Injector Mechanical Failure Detection via Valve Closing Time
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Solution Overview
Problem
Current methods struggle to accurately determine the cause of engine misfire, often leading to incorrect maintenance and excessive costs, as they fail to differentiate between electrical and mechanical failures in injectors, resulting in unnecessary replacement of igniter systems.
Innovation Solution
A system and method that senses engine misfire and determines mechanical failure in injectors by monitoring closing sensing values and static flow rates, storing maintenance codes to accurately identify the cause of misfire, thereby reducing incorrect maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the ECU determines misfire cause based on electrical failure codes only, then electrical failures can be detected, but mechanical failures in injectors cannot be accurately identified
Solution Approach 1:
The patent replaces traditional electrical diagnostic methods with a mechanical measurement approach. By measuring the closing time of the injector valve using a current sensor and voltage signal analysis, the system can detect mechanical failures in the injector valve mechanism. This substitution of measurement methodology enables accurate identification of mechanical failures that were previously undetectable by electrical code analysis alone.
Solution Approach 2:
The patent introduces an intermediary measurement parameter (closing time of injector valve) that serves as a mediator between the injector's mechanical state and the ECU's diagnostic capability. By measuring the closing time through electrical signals (current and voltage) and comparing it against reference values, the system translates mechanical valve behavior into quantifiable data that the ECU can process for accurate failure diagnosis.
2Reliability
If the vehicle replaces igniter components upon misfire detection, then potential ignition failures are addressed, but unnecessary replacements occur when the actual cause is injector mechanical failure
Solution Approach 1:
The patent performs preliminary diagnostic measurement of the injector valve closing time before any maintenance action is taken. By measuring the closing time through current and voltage signal analysis and comparing it against reference values stored in the ECU, the system determines the actual cause of misfire in advance. This preliminary measurement prevents premature or incorrect replacement of igniter components when the actual problem lies with the injector valve mechanism.
Solution Approach 2:
The patent implements a feedback mechanism where the measured closing time of the injector valve is continuously compared against reference values, and the result feeds back to the ECU to determine the appropriate maintenance action. This feedback loop ensures that maintenance decisions are based on actual measured data rather than assumptions, preventing unnecessary replacements and directing repairs to the correct component.
3Loss of information
If the ECU monitors only engine angular velocity for misfire detection, then misfire occurrence can be sensed, but the specific cause of misfire cannot be determined
Solution Approach 1:
The patent segments the diagnostic process into distinct measurement stages: first detecting misfire through engine angular velocity, then separately measuring the injector valve closing time using current sensor signals, and finally comparing the closing time against reference values. This segmentation of diagnostic functions allows each measurement to be optimized independently while maintaining overall system simplicity.
Solution Approach 2:
The patent makes the existing current sensor serve multiple functions: it continues to monitor electrical signals for ignition system diagnostics while simultaneously enabling measurement of injector valve closing time. By analyzing the voltage signal characteristics during injector operation, the same sensor infrastructure provides both traditional electrical diagnostics and new mechanical failure detection capabilities without requiring additional dedicated sensors.
Data Source
AI summary
The present disclosure relates to a method and a system capable of determining the cause of misfire if the misfire occurs due to the mechanical failure of an injector. The present disclosure senses whether the misfire of an engine occurs, determines whether the mechanical failure occurs in an injector of a cylinder in which the misfire occurs, if the misfire of the engine is sensed, and determines that the misfire of the engine occurs due to the injector, and stores the failure content of the injector in a maintenance code, if it is determined that the mechanical failure occurs in the injector.