Fuel Injector Coding via Parametric Resistors for Flow Calibration
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Solution Overview
Problem
Part-to-part variation in engine components due to manufacturing and assembly tolerances, as well as differences between components from various suppliers, leads to decreased engine efficiency and challenges in self-calibration systems.
Innovation Solution
A method involving a controller that receives a current from a component with a parametric resistor, measures the resistance value, maps it to a parametric value, generates a calibration data set, and transmits a signal to calibrate the component's operation. Additionally, a system that includes a fuel injector with a parametric resistor, where the controller measures the resistance value to determine a flow biasing value and dispensing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are manufactured with standard tolerances, then manufacturing cost and ease of manufacture are improved, but part-to-part variation increases leading to decreased engine efficiency
Solution Approach 1:
The patent applies preliminary action by measuring and recording the actual parametric values (such as flow rate, torque, or other component-specific parameters) of each individual component during manufacturing or assembly, before the component is installed in the engine. This preliminary measurement allows the control system to pre-calculate compensation values that will be applied when the component is in operation, thereby compensating for manufacturing variations without requiring tighter manufacturing tolerances.
Solution Approach 2:
The patent utilizes parameter changes by adjusting control parameters (such as injection timing, injection duration, valve actuation timing, or motor controller settings) based on the measured parametric values of individual components. The control system stores these component-specific parameters and modifies operational parameters in real-time to compensate for manufacturing variations, thereby maintaining optimal engine efficiency despite standard manufacturing tolerances.
2Reliability
If embedded software self-calibration is implemented, then compensation for part-to-part variation is improved, but system cost and service difficulty increase
Solution Approach 1:
The patent implements self-service by enabling the control system to automatically read the parametric identification information from each component (via RFID tags, data matrices, or other machine-readable codes), retrieve the corresponding measured parametric values from storage, and apply the appropriate compensation parameters without requiring manual calibration or complex embedded software. The system serves itself by autonomously adapting to each component's characteristics through automated information retrieval and parameter adjustment.
Solution Approach 2:
The patent introduces an intermediary mechanism in the form of machine-readable codes (RFID tags, data matrices, or other coded identifiers) attached to or embedded in each component. These codes serve as intermediaries that carry component-specific identification information and link the physical component to its measured parametric data stored in the system's database. This intermediary approach simplifies the overall system by providing a straightforward information transfer mechanism without requiring complex embedded software or wireless communication hardware in each component.
3Measurement precision
If machine-readable codes are used for component identification, then calibration accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary mechanism in the form of machine-readable codes (RFID tags, data matrices, or other coded identifiers) attached to or embedded in each component. These codes serve as intermediaries that carry component-specific identification information and link the physical component to its measured parametric data stored in the system's database. This intermediary approach simplifies the overall system by providing a straightforward information transfer mechanism without requiring complex embedded software or wireless communication hardware in each component.
Solution Approach 2:
The patent applies copying by creating a digital representation (machine-readable code) of the component's identification and parametric information. Instead of embedding complex electronics or sensors in each component, the system creates a simplified copy or representation of the component's identity and characteristics in the form of a machine-readable code. This code can be easily manufactured and applied to the component while containing sufficient information for the control system to retrieve the appropriate calibration data from external storage.
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 enables effective calibration of control systems and engine components, improving engine efficiency by accounting for part-to-part variations and reducing the need for expensive self-calibration systems.
Implementation Method 1
determining the resistance value of the parametric resistor by measuring a parametric voltage rating from the current
Implementation Method 2
laser etching a resistor having the resistance value onto the component
Data Source
AI summary
A method of calibrating a control system based on a parametric value of a component. The method includes receiving a current from a component of the control system. The component is communicatively coupled to a controller and has a parametric resistor with a parametric resistance value correlating to a parametric value associated with the component. The method further includes determining the resistance value of the parametric resistor by measuring a parametric voltage rating from the current. The method further includes mapping the resistance value to the parametric value associated with the component. The method further includes generating a calibration data set. The calibration data set is based on calibrating the control system to calibrate for the parametric value. The method further includes transmitting a signal to the component. The signal is based on the calibration data set and is configured to calibrate operation of the component.