Fuel Injector Controller Fault Detection via Magnetic Flux Compensation
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Solution Overview
Problem
Existing controllers for fuel injectors face challenges in reliably detecting operating faults due to increased risks of short-circuits and fault currents, particularly in automotive applications, which complicates fault detection and initiation of protective measures.
Innovation Solution
A controller design where the output-side line sections are configured to produce mutually compensating magnetic flux components during normal operation, using a magnetic flux part made of magnetically soft materials, allowing for efficient detection of faults through a detection coil arrangement that evaluates induced voltage, even under demanding electrical power characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fault detection devices are added to detect short-circuits and fault currents, then reliability of fault detection is improved, but device complexity increases
Solution Approach 1:
The patent combines the fault detection function with the existing output stage by integrating a detection coil arrangement that shares the magnetic flux part with the line sections. This merging approach allows fault detection without adding separate detection hardware, thereby improving reliability while avoiding increased device complexity
Solution Approach 2:
The magnetic flux part acts as an intermediary element that both conducts the operational current through the line sections and enables fault detection through the detection coil. This intermediary component allows the system to detect faults by evaluating induced voltage without requiring additional complex detection circuits
2Ease of operation
If current is supplied via external lines to piezoelectric actuators, then control capability is improved, but risk of short-circuits and fault currents increases
Solution Approach 1:
The patent implements feedback by continuously monitoring the magnetic flux through the detection coil arrangement and evaluating induced voltage to detect fault currents. This feedback mechanism allows the controller to detect short-circuits and take protective measures, thereby managing the risks associated with external line connections while maintaining control capability
3Measurement precision
If detection coil arrangement is added to detect faults, then measurement precision of fault detection is improved, but device complexity increases
Solution Approach 1:
The detection coil arrangement is merged with the existing magnetic flux part and line section structure, allowing fault detection through induced voltage evaluation without adding separate complex detection hardware. This integration achieves measurement precision while avoiding increased device complexity
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
The solution provides a reliable and simple method for fault detection, effectively canceling out magnetic flux components during normal operation and detecting faults by evaluating induced voltage, suitable for high-voltage and high-frequency applications like fuel injectors, ensuring robust and efficient fault detection.
Implementation Method 1
there is provided a magnetic flux part (20) which produces magnetic flux components (Phi1, Phi2) in response to current flows (Ip1, Ip2) in the two line sections (12, 14)
Implementation Method 2
a detection coil arrangement (22) for detecting operating faults on the basis of evaluation (24) of a voltage induced on the detection coil arrangement
Data Source
AI summary
To simplify reliable detection of operating faults in a control unit for operating an electrical component (for example, a fuel injector), an end stage is provided on the output side and is provided with a first line section and a second line section for supplying current in a synchronized manner to an electrical consumer which can be connected to the two line sections via an external line pair. A detection coil configuration is provided for detecting operating faults on the basis of an evaluation of a current that is induced at the detection coil configuration. The detection coil configuration is flowed through by a magnetic flux that is composed of magnetic flow components which are caused by the current flows in the two line sections, and wherein mutual compensation of the magnetic flow components is provided in a normal mode.