Fuel Injector Control Module for Precise Zero-Fueling Pulse Calibration
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Solution Overview
Problem
Conventional methods for determining and controlling fuel injection in engines struggle to deliver precise and accurate small injection pulses, leading to issues like undesired injection times, fuel economy parasitism, increased noise, vibration, and harshness, and elevated emissions.
Innovation Solution
The system employs a control module that calculates and adjusts fuel injection parameters, including maximum injector on-time and pilot valve drain quantity, using off-engine calibration and on-engine adaptation, to ensure precise fuel delivery based on operating conditions, utilizing a test fixture to define relationships between drain flow and injected fuel quantity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional methods are used to control fuel injection, then the system is simple to operate, but injection precision and accuracy deteriorate leading to undesired injection times and poor fuel economy
Solution Approach 1:
The system performs preliminary calibration to determine injector-specific parameters (such as maximum on-time for zero fueling) before actual operation. This pre-characterization of each injector allows the control system to achieve high precision by applying pre-determined correction factors during runtime, rather than attempting to calculate precise injection parameters in real-time during engine operation.
Solution Approach 2:
The system implements feedback mechanisms where actual injection results are monitored and compared against target values. The control module adjusts injection parameters based on feedback from sensors measuring injection timing, fuel quantity, and engine operating conditions, continuously refining control accuracy through closed-loop regulation.
2Loss of energy
If small injection pulses are delivered to improve fuel economy, then fuel efficiency improves, but injection accuracy deteriorates causing parasitic drag and increased emissions
Solution Approach 1:
The system applies injector-specific control parameters tailored to each individual injector's characteristics. By determining unique maximum on-time values and drain quantity relationships for each injector, the system optimizes small injection pulses locally for each injector rather than using generic control, enabling precise delivery of minimal fuel quantities without parasitic effects.
Solution Approach 2:
The system dynamically adjusts injection parameters including on-time, off-time, and drain quantity based on operating conditions and measured actual performance. By changing these parameters in response to feedback and calibration data, the system maintains precise control over very small injection pulses across varying engine loads and speeds, preventing both parasitic drag and emissions issues.
3Adaptability or versatility
If conventional calibration methods are used, then the calibration process is simple, but adaptability to different operating conditions deteriorates
Solution Approach 1:
The system transitions from static calibration to dynamic adaptation by continuously updating injector parameters based on real-time operating conditions. The control module adapts injection timing and quantity parameters in response to varying engine speed, load, temperature, and pressure conditions, allowing the system to maintain optimal performance across the full operating range rather than relying on fixed calibration maps.
Data Source
AI summary
A method of controlling an engine system includes controlling a fuel injector to perform a zero-fueling injector operation during operation of the engine, the zero-fueling injector operation including a non-zero injector on-time resulting in zero fueling by the injector, determining an injection system pressure change associated with the zero-fueling injector operation, modifying at least one fuel injection control parameter in response to the injection system pressure change, and using the modified fuel injection control parameter to control injection of fuel by the fuel injector during operation of the engine.