Fuel Pressure Control Modulating Injectors for Pump Capacity Limits
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Solution Overview
Problem
Fuel control systems in engine fuel systems face challenges when the capacity of the fuel pump is insufficient to meet the demand, leading to low fuel pressure, which can result in intermittent fuel injection, poor engine performance, and progressive damage to engine components.
Innovation Solution
A controller system that modulates both the high pressure pump control valve and fuel injectors to maintain target fuel pressure by interpreting pressure differences and adjusting fuel injection commands based on thresholds, ensuring the fuel pressure remains within desired limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the fuel pump capacity is increased to meet engine fuel demand, then the fuel pressure can be maintained, but the system complexity and potential for damage increase
Solution Approach 1:
The system continuously monitors actual fuel pressure and compares it to the target pressure, using this feedback to modulate the pump control valve and fuel injector commands. This closed-loop control ensures fuel pressure remains within safe operating limits while meeting engine demands, preventing both pressure deficiencies and excessive pressure that could cause component damage.
Solution Approach 2:
The system dynamically adjusts fuel injection commands based on real-time pressure differences and time thresholds. When pressure deviations persist beyond a time threshold, the system modulates injection commands to compensate, allowing the system to adapt to varying pump capacities and maintain reliable operation under different loading conditions.
2Productivity
If the fuel control system operates with pump capacity less than engine demand, then the system can operate in low-power conditions, but fuel pressure drops causing intermittent injection and poor performance
Solution Approach 1:
The system uses feedback from pressure sensors to continuously monitor actual fuel pressure and adjusts pump control valve and fuel injector commands accordingly. This ensures that even when pump capacity is limited, the system maintains sufficient fuel pressure for reliable injection by compensating for pressure deficiencies through coordinated control of both the pump and injectors.
Solution Approach 2:
The system changes operational parameters by modulating fuel injection commands based on pressure differences and time thresholds. When pressure deviations exceed thresholds persisting beyond time thresholds, the system adjusts injection parameters to match actual pump capacity, ensuring reliable fuel delivery while operating within the mechanical limits of the fuel system.
3Adaptability or versatility
If the fuel pressure is allowed to vary freely to match pump capacity, then the system adapts to mechanical limitations, but cyclic low pressure conditions cause progressive engine damage
Solution Approach 1:
The system takes preliminary action by continuously monitoring fuel pressure and detecting developing pressure deficiencies before they cause damage. When pressure deviations exceed thresholds and persist beyond time thresholds, the system proactively modulates fuel injection commands to prevent cyclic low pressure conditions, thereby preventing progressive engine damage before it occurs.
Solution Approach 2:
The closed-loop feedback control system continuously monitors actual fuel pressure and adjusts pump and injector commands to maintain pressure within safe operating limits. This feedback mechanism prevents the development of harmful cyclic pressure variations by actively correcting deviations, thereby protecting engine components while adapting to the mechanical capabilities of the fuel system.
Data Source
AI summary
An apparatus includes an input module structured to interpret a fuel pressure command indicative of a target fuel pressure within an accumulator and a target fuel injection characteristic, a pump module structured to control a pump assembly to provide fuel to the accumulator to maintain the target fuel pressure within the accumulator, an injector module structured to control a plurality of fuel injectors to inject fuel into an engine based on the target fuel injection characteristic, a pressure module structured to interpret pressure data regarding an actual fuel pressure within the accumulator and to determine a pressure difference between the target fuel pressure and the actual fuel pressure, and a modulation module structured to determine a final fuel injection command responsive to the pressure difference exceeding a first magnitude threshold where the final fuel injection command is based on the pressure difference and the target fuel injection characteristic.