Fuel Injector Nozzle Spray Testing Spherical Sensor
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Solution Overview
Problem
Current methods for testing fuel injector nozzles, such as Multi-Stream and Outward Opening Injectors, face limitations in accurately measuring spray distribution and patternation, especially at higher fuel pressures, due to resolution constraints, splashing, and aerodynamic interactions, leading to unreliable measurements and increased errors.
Innovation Solution
An apparatus and method that positions a sensor on a spherical surface around the fuel injector nozzle, allowing for equidistant measurement points to capture the dynamic force distribution of the atomized fuel spray, enabling a spherical fuel distribution map that compensates for nozzle misalignment and reduces splashing effects, while using a force sensor to measure the spray's dynamic pressure at high frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cell-based liquid fraction collection is used for spray patternation, then measurement is simplified, but resolution is limited by cell dimensions and measurement accuracy decreases at higher pressures
Solution Approach 1:
The patent replaces the mechanical cell-based collection system with a wireless sensor system that measures spray parameters electrically. The sensor node contains acceleration sensors and other detectors that wirelessly transmit data, eliminating the need for physical cell arrays and their associated resolution limitations.
2Measurement precision
If laser sheet/light extinction methods are used for spray patternation, then resolution is improved, but measurement becomes unreliable at higher pressures due to light obscuration and scattering
Solution Approach 1:
The patent substitutes optical measurement methods with wireless sensor-based detection. The sensor nodes use acceleration sensors and other non-optical detectors to measure spray characteristics, eliminating light obscuration and scattering issues that plague laser-based methods at high pressures.
3Device complexity
If traditional sensor positioning is used, then device complexity is reduced, but measurement accuracy decreases due to nozzle misalignment and non-uniform spray coverage
Solution Approach 1:
The patent positions sensor nodes on a spherical surface surrounding the nozzle outlet. This spherical arrangement ensures equidistant positioning from the spray source in all directions, providing uniform spray coverage and eliminating misalignment issues while maintaining manageable device complexity.
Solution Approach 2:
The patent transitions from planar or linear sensor positioning to a three-dimensional spherical arrangement. This spatial reconfiguration allows simultaneous measurement of spray patterns in multiple directions from equidistant positions, significantly improving measurement accuracy and completeness.
4Productivity
If high fuel pressure is used for injection, then combustion efficiency is improved, but measurement errors increase due to enhanced atomization and splashing effects
Solution Approach 1:
The patent replaces contact-based measurement systems with wireless sensor nodes that detect spray characteristics remotely. This eliminates interference with high-pressure spray dynamics and avoids measurement errors caused by splashing and aerodynamic interactions with physical measurement structures.
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 provides a reliable and high-resolution assessment of fuel spray patterns at higher pressures, allowing for accurate comparison and optimization of nozzle designs, reducing errors and improving combustion efficiency by capturing spatially uniform and detailed fuel distribution data.
Implementation Method 1
using a force sensor to measure the spray's dynamic pressure at high frequencies
Implementation Method 2
The wire is heated by applying an electric current to the wire. As the liquid spray flows past the wire, the wire cools and its resistance decreases as enabling the mass of the liquid spray flowing past the wire to be determined by the change in resistance of the wire
Data Source
AI summary
An apparatus and a method for testing a fuel injector nozzle with a tip having at least one fuel outlet are provided. The apparatus comprises a test chamber, a holder for holding the fuel injector nozzle such that the outlet is within the test chamber, a fuel supply arrangement for supplying fuel to the fuel injector nozzle, a sensor having a sensor surface for sensing an atomized fuel spray supplied by the fuel injector nozzle through the fuel outlet and movement module for moving the sensor. The movement module is configured to position the sensor surface of the sensor at a plurality of positions corresponding to a surface of a sphere having a radius R and a center point C adjustable to match a center point ct of the tip of the fuel injector nozzle or a center point cf of an orifice of the fuel outlet.