Fuel Injector Type Identification via Electrical Monitoring

Solution Overview

Problem

Internal combustion engines face performance issues due to improper configuration of fuel injectors, where incorrect programming of electronic control units can lead to inefficient fuel injection, increased emissions, and adverse engine effects, and existing methods are inadequate for identifying mismatched fuel injector types.

Innovation Solution

A method and system that generate a control signal to supply electrical energy to fuel injectors, monitor current patterns, and identify the type of fuel injector based on these patterns, allowing for corrective actions to be taken to prevent mismatched configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the control unit is updated with new programming for a different fuel injector type, then the fuel injection performance can be optimized, but the risk of incorrect configuration and performance issues increases

Engineering Contradiction:

Improvefuel injection performanceVSAvoidconfiguration accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system automatically detects the actual fuel injector type by monitoring electrical characteristics (current, voltage, resistance) and provides feedback to the control unit. This feedback mechanism ensures the control unit receives accurate information about the installed injector, allowing it to load the correct programming without manual intervention, thereby eliminating configuration errors while optimizing performance.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The fuel injector identification system operates autonomously by self-testing the electrical characteristics of the installed injector. The control unit automatically identifies the injector type and configures itself without requiring manual input or external assistance, reducing human error and ensuring reliable configuration while maintaining optimal performance.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual programming is performed for fuel injector configuration, then configuration flexibility is maintained, but the risk of human error and incorrect coding increases

Engineering Contradiction:

Improveconfiguration flexibilityVSAvoidcoding accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The system automatically detects the actual fuel injector type by monitoring electrical characteristics (current, voltage, resistance) and provides feedback to the control unit. This feedback mechanism ensures the control unit receives accurate information about the installed injector, allowing it to load the correct programming without manual intervention, thereby eliminating configuration errors while optimizing performance.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The manual mechanical process of physically coding or manually programming the control unit is replaced with an automated electrical detection system. The control unit electronically measures electrical characteristics of the fuel injector and automatically determines the correct programming, eliminating human error in the coding process while maintaining full adaptability to different injector types.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the control unit is not updated when a different fuel injector is installed, then system simplicity is maintained, but performance issues and emissions problems occur

Engineering Contradiction:

Improvesystem simplicityVSAvoidemissions and performance degradation

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The fuel injector identification system operates autonomously by self-testing the electrical characteristics of the installed injector. The control unit automatically identifies the injector type and configures itself without requiring manual input or external assistance, reducing human error and ensuring reliable configuration while maintaining optimal performance.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary automatic detection and identification of the fuel injector type before normal operation begins. By pre-configuring the control unit with the correct programming based on automated detection, the system prevents performance degradation and emissions problems from occurring in the first place, while adding minimal complexity to the overall system.

Inventive Principle:

Principle #10Preliminary action

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

The system effectively identifies incorrect fuel injector types and takes corrective actions to ensure proper configuration, preventing performance issues and emissions, thereby improving engine efficiency and reducing wear.

Implementation Method 1

generating a control signal to supply electrical energy from a power source for actuating the fuel injector

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a current sensor configured to generate a signal indicative of an amount of current present in a circuit associated with a fuel injector

Methodology Applied

Scientific EffectElectrical resistance measurement: Electrical Resistance

Data Source

PatentUS11268471B1Method and system for identification of fuel injector type

Publication Date: 2022.03.08 CATERPILLAR INC

AI summary

A method for identifying a type of a fuel injector installed in an internal combustion engine includes generating a control signal to supply electrical energy from a power source for actuating the fuel injector, monitoring the electrical energy, identifying a pattern in the electrical energy, the pattern being indicative of the type of the fuel injector, and outputting a notification indicative of an incorrect injector type based on the pattern.