Add-on Fuel Injector Control System for Engine Performance Optimization
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Solution Overview
Problem
Existing add-on control systems for internal combustion engines do not efficiently manage fuel injector pulse width across various operating conditions, leading to suboptimal engine performance, especially after aftermarket modifications, and fail to provide smooth transitions between operational modes without reducing the pulse width below stock levels.
Innovation Solution
An add-on electronic fuel injector control system that intercepts the ECU's control signal and uses a controller to determine the optimal operating band by modifying the fuel injector pulse width based on engine conditions, employing four operating bands (pass-through, cruise, acceleration, and auto-tune) to ensure seamless transitions and improved engine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the Dobeck system increases fuel duration when engine speed increases, then engine performance is improved under certain conditions, but fuel is wasted when speed increases downhill and fuel requirements decrease
Solution Approach 1:
The patent implements a feedback mechanism by monitoring both engine speed changes and fuel duration changes, and using this information to dynamically adjust fuel delivery. The system compares current operating conditions with previous conditions and modifies fuel pulse width accordingly, creating a closed-loop control system that responds to actual engine needs rather than simply reacting to speed changes.
Solution Approach 2:
The system dynamically adjusts fuel delivery based on real-time operating conditions by implementing four distinct operational bands (pass-through, cruise, acceleration, and hunt/auto-tune) that transition smoothly based on engine state. This dynamic adaptation allows the system to optimize fuel delivery for varying driving conditions including uphill climbs, downhill coasting, and steady-state cruising.
2Loss of energy
If the Dobeck system decreases fuel duration when engine speed decreases, then fuel efficiency is improved, but engine performance deteriorates when more fuel is needed such as when climbing steep hills
Solution Approach 1:
The system uses feedback from both speed sensor and fuel injector duration data to determine when to decrease fuel delivery. By analyzing the combination of speed change and duration change, the system can distinguish between situations where fuel reduction is appropriate (normal deceleration) and situations where fuel should be maintained or increased (steep hill climbing), preventing performance deterioration.
Solution Approach 2:
The patent changes the control parameters by implementing multiple operational bands with different fuel adjustment strategies. The system transitions between pass-through, cruise, acceleration, and hunt/auto-tune bands based on operating conditions, allowing it to adapt fuel delivery parameters dynamically rather than using a single fixed control strategy.
3Manufacturing precision
If the stock ECU uses pre-computed look-up table values, then fuel delivery is optimized for ideal new engine conditions, but performance deteriorates after significant aftermarket modifications
Solution Approach 1:
The patent introduces an intermediary control system that sits between the stock ECU and the fuel injectors. This add-on controller intercepts the fuel injector control signal from the stock ECU and modifies it based on detected operating conditions and vehicle modifications. The intermediary system preserves the stock ECU's precise fuel delivery calculations while adding adaptability through real-time signal modification.
Solution Approach 2:
The system transitions from the static, pre-computed look-up table approach to a dynamic, real-time adjustment system. By implementing operational bands that smoothly transition based on engine state and detecting vehicle modifications, the system adapts fuel delivery dynamically to match actual operating conditions and modifications, maintaining precision while gaining versatility.
4Productivity
If the add-on control system modifies fuel injector pulse width, then engine performance is improved, but smooth transitions between operational modes are not achieved
Solution Approach 1:
The patent implements dynamic transitions between operational bands by continuously monitoring engine conditions and smoothly shifting between pass-through, cruise, acceleration, and hunt/auto-tune modes. The system uses dynamic thresholds and transition logic to ensure seamless mode changes without abrupt disruptions to fuel delivery, maintaining operational stability while adapting to varying conditions.
Solution Approach 2:
The system prepares for mode transitions by continuously monitoring operating conditions and pre-positioning control parameters before actual transitions occur. By detecting trends in engine state and anticipating upcoming mode changes, the system can smooth transitions and prevent erratic behavior, ensuring stable operation during operational band changes.
Data Source
AI summary
An add-on fuel injector control system and method for modifying a fuel injector pulse width for an electronically-controlled internal combustion engine is provided, which intercepts a pulse from an engine control unit (ECU) to a fuel injector, determines the optimal operational band, and either sends a modified or unmodified control signal pulse width to the fuel injector, depending on the band determination. The pulse width is increased by a total fuel adder. If the ECU control signal is determined to be in the auto-tune band, the controller modifies the output pulse width based on a comparison of current and previous values correlated to the rate of change of acceleration and whether the previous total fuel adder included an addition or subtraction of an auto-tune adder.