Fuel Injector Valve Arrival Detection Using Dual Solenoid Waveforms
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Solution Overview
Problem
Existing fuel systems in internal combustion engines face challenges in accurately monitoring and controlling the operational changes of fuel injectors over their service life, affecting fuel injection timing, amount, and efficiency, which can impact emissions and overall system performance.
Innovation Solution
A fuel system with dual solenoid actuators and a control unit that uses boosted and lower voltage power supplies to generate specific waveforms for valve actuation, allowing precise detection of valve arrival timing and electronic trimming to correct deviations, enhancing accuracy and precision in fuel injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single solenoid actuator is used to control the fuel injection valve, then the device complexity is reduced, but the measurement precision of valve arrival timing deteriorates
Solution Approach 1:
The patent introduces a second solenoid actuator as an intermediary measurement device that does not directly control the fuel injection valve but instead controls a separate indicator valve. This intermediary valve's position, detected through current monitoring, provides precise timing information about the main fuel injection valve's state without requiring direct measurement on the fuel valve itself, thus achieving high measurement precision while keeping the control system relatively simple.
Solution Approach 2:
The system creates a copy of the fuel injection valve's operational state using the indicator valve controlled by the second solenoid actuator. The indicator valve mirrors the position states (open/closed) of the fuel injection valve, allowing the control system to detect valve arrival timing by monitoring the simpler indicator valve rather than directly measuring the complex fuel injection valve, thereby improving measurement precision without proportionally increasing device complexity.
2Measurement precision
If dual solenoid actuators with separate power supplies are used, then the valve arrival timing detection accuracy is improved, but the use of energy increases
Solution Approach 1:
The system employs periodic switching between two distinct power supply voltages (first and second voltages) to energize the second solenoid actuator. By alternating between voltage levels in a controlled sequence, the system achieves precise current monitoring for valve timing detection while managing energy consumption through duty cycling rather than continuous high-power operation.
Solution Approach 2:
The patent changes the electrical parameters (voltage levels) supplied to the second solenoid actuator by switching between two different power supply voltages. This parameter variation allows the system to operate the solenoid at different power levels depending on the detection phase, enabling accurate timing measurement during critical transitions while reducing overall energy consumption during stable states.
3Manufacturing precision
If traditional single power supply waveform control is used, then the device complexity is reduced, but the fuel injection timing precision deteriorates
Solution Approach 1:
The control system segments the waveform generation into two distinct power supply channels (first voltage and second voltage), each contributing a separate current component to the second solenoid actuator. This segmentation allows independent optimization of each power supply's waveform characteristics, enabling precise control of the indicator valve timing to match the fuel injection valve timing, thereby improving fuel injection timing precision while distributing the control complexity across two simpler, independent power supply circuits.
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
Improves the precision and accuracy of fuel injection timing and amount by detecting valve arrival timing and electronically adjusting the fuel injectors, thereby optimizing performance and reducing emissions.
Implementation Method 1
energizing a first solenoid actuator to move a first valve in a fuel injector from a first position to a second position, and energizing a second solenoid actuator to move a fuel injection valve in the fuel injector from a closed position to an open position
Data Source
AI summary
Operating a fuel injector in a fuel system for an engine includes energizing a first solenoid actuator to move a spill valve from a first position to a second, closed position, and energizing a second solenoid actuator to move a fuel injection valve in the fuel injector from a closed position to an open position. A pull-in tier of a waveform energizing the second solenoid actuator is generated via a first current produced by a boosted voltage power supply and a second current produced by a lower voltage power supply. Arrival timing of the valve at the open position is detected based on a property of the second current, such that a valve arrival timing error may be used to trim the fuel injector. Related methodology and control logic is also disclosed.