Fuel Injector Control via Solenoid Resistance-Based Model Selection

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Solution Overview

Problem

Existing methods for correcting fuel injector errors, particularly after a period of disuse, often result in lean fueling issues due to the solenoid coil's increased resistance, which is not accurately addressed by temperature-based correction models.

Innovation Solution

Implementing a transient pressure-based injector balancing (PBIB) model that differentiates between steady-state and transient conditions based on solenoid coil resistance, adjusting pulse width and injector operation to prevent lean fuel injections by using separate models for each state.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a temperature-based correction model is used to compensate for injector variability, then injector accuracy is improved, but the model fails to correctly address lean fueling issues after periods of disuse because it misattributes the cause to temperature rather than solenoid coil resistance

Engineering Contradiction:

Improveinjector accuracyVSAvoidcorrection accuracy after disuse

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent changes the correction parameter from temperature-based to resistance-based. Instead of using temperature models to predict injector behavior, the system directly measures solenoid coil resistance and uses this electrical parameter to determine and apply the appropriate correction factor, thereby accurately addressing lean fueling issues after periods of disuse

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal/mechanical temperature measurement approach with an electrical resistance measurement approach. By substituting the temperature-based correction mechanism with a resistance-based correction mechanism, the system directly detects the solenoid coil's actual state and applies accurate corrections without the intermediary of temperature modeling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If a multiplicative correction factor is applied based on temperature models, then hot tip injector errors are addressed, but offset errors caused by increased solenoid resistance are not corrected

Engineering Contradiction:

Improveinjection parameter accuracyVSAvoidcorrection effectiveness for resistance errors

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements a feedback mechanism where the actual solenoid coil resistance is measured and used to dynamically adjust the correction factor. This closed-loop approach ensures that the correction applied is based on the actual physical state of the injector, allowing accurate compensation for both multiplicative and offset errors

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If the steady-state PBIB model is updated during transient phase operation, then the model adapts to current conditions, but it incorporates inaccurate data from transient solenoid resistance, leading to poor steady-state performance

Engineering Contradiction:

Improvemodel adaptabilityVSAvoidsteady-state model accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent segments the PBIB model into two distinct models: a transient PBIB model for transient phase operation and a steady-state PBIB model for steady-state operation. Each model is updated independently during its appropriate operational phase, preventing contamination of steady-state model data with transient phase inaccuracies while maintaining adaptability during transients

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic model selection and updating based on the operational phase. The system dynamically determines whether the injector is in transient or steady-state operation and selectively updates only the appropriate model, allowing the system to adapt to changing conditions while maintaining the integrity of each model for its intended operating regime

Inventive Principle:

Principle #15Dynamics

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

Effectively corrects fueling errors by dynamically adjusting injector parameters during transient and steady-state operations, ensuring accurate fuel delivery and preventing lean fueling phenomena.

Implementation Method 1

a solenoid coil with increased resistance while hot results in a longer opening time

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11359568B1Methods and systems for fuel injection control

Publication Date: 2022.06.14 FORD GLOBAL TECH LLC

AI summary

Methods and systems are provided for a fuel system. In one example, a method includes comparing a resistance of a solenoid coil of a direct injector to a threshold resistance. The method further includes selecting one of a transient or a steady-state pressure-based injector balancing (PBIB) model in response to the comparison.