Flexible Fuel Engine Control System with Segmented Units
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Solution Overview
Problem
Conventional control systems for flexible fuel internal combustion engines lack the ability to effectively determine and control the quantity and timing of gaseous fuel injection in dual-fuel or bi-fuel modes, requiring significant modifications to existing OEM control systems for gaseous fuel operation.
Innovation Solution
A control system comprising a first control unit for liquid fuel injection and a second control unit for gaseous fuel injection, connected via a communication line, where both units determine their respective fuel quantities and timings based on total fuel energy and engine conditions, allowing for efficient operation with minimal changes to OEM systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional OEM control system is used for liquid fuel injection, then the control algorithms are advanced and engine parameters are maintained within thresholds, but the system lacks the ability to determine quantity and timing of gaseous fuel injection in dual-fuel or bi-fuel modes
Solution Approach 1:
The control system is segmented into two independent control units: a first control unit for liquid fuel injection and a second control unit for gaseous fuel injection. Each control unit operates independently with its own algorithms, allowing the system to handle multiple fuel types without requiring a complete redesign of the control system architecture.
Solution Approach 2:
A communication line acts as an intermediary between the first control unit and the second control unit, enabling data exchange and coordination. The second control unit receives information from the first control unit and uses it to determine gaseous fuel injection parameters, facilitating integrated multi-fuel control while maintaining independence of each fuel system.
2Adaptability or versatility
If a gaseous fuel control system is added to an existing liquid fuel system, then dual-fuel operation is enabled, but significant modifications to the OEM control system are required
Solution Approach 1:
The system is divided into separate control units for liquid and gaseous fuel systems. This segmentation allows each unit to be developed and manufactured independently, reducing integration complexity and making the system easier to manufacture and implement in existing engines.
Solution Approach 2:
The communication line between control units provides a universal interface that can accommodate different fuel types and operating modes (dual-fuel and bi-fuel). This universal communication protocol simplifies system integration and reduces the need for mode-specific hardware modifications.
3Manufacturing precision
If the second control unit determines pulse widths based on fuel mass from the first control module, then fuel injection timing can be controlled, but the second control module lacks algorithms for determining quantity of second fuel and injection timing
Solution Approach 1:
The communication line serves as an intermediary that transfers fuel mass information from the first control unit to the second control unit. The second control unit uses this information as input for its own algorithms that determine gaseous fuel injection quantity and timing, enabling precise control while distributing algorithmic complexity across both control units.
Solution Approach 2:
The second control unit receives feedback from the first control unit regarding fuel mass and uses this feedback to adjust gaseous fuel injection parameters. This feedback mechanism ensures coordinated control of both fuel systems while maintaining the ability to independently optimize each fuel type's injection strategy.
Data Source
AI summary
In previous control systems for engines that fuelled with a conventional fuel and an alternative fuel, a conventional fuel controller controlled fuelling for both fuels. This required extensive modifications to both the conventional fuel controller and an alternative fuel controller. A control system for an engine comprises a first control unit programmed to generate a first pulse width to actuate a first fuel injector to introduce a first fuel; a second control unit programmed to generate a second pulse width to actuate a second fuel injector to introduce a second fuel; and a communication line between the first and second control units. The first control unit determines a total fuel energy amount to be introduced by the first and second fuel injectors. The second control unit determines a first fraction of the total fuel energy amount to be from the first fuel and a second fraction of the total fuel energy amount to be from the second fuel.