Injection Control Device Dynamic Threshold Boost Capacitor
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Solution Overview
Problem
The existing injection control devices for fuel injection valves experience a temporary excess of boosted voltage beyond the full-charge threshold due to regenerative currents, leading to insufficient voltage accumulation in the boost capacitor.
Innovation Solution
The injection control device temporarily shifts the full-charge threshold upward during periods of regenerative current flow, preventing the boosted voltage from exceeding the full-charge threshold and ensuring continuous boost control by adjusting the threshold dynamically based on detected voltage and current conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the boost controller stops boost control when the boosted voltage reaches the full-charge threshold, then the boost controller prevents overcharging, but when regenerative current flows, the boosted voltage temporarily exceeds the threshold due to ESR effect, causing the boost controller to stop prematurely and insufficient voltage accumulation
Solution Approach 1:
The patent applies the Dynamics principle by making the full-charge threshold dynamic rather than fixed. The control unit adjusts the full-charge threshold based on whether regenerative current is flowing: using a first (lower) threshold when regenerative current is present and a second (higher) threshold when it is absent. This dynamic adjustment allows the system to accommodate temporary voltage spikes caused by ESR during regenerative braking while maintaining proper charge control under normal conditions.
Solution Approach 2:
The patent implements Parameter changes by modifying the voltage threshold parameter based on operating conditions. The full-charge threshold is changed from a constant value to a conditional value that depends on the state of regenerative current. This parameter adaptation resolves the contradiction by allowing the system to tolerate temporary voltage exceedances during regenerative braking without triggering premature shutdown of the boost control.
2Loss of energy
If the boost controller continues boost control during regenerative current flow with standard threshold, then sufficient voltage accumulation is achieved, but the boosted voltage temporarily exceeds the full-charge threshold causing false stop of boost control
Solution Approach 1:
The patent introduces an intermediary mechanism - the conditional threshold adjustment logic that acts as a mediator between the voltage monitoring system and the boost control system. This intermediary layer interprets the relationship between regenerative current state and voltage threshold, allowing the boost control to continue appropriately during regenerative braking by temporarily lowering the threshold, thus preventing false shutdown while maintaining energy efficiency.
3Device complexity
If a fixed full-charge threshold is used, then the control logic is simple, but it cannot accommodate temporary voltage spikes during regenerative current flow, leading to premature termination of boost control
Solution Approach 1:
The patent resolves this contradiction by implementing a dynamic threshold system that automatically adapts to operating conditions. The control unit monitors regenerative current state and adjusts the full-charge threshold accordingly, maintaining simple control logic from the perspective of the overall system while achieving high voltage accumulation efficiency through conditional parameter adjustment.
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 approach prevents the boosted voltage from temporarily exceeding the full-charge threshold, ensuring sufficient voltage accumulation and maintaining stable boost control, thereby optimizing the manufacturing costs and performance of the circuit components.
Implementation Method 1
the boost controller is configured to perform the boost control until the boosted voltage rises to a full-charge threshold when the boosted voltage falls below a charge start threshold
Implementation Method 2
when a regenerative current flows through a boost capacitor of the booster circuit, a floating voltage occurs due to the effect of an equivalent series resistor (ESR) of the boost capacitor
Data Source
AI summary
An injection control device includes a boost controller performing boost control of a boosted voltage generated by a booster circuit until a boosted voltage, which is generated in a boost capacitor, rises to a full-charge threshold when the boosted voltage falls below a charge start threshold. When, for stopping a peak current by a drive unit, a power interruption controller interrupts electric current supplied to the fuel injection valve by the drive unit as interruption control (i) of an application voltage to a fuel injection valve or (ii) of a constant current by the drive unit, a regeneration unit regenerates electric current generated in the fuel injection valve to the boost capacitor of the booster circuit. The boost controller upward-shifts (i.e., raises) the full-charge threshold of the booster circuit.