Fuel Injector Solenoid Control Segmentation for Reliability
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Solution Overview
Problem
Electronically controlled fuel injection systems in internal combustion engines face reliability issues due to increased complexity, where parallel connections can lead to system failure if one component malfunctions, causing interference with operational components and increasing the risk of overall system failure.
Innovation Solution
The system employs at least two fuel injector nozzles with paired solenoids, each connected to a different control unit, with a shared core, ensuring electrical independence and allowing one solenoid to monitor the other, enabling seamless operation even if one solenoid fails, and includes a communication and diagnostics module to manage data communication and diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parallel connections are used to improve reliability, then system redundancy increases, but interference between parallel components can cause system failure
Solution Approach 1:
The system divides the control architecture into separate control units, with each control unit independently controlling one solenoid. This segmentation prevents interference propagation between parallel components while maintaining redundancy, as each control unit operates independently without shared electrical connections that could cause ground faults or signal interference.
Solution Approach 2:
The patent introduces a shared core as an intermediary mechanical element that both solenoids actuate. This mechanical intermediary allows both solenoids to control the same injection valve without direct electrical connection, enabling redundancy while preventing electrical interference between parallel control paths.
2Reliability
If multiple solenoids are used to improve reliability, then redundancy increases, but device complexity increases
Solution Approach 1:
The patent merges the control functions by having both solenoids actuate a shared core mechanism. This combining approach reduces complexity compared to fully independent parallel systems, as the shared core provides a common mechanical interface that simplifies the overall architecture while maintaining the redundancy benefits of multiple solenoids.
Solution Approach 2:
Each solenoid is designed with multi-functionality: the primary solenoid performs normal injection control, while the secondary solenoid serves as both a backup and a diagnostic monitoring element. This universal design reduces the need for completely separate redundant systems, thereby reducing overall device complexity while maintaining high reliability.
3Ease of operation
If solenoids are electrically connected in parallel to share control, then control coordination improves, but failure propagation increases
Solution Approach 1:
The control system is segmented into independent control units, each managing one solenoid separately. This segmentation eliminates electrical interference and failure propagation between parallel components while maintaining control coordination through the shared core mechanism, which ensures both solenoids work toward the same mechanical outcome without electrical coupling.
4Measurement precision
If more control units are added to monitor solenoids, then diagnostic capability improves, but device complexity increases
Solution Approach 1:
The control units are designed with multi-functionality, performing both primary control and diagnostic monitoring functions. The secondary control unit monitors the primary solenoid's operation while also serving as a backup control unit, eliminating the need for dedicated monitoring hardware and reducing overall system complexity while maintaining high diagnostic capability.
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 configuration significantly minimizes engine malfunction risks by allowing continued operation with one solenoid failure, maintaining system reliability and efficiency while reducing the impact of control unit inoperability.
Implementation Method 1
the injection action of which is controllable via a solenoid
Data Source
Figure 1
AI summary
A control arrangement (2) for a fuel injection apparatus (1) of an internal combustion engine, the fuel injection apparatus comprising at least two fuel injector nozzles (4), the injection action of which is controllable via a solenoid (5.1), and at least two control units (2.1) arranged to control the solenoids (5.1) controlling the injection action. According to the invention each injector nozzle is provided with a first and second solenoid (5.1, 5.2) and the first and second solenoid are in connection with a different control unit (2.1).