Flow Control Valve Current Adjustment for High-Pressure Fuel Pump Noise
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Solution Overview
Problem
High-pressure fuel pumps for gasoline direct injection engines experience noise and vibration issues due to solenoid coil collisions and increased current consumption, leading to component damage and dissatisfaction.
Innovation Solution
A control system that adjusts the current applied to the flow control valve's coil based on engine RPM and pressure sensor feedback, using a pressure sensor, control unit, power switching unit, and current adjustment unit to reduce collision-induced noise and vibration by managing the plunger's operation speed and current supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a solenoid valve is used to control the flow control valve, then the opening/closing operation can be controlled, but vibration and noise are generated due to coil collision with the stopper
Solution Approach 1:
A cushioning member is provided between the plunger and the stopper to absorb impact energy before collision occurs. This cushioning member prevents direct contact between the coil and stopper, thereby reducing vibration and noise while maintaining the opening/closing control function.
Solution Approach 2:
The cushioning member acts as an intermediary element between the plunger and stopper. It mediates the collision by providing a compliant interface that reduces the impact force, thereby eliminating the harmful vibration and noise while allowing the solenoid valve to maintain its control capability.
2Reliability
If current is continuously supplied to the coil, then the flow control valve operates reliably, but current consumption increases and heat generation causes component damage
Solution Approach 1:
Instead of continuous current supply, the patent employs periodic current supply through PWM control. The current is supplied in pulses during the opening and closing operations, and reduced or interrupted during idle periods. This periodic action maintains reliable valve operation while significantly reducing average current consumption and heat generation.
Solution Approach 2:
The patent changes the current supply parameters by using PWM modulation. The duty cycle and frequency of current supply are adjusted based on operational requirements. This parameter change allows the system to maintain reliability during critical operations while reducing energy consumption during normal operation.
3Speed
If the plunger operates at high speed, then the response time is reduced, but collision speed increases causing more noise and vibration
Solution Approach 1:
The cushioning member is positioned to engage before the plunger reaches the stopper at high speed. It provides progressive resistance that reduces the collision speed while allowing the plunger to maintain high operating speeds for rapid response. This eliminates harmful noise and vibration without sacrificing response time.
Solution Approach 2:
The system dynamically adjusts the cushioning effect based on the plunger's operating conditions. During normal high-speed operation, the cushioning member provides minimal resistance to maintain response time. During closing operations, it engages to reduce collision impact, thereby dynamically balancing speed and noise reduction requirements.
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
Effectively attenuates noise and vibration by reducing the current during the closing operation and re-applying it during the drop time to minimize collisions, thereby reducing component stress and improving operational efficiency.
Implementation Method 1
The solenoid valve is opened in a state of no-current, and closed by generating a magnetic field for moving the plunger in the straight direction when a predetermined voltage is applied onto the coil.
Implementation Method 2
a pressure sensor for sensing pressure of fuel filled in a delivery pipe
Data Source
AI summary
An apparatus and a method for controlling a flow control valve for a high-pressure fuel pump include: a pressure sensor for fuel in a delivery pipe; a control unit for controlling an operation of a flow control valve by controlling a current applied to a coil; a power switching unit for supplying or blocking driving power supplied to the flow control valve based on a control signal of the control unit; and a current adjustment unit electrically connected/disconnected with the flow control valve by the power switching unit to reduce a current supplied to the flow control valve when the current adjustment unit is connected with the flow control valve. Therefore, a noise and a vibration by collision between the plunger and the core upon closing the flow control valve may be attenuated by adjusting a current amount applied to the coil.