Fuel Injector Needle Braking Pulse Control

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Solution Overview

Problem

Existing fuel injection control methods in internal combustion engines, particularly those using solenoid or piezo-electric actuated fuel injectors, face challenges such as noise, damage to valve seats, and deteriorated injector performance due to high kinetic energy of the needle during closure, especially when handling gaseous fuels like hydrogen.

Innovation Solution

A method of controlling fuel injection that includes a drive signal with a fueling pulse to open the needle and a braking pulse to slow down the needle during closure, where the braking pulse ends at the moment the needle reaches the closed position, minimizing noise and wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the needle is strongly accelerated to reach closed position quickly, then the closing speed is improved, but noise increases and valve seat damage occurs

Engineering Contradiction:

Improveneedle closing speedVSAvoidnoise and valve seat damage

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The braking pulse is applied in advance during the closing phase to pre-slow the needle before it reaches the valve seat. This preliminary action reduces the kinetic energy at impact, thereby minimizing noise and wear on the valve seat while maintaining acceptable closing speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention converts the harmful high kinetic energy of the closing needle into a beneficial controlled deceleration process. By applying the braking pulse, the system transforms the potentially damaging impact force into a controlled slowing effect that protects the valve seat while still achieving rapid closing.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If a braking pulse is applied to slow down the needle, then noise and wear are reduced, but closing delay increases

Engineering Contradiction:

Improvenoise and wearVSAvoidclosing delay

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The braking pulse is applied partially during the closing phase rather than continuously. It is activated only when needed to slow the needle, and its duration is precisely controlled to end exactly when the needle reaches the closed position. This partial action reduces noise and wear while minimizing the impact on closing speed.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system dynamically changes the parameters of the braking pulse (duration, timing, intensity) based on the actual closing characteristics of the needle. By optimizing these parameters, the system achieves the minimum necessary braking action to reduce noise and wear while maintaining acceptable closing timing.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If the braking pulse ends exactly when the needle reaches closed position, then noise and wear are minimized, but precise timing control is required

Engineering Contradiction:

Improvenoise and wearVSAvoidtiming control precision

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The system uses feedback from the drive signal characteristics to determine when the braking pulse should end. By monitoring the voltage trace and detecting the closing event, the system automatically adjusts the braking pulse timing to ensure it ends precisely when the needle reaches the closed position, minimizing noise and wear without requiring complex mechanical timing mechanisms.

Inventive Principle:

Principle #23Feedback

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

This method effectively reduces the needle's closing speed and kinetic energy at impact, thereby minimizing noise, reducing wear on valve seats, and improving injector performance, especially when operating with gaseous fuels.

Implementation Method 1

Solenoid or piezo-electric actuated fuel injectors typically are controlled by pulses sent to the actuator of a fuel injector which act to open a fuel injector valve

Methodology Applied

Scientific EffectSolenoid: Solenoid

Implementation Method 2

Solenoid or piezo-electric actuated fuel injectors typically are controlled by pulses sent to the actuator of a fuel injector

Methodology Applied

Scientific EffectPiezo-electric effect: Piezoelectric Effect

Implementation Method 3

when the pulse falls there is no power to the actuator and the valve is forced to a closed position

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS20250198360A1Method of controlling fuel injection

Publication Date: 2025.06.19 PHINIA DELPHI LUXEMBOURG SARL

AI summary

A method of controlling fuel injection in an internal combustion engine having at least one cylinder with an associated electrically actuated fuel injector for performing injection events, wherein a drive signal is applied to the fuel injector in order to actuate a needle therein that controls flow through a valve seat. The drive signal comprises a fueling pulse adapted to move and/or hold the needle to an open position relative to a valve seat, followed by a braking pulse adapted to slow down the needle moving towards a closed position relative to the valve seat, the braking pulse being separated from the fueling pulse by a separation period. The braking pulse is configured to end at a timing that substantially matches the moment when the needle reaches the closed position.