Internal Combustion Engine Injector Condition Monitoring
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Solution Overview
Problem
Existing internal combustion engines replace injectors based on service life rather than their actual condition, leading to unnecessary replacements and potential inefficiencies.
Innovation Solution
An algorithm stored in the control device calculates the injector's state using input variables and a model, comparing it to a target state to determine if replacement is necessary due to wear, damage, or other changes, allowing for condition-based maintenance by monitoring key variables like actuator control signals and sensor measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If injectors are replaced based on service life (number of operating hours), then maintenance scheduling is simplified, but unnecessary replacements occur and maintenance efficiency deteriorates
Solution Approach 1:
The system continuously monitors injection quantity through sensors and compares actual values against target values. This feedback mechanism enables real-time detection of injector performance degradation, allowing maintenance to be triggered only when actually needed rather than following a fixed schedule. The control device processes measurement values and generates maintenance indications based on actual injector state.
Solution Approach 2:
The injector system performs self-diagnosis by monitoring its own injection quantity through integrated sensors and control electronics. The system automatically detects when an injector deviates from expected performance and generates maintenance indications without external intervention, enabling the system to serve its own maintenance needs.
2Reliability
If injectors are replaced based on service life, then component reliability is maintained through regular replacement, but loss of time and resources occur due to unnecessary replacements
Solution Approach 1:
Continuous monitoring of injection quantity provides real-time feedback on injector health status. By comparing actual injection values against target values and tracking deviations over time, the system can reliably determine when an injector truly needs replacement, maintaining component reliability through condition-based rather than time-based replacement criteria.
Solution Approach 2:
The system transitions from time-based replacement parameters (service hours) to condition-based parameters (injection quantity deviation). By monitoring parameters such as injection quantity, pressure progression, and needle position, the system identifies when actual injector performance warrants replacement, eliminating unnecessary replacements and associated downtime.
3Measurement precision
If condition monitoring is implemented to assess injector state, then maintenance precision is improved, but device complexity increases due to additional sensors and algorithms
Solution Approach 1:
The control device utilizes existing sensors to measure injection quantity and compares these measurements against target values stored in memory. This feedback approach achieves precise injector state assessment by evaluating the difference between actual and expected performance, leveraging already-present measurement capabilities rather than requiring entirely new sensing systems.
Solution Approach 2:
The system creates a virtual model of injector behavior by storing target injection values and comparing them against actual measurements. This copying approach allows precise state assessment by comparing real-world performance against a reference model, achieving accurate monitoring without requiring complex physical modifications to the injector itself.
Data Source
AI summary
An internal combustion engine is provided. The internal combustion engine includes a control device, and at least one injector for liquid fuel. The injector(s) can be controlled by the control device via an actuator control signal. The injector(s) include an injector outlet opening for the liquid fuel which can be closed by a needle. A sensor is also provided for measuring a measurement variable of the injector(s). The sensor is or can be in a signal connection with the control device. An algorithm is stored in the control device, which algorithm calculates a state of the injector(s) based on input variables and an injector model, compares the state calculated via the injector model with a target state, and produces a state signal in accordance therewith. The state signal is characteristic of a change in the state of the injector(s) that occurs during intended use of the injector(s) and/or an unforeseen change in the state of the injector(s). The input variables include at least the actuator control signal and the measurement values of the sensor. A method for operating such an internal combustion engine and an injector is also provided.