F), and generates a simulated temperature signal for fuel injection control. This intermediary function adds minimal complexity to the controller while enabling optimized emissions control during engine warm-up phases.
Solution Approach 2:
The controller changes the temperature parameter based on actual engine conditions. When the coolant temperature is between 120°F and 250°F, it transforms this reading into a simulated temperature of 250°F or higher for fuel injection purposes. This parameter transformation enables emissions optimization without requiring complex additional hardware, as the change is implemented through software logic in the existing controller.
Data Source
AI summary
An internal combustion engine has a fuel injector that is controlled by an engine control unit. According to one embodiment a device receives from a temperature sensor information corresponding to the temperature of the engine. The device transmits substitute temperature information to the engine control unit when the temperature of the engine is within a predetermined range of temperatures. The substitute temperature information corresponds to a temperature that is different than the actual temperature of the ICE. The engine control unit controls the fuel injector so that it operates in response to the substitute temperature information.