Multi-Fuel Injector Needle Actuation for Pressure Control

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Solution Overview

Problem

Internal combustion engines face limitations in high-load operations due to high initial fuel energy release rates, leading to excessive pressure rise rates that exceed structural limits, necessitating control over fuel injection rates to manage engine performance and emissions.

Innovation Solution

A fuel injector assembly with a movable needle and actuator system that switches between multiple fuel delivery configurations, allowing for controlled fuel injection rates, including a first lower rate for initial combustion and a higher rate later in the cycle, managed by a processor to optimize combustion phasing and pressure control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a high fuel injection rate is used to maintain engine performance at high loads, then power output is improved, but pressure rise rate becomes excessive and exceeds structural limits

Engineering Contradiction:

Improveengine power outputVSAvoidpressure rise rate

Core Design Contradiction:

PowerVSStress or pressure

Solution Approach 1:

The fuel injection process is divided into multiple distinct phases: an initial delay period with no injection, followed by a main injection phase. This segmentation allows control over the rate of fuel energy release, preventing excessive pressure rise while maintaining required power output.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system prepares for controlled combustion by implementing a deliberate delay period before fuel injection begins. This preliminary action allows optimal timing conditions to be established, ensuring that when injection occurs, the pressure rise rate remains within structural limits while still achieving necessary power levels.

Inventive Principle:

Principle #10Preliminary action

2Stress or pressure

If fuel injection is delayed to reduce initial energy release rate, then pressure rise rate is controlled, but combustion phasing may be affected

Engineering Contradiction:

Improvepressure rise rateVSAvoidcombustion phasing

Core Design Contradiction:

Stress or pressureVSDuration of action of moving object

Solution Approach 1:

The system incorporates feedback mechanisms that monitor combustion conditions and adjust injection timing and duration accordingly. This ensures that the delay period and main injection phase are optimized in real-time to maintain both controlled pressure rise rates and proper combustion phasing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts injection parameters including timing, duration, and rate based on operating conditions. By changing these parameters adaptively, the system maintains controlled pressure rise rates while ensuring optimal combustion phasing across different engine loads and speeds.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11867142B2Systems and methods for fuel injector control

Publication Date: 2024.01.09 TRANSPORTATION IP HOLDINGS LLC

AI summary

A multi-fuel injector assembly in one embodiment includes a first fuel injector assembly to deliver a first type of fuel and a second fuel delivery system to deliver a second type of fuel. The first fuel injector includes a first nozzle, at least one first needle, and at least one first actuator configured to move the at least one first needle. The at least one first actuator moves the at least one first needle to a first fuel delivery configuration that corresponds to a first fuel mixture composition, and a second fuel delivery configuration that corresponds to a second fuel mixture composition.