Single Rail Fuel Injector with Flow Selection Valve
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Solution Overview
Problem
Dual fuel injection systems in internal combustion engines require separate components and fuel lines for port and direct injectors, leading to increased costs and packaging challenges due to the need for distinct fuel pressures and complex routing of fuel lines.
Innovation Solution
A fuel distributing injector system that uses a common high-pressure fuel rail to supply both direct and port injectors, with a flow selection valve and pressure regulator to adjust fuel pressure, allowing for simultaneous operation with a single fuel pump, rail, and line, reducing component count and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fuel rails and pressure regulators are used for port and direct injectors, then different fuel pressures can be delivered to each injector type, but component costs increase and packaging space is reduced
Solution Approach 1:
The patent combines the direct injector and port fuel injector into a single integrated fuel injector assembly. The direct injection portion injects fuel directly into the combustion chamber at high pressure, while the port injection portion injects fuel into the intake manifold at lower pressure. This merging eliminates the need for separate fuel rails and pressure regulators, reducing component count and packaging space while maintaining the ability to deliver different fuel pressures to each injector type through internal pressure control mechanisms
Solution Approach 2:
The integrated fuel injector assembly serves multiple functions: it acts as both a direct injector and a port fuel injector, and also functions as a pressure regulator for the port injection portion. The single assembly can deliver fuel at different pressures to different locations (combustion chamber and intake manifold) based on engine operating conditions, providing multi-functionality that replaces multiple separate components
2Adaptability or versatility
If separate fuel lines are used for port and direct injectors, then independent fuel delivery is achieved, but routing complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the fuel delivery paths by using a single common fuel rail that supplies both the direct injection portion and the port injection portion of the integrated fuel injector assembly. This eliminates the need for separate fuel lines and complex routing, simplifying manufacturing while maintaining the ability to deliver fuel independently to each injector type through internal flow control mechanisms within the integrated assembly
3Productivity
If high pressure fuel is delivered to port injector, then fuel injection is achieved, but excess fuel deposition in intake manifold occurs
Solution Approach 1:
The patent applies local quality by delivering fuel at different pressures to different locations based on the specific requirements of each injection point. The direct injection portion receives high pressure fuel (e.g., 2000-3000 psi) appropriate for direct combustion chamber injection, while the port injection portion receives lower pressure fuel (e.g., 40-80 psi) appropriate for intake manifold delivery. This localized pressure control prevents excess fuel deposition in the intake manifold that would occur if high pressure fuel were delivered to the port injector, while maintaining effective fuel injection at both locations
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 configuration reduces manufacturing costs and improves packaging efficiency by using a single fuel system for both injectors, maintaining accurate fuel control and delivery without compromising performance.
Implementation Method 1
a pressure regulator to reduce a pressure of the fuel delivered to the port injector
Implementation Method 2
a flow selection valve to direct the fuel delivered from the common fuel rail to one of the direct injector and the port injector
Data Source
AI summary
Methods and systems are provided for adjusting operation of an internal combustion engine configured for dual fuel injection from a single fuel rail. In one example, a method may include directing fuel from a common high pressure fuel rail to one or more of a direct injector and a port injector, wherein each of the direct injector and port injector may be coupled to a cylinder of an engine. The flow of fuel to the direct injector and port injector from the single fuel rail is mediated by a flow selection valve.