Injector Corrosion Estimation via Reference Flow Comparison
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Solution Overview
Problem
Current methods cannot accurately estimate the level of corrosion in injectors of injection engines, as corrosion and clogging phenomena compensate each other, making it difficult to determine the extent of damage without additional sensors, and uneven corrosion affects fuel atomization and pollutant emissions.
Innovation Solution
A method that uses a reference injector to compare static flow rates with other injectors while inhibiting exhaust gas propagation, allowing for precise corrosion estimation without additional sensors, and triggers an alert when corrosion levels exceed a threshold, while also distributing corrosion uniformly among multiple injectors by opening the exhaust valve of the least corroded injector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional methods are used to measure injected quantity, then the measurement is simple, but the measurement precision is insufficient because corrosion and clogging phenomena compensate each other
Solution Approach 1:
The patent uses a reference injector that replicates the normal injector's structure and function to create a baseline for comparison. By having an identical reference injector operating under the same conditions, the system can detect corrosion-specific changes without adding complex measurement equipment to the original injector.
Solution Approach 2:
The patent introduces exhaust gas propagation as an intermediary mechanism to differentiate corrosion from clogging. By controlling exhaust gas flow through the injector, the system creates a condition where only corroded injectors will show abnormal flow patterns, allowing precise corrosion detection without additional sensors.
2Measurement precision
If additional sensors are added to detect corrosion, then the measurement precision improves, but the device complexity increases significantly
Solution Approach 1:
The system uses the engine's existing exhaust gases and normal operational parameters to detect corrosion. By analyzing how exhaust gases propagate through the injector and how the injector responds to normal fuel injection cycles, the system achieves corrosion detection without requiring dedicated sensors or additional measurement equipment.
Solution Approach 2:
The reference injector serves multiple functions: it acts as a baseline comparator, a flow resistance reference, and a corrosion-specific detection target. The exhaust valve and existing injection system components are used for both their primary functions and for corrosion detection, eliminating the need for dedicated detection hardware.
3Reliability
If the engine operates normally without intervention, then productivity is maintained, but corrosion accumulates and reduces reliability
Solution Approach 1:
The system continuously monitors the reference injector's flow characteristics and compares them against the normal injector's performance. When corrosion reaches a threshold level, the system provides feedback by triggering an alert or adjusting operation, allowing proactive maintenance while maintaining normal operation during the monitoring period.
Solution Approach 2:
The system detects corrosion trends before they cause significant performance degradation or failure. By continuously comparing the reference injector against the normal injector and identifying gradual flow changes, the system can alert operators to perform maintenance before reliability is compromised, extending the injection system's useful life.
Data Source
AI summary
Disclosed is a method for estimating a level of corrosion of an injector of an engine, the engine including a reference injector and at least one other injector, each injector including a tip in fluidic communication with a combustion chamber specific to each of the injectors, the respective combustion chamber of each injector also being in fluidic communication with an exhaust system of the engine. The method includes: while the engine is stopped, inhibiting a propagation of the gases from the exhaust system toward the tip of the reference injector; determining a static flow rate of an injector and a static flow rate of the reference injector; and estimating a level of corrosion of the injector by comparing the static flow rate of the injector with the static flow rate of the reference injector.