Fuel Injection Test Equipment IMV Control

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Solution Overview

Problem

Existing fuel injection test equipment struggles with unknown injector characteristics, leading to issues of excessive or insufficient flow and power consumption when testing faulty fuel injectors, due to manufacturing tolerances and wear, which are not accounted for in current control methods relying on theoretical maps and lookup tables.

Innovation Solution

The method involves controlling the Inlet Metering Valve (IMV) current or voltage based on the power supplied to the high-pressure fuel pump, ensuring the power remains within a specific threshold to optimize fuel flow and pressure, eliminating the need for lookup tables and accounting for variable injector characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If IMV drive current is set at a particular level based on pressure test ranges, then the control is simplified, but the flow and power become suboptimal leading to excessive power consumption or insufficient fuel flow

Engineering Contradiction:

ImproveIMV control simplicityVSAvoidpower consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The system continuously monitors the actual power consumed by the high pressure pump and uses this feedback signal to dynamically adjust the IMV drive current. The controller compares the measured power against a reference power level and adjusts the IMV current accordingly to maintain optimal operating conditions, resolving the contradiction between simple control and optimal power usage.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The IMV drive current is transformed from a static fixed value to a dynamic variable that automatically adjusts based on real-time power measurements. This dynamic control allows the system to adapt to changing conditions and maintain optimal fuel flow and power consumption throughout the testing process.

Inventive Principle:

Principle #15Dynamics

2Reliability

If IMV drive current is increased to ensure adequate fuel flow, then fuel starvation is prevented, but power consumption increases excessively

Engineering Contradiction:

Improvefuel supply adequacyVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The power feedback mechanism enables the system to determine the minimum necessary IMV drive current required to achieve adequate fuel flow. By continuously monitoring power consumption and adjusting IMV current accordingly, the system ensures reliable fuel supply while avoiding excessive power consumption that would occur with fixed high current settings.

Inventive Principle:

Principle #23Feedback

3Use of energy by moving object

If IMV drive current is decreased to reduce power consumption, then power usage is optimized, but fuel flow becomes insufficient causing injector starvation

Engineering Contradiction:

Improvepower consumptionVSAvoidfuel supply adequacy

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The feedback control system prevents fuel starvation by continuously monitoring power consumption and adjusting IMV drive current to maintain adequate fuel flow. The system automatically increases current when power consumption indicates insufficient fuel delivery, ensuring reliability while optimizing power usage.

Inventive Principle:

Principle #23Feedback

4Device complexity

If lookup tables and theoretical maps are used to determine IMV drive current, then control is simplified, but manufacturing tolerances and component wear are not accounted for

Engineering Contradiction:

Improvecontrol methodologyVSAvoidtesting accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system replaces theoretical lookup tables with actual measured power feedback signals. This feedback-based approach automatically compensates for manufacturing tolerances, component wear, and variations in injector characteristics, maintaining both simple control and high testing accuracy simultaneously.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses the actual power consumption measurements from the specific hardware being tested to automatically determine the correct IMV drive current, allowing each test setup to self-adjust to its actual characteristics rather than relying on pre-programmed theoretical values.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11149704B2Method of testing fuel injection equipment

Publication Date: 2021.10.19 PHINIA JERSEY HOLDINGS LLC

AI summary

A method of testing a fuel injection system or components thereof includes running a high pressure fuel pump to provide fluid under pressure to the fuel injection system or components. The pump flow is controlled via an inlet metering valve by controlling current or voltage supplied to the inlet metering valve dependent on the power to the fuel pump.