Fuel Injector Drift Calibration Through Engine Output Feedback

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Solution Overview

Problem

Improper fuel injection due to fuel injector drift can cause engine damage and decreased performance in internal combustion engines, particularly in dual fuel systems where fuel flow rates and substitution rates affect engine output.

Innovation Solution

A method and system for calibrating fuel injectors in internal combustion engines that includes operating the injectors based on target loads, detecting engine outputs, modifying injector operations, and updating parameters to compensate for reduced power outputs, using a hybrid system with an electric motor and battery to provide power adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fuel injector calibration is not performed, then fuel injector drift occurs, but engine performance decreases and engine damage may occur

Engineering Contradiction:

Improvefuel injector operation reliabilityVSAvoidengine performance

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system implements a feedback mechanism where the controller monitors engine output and compares it to expected values. When drift is detected through this feedback loop, the controller automatically adjusts fuel injector parameters to correct the deviation, ensuring continuous reliable operation without manual intervention

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The calibration system enables the engine control system to self-diagnose and self-correct fuel injector drift conditions. Through automated monitoring and adjustment, the system maintains its own performance without requiring external service, preventing both reliability issues and performance degradation

Inventive Principle:

Principle #25Self-service

2Measurement precision

If fuel injector operation is modified for calibration, then parameter accuracy improves, but engine power output decreases temporarily

Engineering Contradiction:

Improvefuel injector parameter accuracyVSAvoidengine power output

Core Design Contradiction:

Measurement precisionVSPower

Solution Approach 1:

The calibration process modifies fuel injector parameters partially rather than completely shutting down fuel injection. This partial action approach allows sufficient fuel delivery to maintain acceptable power output while still enabling accurate drift detection and parameter adjustment

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system performs preliminary calibration adjustments based on detected drift before the deviation significantly impacts engine performance. By acting early in the drift process, the system maintains parameter accuracy while minimizing temporary power output reductions

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4632209A1A calibration system and method for fuel injection calibration

Publication Date: 2025.10.15 CUMMINS POWER GENERATION INC

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AI summary

The present disclosure relates to a system and method for fuel injection calibration for use with a fuel injector coupled with an engine. The method includes operating the fuel injector according to a parameter for the fuel injector that corresponds to a first target load for the engine, detecting a first output of the engine while operating the fuel injector according to the parameter, modifying operation of the fuel injector, detecting a second output of the engine responsive to modifying the operation of the fuel injector, and updating the parameter based on a comparison of the first output with the second output.