High Pressure Pump Bore Wear Detection Model
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Solution Overview
Problem
Existing methods for detecting bore wear and abnormal fuel leakage in high-pressure fuel pumps are prone to inaccuracies due to reliance on multiple sensors and lack of calibration for component wear and aging, failing to distinguish between necessary and excessive leakage.
Innovation Solution
A method involving a pump performance model that calculates a target pump rate based on factors like fuel rail pressure, engine speed, and duty cycle, allowing for continuous on-board detection of piston-bore interface leaks during engine idling, with periodic updates to account for aged pump conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a leak calculation based on multiple sensors (temperature, pressure, angle sensors) is used to detect fuel leakage, then the detection can be performed under various operating conditions, but the system complexity increases and measurement accuracy decreases due to potential sensor inaccuracies
Solution Approach 1:
The patent extracts the essential detection function from a complex multi-sensor system and implements it through a simplified model-based approach. Instead of using multiple sensors (temperature, pressure, angle sensors) to calculate leak amounts, the invention uses a pump performance model that processes fewer inputs to determine piston-bore interface leaks, thereby reducing system complexity while maintaining detection versatility
Solution Approach 2:
The patent creates a virtual model (pump performance model) that replicates pump behavior under various operating conditions. This model copies the essential relationships between pump rate, fuel rail pressure, engine speed, and duty cycle, allowing the system to detect leaks without requiring physical sensors for all these parameters, thus reducing sensor requirements while maintaining adaptability
2Reliability
If a leak calculation method is used to diagnose fuel leakage, then leakage detection is provided, but the method cannot distinguish between necessary leakage for pump lubrication and excessive leakage from wear
Solution Approach 1:
The patent applies local quality by making the detection method condition-specific. The pump performance model is designed to detect leaks under specific conditions (engine idling with increased fuel rail pressure), allowing precise measurement of piston-bore interface leaks. By targeting specific operating conditions and using a dedicated model for piston-bore interface detection, the system can distinguish normal lubrication leakage from abnormal wear-induced leakage with higher precision
Solution Approach 2:
The patent performs preliminary action by periodically updating the pump performance model to reflect aged pump conditions. This allows the system to adapt to normal wear over time and distinguish it from abnormal leakage. The model is pre-calibrated with factors affecting pump rate, and periodically updated to account for aging, enabling the system to differentiate between necessary leakage and excessive leakage caused by abnormal wear
3Measurement precision
If the pump performance model is periodically updated to reflect aged pump conditions, then the measurement precision improves, but the loss of time for periodic updates increases
Solution Approach 1:
The patent implements periodic action by updating the pump performance model at scheduled intervals rather than continuously. The model is periodically updated to reflect aged pump conditions, which maintains measurement precision while minimizing time loss. This periodic update approach balances the need for accurate leak detection with the constraint of available time, avoiding continuous updates that would consume excessive time
Data Source
AI summary
Methods are provided for detecting high pressure pump bore wear, wherein wear between a piston and bore of a pump may cause an excessive amount of fuel to leak out of a compression chamber of the pump. A reliable method is needed that involves a pump performance model that incorporates a number of physical effects and is verified by real high pressure pump test data. A method is proposed that involves comparing a target pump rate based on the pump performance model to a real fuel injection rate in order to determine if an abnormal amount of fuel may be leaking from the high pressure pump.