Injector Control Data Correction via Crankshaft Acceleration
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Solution Overview
Problem
Existing methods for adapting injection quantities in internal combustion engines, particularly in common-rail systems, face challenges in maintaining precision and accuracy over the service life of injectors due to wear and deposits, leading to inadequate emission standards compliance and fuel efficiency, especially with reduced non-injection phases.
Innovation Solution
The method involves online adjustment of injection control parameters by determining the actual fuel quantity during the normal operating state through a test cycle with additional test pulses, allowing for quick correction of injector control data, independent of fuel cut-off phases, and using statistically relevant combustion signals to ensure precise fuel injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single test pulse is used during a fuel cut-off phase for adapting injection quantities, then the adaptation process can be implemented, but the adaptation speed is dramatically slowed down due to reduced non-injection phases in newer vehicles
Solution Approach 1:
The injection cycle is divided into multiple test pulses (first test pulse and second test pulse) separated by a test pulse free running phase. This segmentation allows the system to perform multiple measurements within a single operating cycle, significantly increasing the adaptation speed while maintaining accuracy. The first test pulse measures baseline injection quantity, the free running phase allows engine recovery, and the second test pulse measures adjusted injection quantity, enabling rapid iterative optimization.
Solution Approach 2:
The patent implements continuous adaptation by performing test pulses multiple times within the normal operating cycle rather than relying on rare fuel cut-off phases. The test pulses are integrated into the regular injection sequence, allowing the adaptation process to continue uninterrupted throughout engine operation. This ensures that injection quantity corrections are made continuously and rapidly, addressing the limitation of intermittent measurement in conventional systems.
2Measurement precision
If test pulses are performed during fuel cut-off phases, then injection quantity can be measured, but the method becomes less effective when non-injection phases are reduced
Solution Approach 1:
The patent dynamically adapts the test pulse strategy to the current operating conditions. Instead of relying on fixed fuel cut-off phases that may be reduced or eliminated in modern vehicles, the system performs test pulses during normal injection cycles, adjusting the timing and frequency based on real-time engine state. This dynamic approach maintains measurement precision across various vehicle configurations and operating modes, making the system universally applicable.
Solution Approach 2:
The test pulse mechanism is designed to function effectively in both traditional fuel cut-off modes and modern continuous injection modes. By integrating test pulses into the normal injection cycle and using multiple measurement points, the system achieves universal applicability across different vehicle types and emission standard requirements. The same basic principle works whether the engine operates with frequent or rare non-injection phases.
3Manufacturing precision
If injection parameters are adapted using crankshaft acceleration during fuel cut-off phases, then correction can be made, but the correction process is dramatically slowed down
Solution Approach 1:
The system performs preliminary measurements during the first test pulse to establish a baseline injection quantity before making corrections. This preliminary action allows the control unit to calculate initial correction values based on the difference between measured and target injection quantities. By preparing and calculating corrections in advance during the test pulse phase, the system minimizes the time required for actual parameter adaptation during normal operation.
Solution Approach 2:
The patent implements a feedback loop where the actual injection quantity measured during test pulses is continuously fed back to the control unit. This feedback enables real-time calculation of correction values that are applied to subsequent injection parameters. The feedback mechanism ensures that corrections are made based on actual measured performance rather than theoretical values, significantly reducing the time needed to achieve accurate injection parameters by enabling iterative optimization within single operating cycles.
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 enables rapid and accurate adaptation of injection parameters, ensuring precise fuel injection over the injector's service life, improving emission standards compliance and fuel efficiency across various vehicle types.
Implementation Method 1
When combustion takes place in the internal combustion engine, acceleration of the crankshaft of the internal combustion engine occurs.
Implementation Method 2
the acceleration of the engine speed caused thereby is determined and used as a display for the fuel quantity actually injected
Data Source
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AI summary
The invention relates to a method for adapting the actual injection quantity of an injector of an internal combustion engine to the target injection quantity, to an injection device for an internal combustion engine, and to an internal combustion engine. In the method, the crankshaft acceleration achieved by a test injection pulse is detected in the rotational speed signal of the internal combustion engine and on this basis the injected fuel quantity of the injector is determined. On the basis of the determined injected fuel quantity, the actuating data of the injector of the internal combustion engine is corrected. To this end, the injected fuel quantity of the injector is detected and corrected by a test injection pulse during the normal fired operational state of the internal combustion engine.