Fuel Injection Valve Calibration via Segmented Measurement
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Solution Overview
Problem
Existing fuel injection control systems for internal combustion engines face complexity in adjusting fuel injection characteristics due to variability in fuel injection valves, leading to inconsistent fuel delivery, which complicates the manufacturing process and reduces control precision.
Innovation Solution
A method involving the classification of adjustment points into actual-measuring and predicting points, with measured variability in injection characteristics used to create a predicting expression and relational expressions to adjust manipulated variables, allowing for precise correction of fuel injection amounts and periods across different operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fuel injection valve characteristics are measured at every adjustment point to correct variability, then control precision is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent segments the adjustment points into two distinct groups: actual-measuring points where physical measurements are performed, and predicting points where variability is calculated using mathematical expressions. This segmentation eliminates the need to measure at every adjustment point while maintaining control precision across the full operating range.
Solution Approach 2:
The patent performs preliminary measurements at a limited set of actual-measuring points to create predicting expressions that can estimate variability at all other predicting points. This preliminary action at key points enables subsequent predictions without requiring exhaustive measurements, thereby simplifying the manufacturing process.
2Manufacturing precision
If fuel injection valve characteristics are measured at every adjustment point, then control precision is improved, but measurement time and productivity are reduced
Solution Approach 1:
The patent divides adjustment points into actual-measuring points and predicting points, requiring measurements only at the former. This segmentation dramatically reduces the total number of measurements needed while maintaining precision through mathematical prediction at the remaining points, thereby improving manufacturing efficiency.
Solution Approach 2:
The patent creates predicting expressions that copy the relationship between injection period and variability observed at actual-measuring points. These expressions serve as mathematical models that replicate the measurement results across predicting points, eliminating the need for repetitive physical measurements and accelerating the manufacturing process.
3Measurement precision
If correcting amounts are calculated for every operation range, then injection accuracy is improved, but adjustment process complexity increases
Solution Approach 1:
The patent segments operation ranges into actual-measuring points and predicting points. Correcting amounts are directly calculated from measurements at actual-measuring points, while correcting amounts at predicting points are derived through predicting expressions. This segmentation maintains injection accuracy across all operation ranges while simplifying the adjustment process by reducing the number of direct measurements required.
Solution Approach 2:
The patent introduces predicting expressions as intermediary mathematical models that bridge the gap between actual-measuring points and predicting points. These expressions serve as mediators that translate measurements from limited points into accurate predictions for the entire operation range, maintaining precision without requiring exhaustive direct measurement and calculation at every point.
Data Source
AI summary
A method is provided to manufacture a fuel injection control system controlling fuel injection in an internal combustion engine with a fuel injection valve. A fuel injection valve is trial-manufactured. Using this valve, correcting amounts for an injection period are calculated at plural adjustment points defined by fuel pressures and injection periods. The adjustment points are divided into actual-measuring points and predicting points, and the correcting amounts at the actual-measuring points are used to calculate predicting expressions to predict correcting amounts at the predicting points and relational expressions to define a relationship among the correcting amounts at the actual-measuring points. When the valve is mass-manufactured, for each mass-manufactured valve, the correcting amounts at the actual-measuring points and the predicting expressions are used to predict correcting amounts at the predicting points, providing the correcting amounts at the actual-measuring and correcting points. Appropriateness of the predicting expressions is also estimated.