Fuel Injector Needle Multi-Position Control
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Solution Overview
Problem
Current fuel injector control systems face limitations in achieving precise timing and reduced variability in fuel delivery during split fuel injections, leading to compromised engine performance and increased wear and tear, due to the need for separate actuation signals for each injection event, especially at short time intervals.
Innovation Solution
A fuel injector assembly that controls the injector needle to move through a single actuation cycle from a first position to a third position via a second position, allowing for the delivery of pilot, main, and post fuel injections within a single actuation cycle, using an actuator and retention springs to manage the needle's movement and coupling with different rows of nozzles, thereby improving timing and precision of fuel delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate actuation signals are provided for each fuel injection event, then each injection can be controlled independently, but the time interval between injections cannot be made sufficiently short due to signal overlap
Solution Approach 1:
The patent merges multiple separate actuation signals into a single continuous actuation signal that controls the injector needle throughout the entire multi-stage injection sequence. This eliminates signal overlap issues and enables shorter time intervals between pilot, main, and post injections while maintaining precise timing control for each stage.
Solution Approach 2:
The patent employs dynamic control of the single actuation signal, varying its characteristics (duration, magnitude) throughout the injection sequence to achieve different injection stages. The actuation signal transitions the needle through different positions (first, second, third positions) to deliver fuel at precisely controlled intervals without signal overlap.
2Measurement precision
If separate actuation signals are used for each injection, then injection timing can be controlled, but variability in fuel delivery amount and timing increases
Solution Approach 1:
By combining control into a single actuation signal sequence, the patent eliminates the variability introduced by multiple separate signals. The continuous control ensures consistent fuel delivery amounts and timing across all injection stages, improving reliability while maintaining precision.
3Productivity
If the injector cycles through actuation for each split fuel injection, then each injection can be delivered, but wear and tear on the injector increases
Solution Approach 1:
The patent combines multiple injection cycles into a single continuous actuation sequence. The injector needle moves through its actuation cycle once, delivering pilot, main, and post injections in sequence without returning to the initial position between stages. This reduces mechanical wear and improves reliability while maintaining full injection functionality.
4Ease of operation
If separate actuation signals are generated for each injection, then injection control is possible, but controller resource consumption increases
Solution Approach 1:
The patent merges the generation of multiple separate actuation signals into a single control operation. The controller generates one continuous actuation signal sequence instead of multiple separate signals, reducing computational resources and energy consumption while maintaining precise control over all injection stages.
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 approach enables precise control of fuel injections with reduced time intervals between events, enhancing engine performance and reducing resource consumption by the engine controller, while minimizing wear and tear on the injector.
Implementation Method 1
one or more retention springs positioned between an upper portion of the needle and the injector body to bias the needle in an upward direction away from the first and second row nozzles
Implementation Method 2
an actuator, which when activated pushes the injector needle against the force of the retention springs in a downward direction towards the first and the second row nozzles
Implementation Method 3
The injector needle may comprise a lower annulus cut portion that couples a fuel supply to either first or second row of nozzles based on a displacement of the needle
Data Source
AI summary
Methods and systems are provided for moving an injector needle of a fuel injector assembly from a first position to a second position to provide a first fuel injection at the first position, and moving the needle from the second position to the third position to provide a second fuel injection at the third position, and moving the needle back to the first position via the second position, and providing a third fuel injection at the second position. In this way, three fuel injections may be performed during a single actuation cycle of the injector during a single combustion cycle.