Hybrid Fuel Control System Using Injector Emulator
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Solution Overview
Problem
Existing dual fuel engine systems, particularly those using LPG in diesel engines, face challenges in efficiently controlling fuel supply and emissions, with simpler systems lacking rate or flow control and more advanced systems experiencing poor hydrocarbon emissions performance.
Innovation Solution
A hybrid fuel control system that includes an emulator to mimic injector characteristics, a control switch to alternate between primary and secondary fuel modes, and a controller to process monitor signals for precise control of fuel supply, allowing operation on a mixture of fuels while maintaining optimal combustion and emissions management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an emulator is used to switch injector control signals, then the ability to control alternative fuel supply is improved, but the device complexity increases
Solution Approach 1:
The patent employs an emulator that replicates the electrical characteristics of a fuel injector to intercept and monitor injector control signals. This copying approach allows the system to capture primary fuel injection data without requiring direct integration with the OEM controller, enabling alternative fuel control while maintaining a relatively simple add-on architecture.
Solution Approach 2:
The emulator serves as an intermediary device between the OEM engine controller and the actual fuel injectors. It receives injector control signals from the OEM controller, processes them to extract fuel injection parameters, and uses this information to control alternative fuel supply timing and quantity, thereby mediating between the existing control system and the alternative fuel system.
2Device complexity
If crude flow control is used for gaseous LPG, then the system simplicity is improved, but the fuel supply control precision deteriorates
Solution Approach 1:
The system implements feedback control by monitoring the primary injector control signals through the emulator to determine actual fuel injection timing and quantity. This feedback information is used by the controller to precisely regulate alternative fuel supply, ensuring accurate fuel metering based on real-time engine operating conditions rather than crude open-loop control.
Solution Approach 2:
The emulator captures and analyzes injector control signals in advance of alternative fuel injection, allowing the controller to pre-calculate the appropriate alternative fuel timing and quantity based on the primary fuel injection parameters before the actual injection event occurs.
3Adaptability or versatility
If remapping of OEM engine controller parameters is used, then the fuel supply control is improved, but the ease of manufacture and installation deteriorates
Solution Approach 1:
The patent extracts the fuel injection control functionality from the OEM engine controller by intercepting its output signals through the emulator. This extraction allows the alternative fuel control system to operate independently using the captured signal data, eliminating the need to reprogram or modify the OEM controller's internal parameters and software.
Solution Approach 2:
The control system is segmented into independent functional modules: the emulator for signal interception, the controller for processing and decision-making, and the alternative fuel injection system for execution. This modular segmentation allows the alternative fuel system to be installed and configured separately without affecting the OEM controller, simplifying manufacture and installation.
4Power
If direct injection of liquid LPG is used, then the power and torque increase is improved, but the emissions control becomes more difficult
Solution Approach 1:
The system uses feedback from monitored primary injector control signals to precisely control the timing and quantity of liquid LPG injection. This feedback mechanism allows the controller to optimize injection parameters for complete combustion, reducing hydrocarbon emissions while maintaining the power benefits of direct injection.
Solution Approach 2:
The control system dynamically adjusts alternative fuel injection timing and quantity based on real-time engine operating conditions derived from the primary injector control signals. This dynamic control ensures optimal combustion across varying loads and speeds, maximizing power output while minimizing harmful emissions through adaptive fuel metering.
Data Source
AI summary
Apparatus for controlling dual fuel supply to a fuel injected engine having an electronic engine management system (1) that supplies a primary injector control signal (8) to each of primary fuel injectors (2), the apparatus comprising an emulator (11) that emulates the electrical characteristics of a primary injector, a fuel control switch (10) that switches the primary injector control signal (8) from the primary injector (2) to the emulator (11) when an alternative mode is selected, a monitor (16) that monitors the primary injector control signal (8) to produce a monitor signal, and a controller (4) that processes the monitor signal to derive an alternative control signal which is used to control the primary fuel supply or a mixture of the primary fuel and a secondary fuel such as LPG, to the engine. Preferably the primary fuel supply is modulated by controlling injector control pulses. A secondary fuel may also be injected (3) and controlled by the controller (4).