Fuel Injector Interface Device for In-Situ Pressure Signal Analysis
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Solution Overview
Problem
The transition to gasoline direct injection systems in automobiles has increased the frequency of fuel system problems, requiring expensive and time-consuming individual bench testing of fuel injectors, which is inconvenient for vehicle owners.
Innovation Solution
A fuel injector interface device with input and output leads connected to the vehicle's fuel injection system and a display device, using circuitry to detect rail pressure signals and display graphical representations of injector performance, allowing technicians to identify anomalies without removing the injectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual bench testing of fuel injectors is performed to identify malfunctioning injectors, then measurement precision is improved, but loss of time and productivity deteriorate significantly
Solution Approach 1:
The patent introduces a diagnostic device as an intermediary between the fuel injection system and the technician. This device includes a probe with pressure sensor that couples to the fuel rail, serving as a mediator to capture pressure signals without requiring injector removal. The intermediary device enables non-intrusive measurement of injector performance through pressure signal analysis.
Solution Approach 2:
The patent replaces the mechanical bench testing system with an electronic/digital diagnostic system. Instead of physically removing and mechanically testing each injector on a bench stand, the system uses electronic pressure sensors and digital signal processing to analyze injector performance in-situ. The mechanical extraction and bench testing process is substituted with electronic signal capture and analysis.
2Reliability
If all fuel injectors are removed for bench testing to ensure reliable diagnosis, then reliability of diagnosis is improved, but device complexity and ease of operation worsen
Solution Approach 1:
The diagnostic device serves as an intermediary that enables reliable diagnosis without the complex procedure of removing all injectors. The probe with pressure sensor acts as a mediator that captures sufficient data in-situ to reliably identify malfunctioning injectors, eliminating the need for physical removal and complex bench testing setup.
Solution Approach 2:
The system enables the fuel injection system to diagnose itself in-situ. The pressure sensor captures signals directly from the fuel rail during normal operation, and the processing circuitry automatically analyzes these signals to identify malfunctioning injectors. This self-diagnostic capability eliminates the need for external bench testing equipment and complex removal procedures.
3Measurement precision
If traditional removal and bench testing methods are used, then measurement precision is maintained, but productivity and loss of time deteriorate
Solution Approach 1:
The patent enables continuous diagnostic capability during normal vehicle operation. The pressure sensor continuously monitors fuel rail pressure signals, and the processing circuitry continuously analyzes these signals for injector anomalies. This continuous monitoring allows for immediate identification of malfunctioning injectors without interrupting vehicle use, maintaining diagnostic precision while maximizing productivity.
Solution Approach 2:
The patent substitutes the time-consuming mechanical process of injector removal, transport to bench testing facility, and physical testing with an electronic signal analysis system. The processing circuitry rapidly analyzes pressure signals in-situ, providing immediate diagnostic results that maintain measurement precision while dramatically improving diagnostic productivity and reducing vehicle downtime.
Data Source
AI summary
A fuel injector interface device and associated method include an interface device having a plurality of input leads and a plurality of output leads. The input leads are communicatively linked to the fuel pressure sensor on the common rail of a vehicle fuel injection system. The output leads are communicatively linked to a display device such as a diagnostic scope. Circuitry positioned within the interface device detects the rail pressure signals, filters the signals, and outputs data to the display device representing a graphical depiction of the same. A method of using the interface device includes generating the signals, mapping the signals to an individual fuel injector of the vehicle's engine cylinder and determining fluctuations in the strength of the displayed signals to determine anomalies in a particular fuel injector.