Inductive Fuel Injector Temperature Control via Self-Sensing
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Solution Overview
Problem
Existing fuel injector systems require additional circuitry and costly wired sensors to sense and regulate the temperature of the heating element, which is inefficient and increases costs.
Innovation Solution
A fuel delivery system that inductively heats fuel using a valve element sealed within the fuel flow, where the temperature of the heated element is monitored without wires or external sensors, using a driver circuit that detects changes in material parameters such as inductance to adjust power input and maintain the fuel temperature within a desired range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wired temperature sensors are used to sense and regulate heating element temperature, then temperature control accuracy is improved, but device complexity and cost increase due to additional circuitry and sensors
Solution Approach 1:
The heating element itself serves as the temperature sensor by utilizing its inherent inductance changes with temperature. The driver circuit monitors these inductance changes to determine temperature, eliminating the need for separate temperature sensors and reducing system complexity while maintaining temperature control capability
Solution Approach 2:
The system monitors changes in the inductance parameter of the heating element, which varies with temperature. By tracking inductance changes rather than directly measuring temperature with separate sensors, the system achieves temperature sensing functionality using existing component parameters, reducing overall device complexity
2Reliability
If wired temperature sensors are installed in the fuel injector, then temperature monitoring capability is improved, but manufacturing cost increases due to additional components and assembly requirements
Solution Approach 1:
The heating element performs dual functions: it serves as both the heating source and the temperature sensor. By making the heating element multi-functional, the system eliminates the need for separate temperature sensing components, thereby reducing manufacturing cost while maintaining temperature monitoring capability
Solution Approach 2:
The heating element monitors its own temperature through inductance changes, making the system self-sufficient for temperature monitoring without requiring external sensors or additional manufacturing steps for sensor installation
3Device complexity
If the heating element temperature is not regulated, then device complexity is reduced, but harmful effects increase due to excessive heating causing fuel system build up
Solution Approach 1:
The driver circuit continuously monitors the inductance of the heating element and uses this feedback to regulate power delivery. When the heating element reaches the desired temperature (indicated by inductance change), the driver circuit reduces or stops power supply, preventing excessive heating and fuel system build up while maintaining relatively simple system architecture
Solution Approach 2:
The heating element automatically regulates its own temperature through inductance changes that are detected by the driver circuit, creating a self-regulating system that prevents harmful effects without requiring complex external control mechanisms
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
This solution allows for efficient temperature control of the fuel without additional sensors, ensuring optimal combustion performance, reducing emissions, and preventing fuel system damage from excessive heating.
Implementation Method 1
A heater coil generates a time varying magnetic field in a heated element. Heating is accomplished by coupling energy through the time varying magnetic field produced by the heater coil. Energy produced by the heater coil is converted to heat within the sealed chamber of the fuel injector by hysteretic and eddy current loses in the heated element material.
Implementation Method 2
Energy produced by the heater coil is converted to heat within the sealed chamber of the fuel injector by hysteretic and eddy current loses in the heated element material.
Implementation Method 3
Energy produced by the heater coil is converted to heat within the sealed chamber of the fuel injector by hysteretic and eddy current loses in the heated element material.
Implementation Method 4
The heated element transfers heat to the fuel flow to produced a heated fuel flow that is injected into the engine
Implementation Method 5
The example driver circuit monitors a material parameter that changes the materials inductance in response to changes in temperature. Changes in material permeability caused by changes in temperature cause a proportional change in parameters responsive to changes in inductance.
Data Source
AI summary
A fuel delivery system for a vehicle includes a fuel injector that dispenses heated fuel flow and controls the temperature of the heated fuel within a desired temperature range. Fuel flowing through the example fuel injector is inductively heated by a valve element sealed with the fuel flow. A driver controller detects changes in temperature by monitoring changes in parameters that vary responsive to temperature in the material of the heated element. Changes in the material responsive to temperature are utilized to tailor input into the heated element to maintain a desired temperature of the heated element and thereby the temperature of the fuel.