Solenoid Boost Voltage Control for Fuel System Energy Reduction
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Solution Overview
Problem
Existing electronically controlled fuel systems rely on solenoid wave form control strategies that consume high power and energy, with ongoing efforts to reduce hardware and energy requirements without compromising performance.
Innovation Solution
A method and system where a solenoid in a fuel system is energized with a boost voltage and then deenergized by switching to a reduced voltage when a trigger current is reached, utilizing an electronic controller with a processor, memory, and a driver circuit to manage the solenoid coil circuit, reducing power and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a boost voltage is applied to the solenoid circuit during the pull-in duration to hasten armature movement, then the actuation speed is improved, but the power and energy consumption increase
Solution Approach 1:
The patent applies periodic action by using a capacitor to provide intermittent boost voltage pulses during the pull-in duration rather than continuous high voltage. The capacitor charges during off-periods and discharges in bursts during on-periods, creating periodic energy delivery that speeds armature movement while reducing overall energy consumption compared to continuous boost voltage.
Solution Approach 2:
The patent changes the voltage parameter dynamically by switching between boost voltage (from capacitor) and reduced voltage (from battery). The controller monitors solenoid current and switches voltage sources accordingly, optimizing the balance between actuation speed and energy consumption based on real-time system state.
2Ease of operation
If current chops are used to control solenoid current during the pull-in duration to maintain minimum and maximum current levels, then the actuation control is improved, but the device complexity and hardware requirements increase
Solution Approach 1:
The patent extracts the current chopping function from the main control circuitry and implements it through the natural discharge characteristics of the capacitor. Instead of using complex current control circuits to chop current, the system uses the capacitor's inherent electrical properties to provide the necessary current modulation, simplifying the hardware requirements while maintaining actuation control.
Solution Approach 2:
The capacitor provides self-regulating current control through its natural charge and discharge cycles. The controller simply needs to monitor solenoid current and switch between capacitor and battery voltage sources, allowing the capacitor to automatically provide the current modulation function without requiring additional complex control hardware.
3Speed
If a substantially higher voltage is applied to the solenoid circuit to initiate armature movement, then the actuation speed is improved, but the power and energy requirements increase
Solution Approach 1:
The capacitor is charged in advance during off-periods before the next injection event. This preliminary charging action stores energy that can be quickly discharged as boost voltage when needed, enabling fast actuation without requiring continuous high power delivery from the battery, thus reducing overall power and energy requirements.
Solution Approach 2:
The system uses periodic charging and discharging of the capacitor to provide intermittent boost voltage rather than continuous high voltage. This periodic energy delivery maintains actuation speed while reducing the average power and energy requirements compared to continuous high voltage application.
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 approach achieves comparable solenoid actuation performance with significantly reduced power and energy requirements, eliminating current chops during the boost period and optimizing hardware needs.
Implementation Method 1
energizing a solenoid of the fuel system and then later deenergizing the solenoid
Implementation Method 2
movement of the solenoid armature changes a pressure configuration within the fuel injector causing a fuel injection event to occur
Data Source
AI summary
An efficient control wave form is utilized to actuate the solenoids of a fuel system to reduce boost power/energy consumption. The solenoid is initially energized by applying a boost voltage from an electronic controller across a solenoid coil circuit. The electronic controller monitors the current level in the solenoid coil circuit, and changes to a reduced battery voltage when the current level in the solenoid coil circuit reaches a predetermined trigger current. The controller then maintains a pull-in current based upon battery voltage for a pull-in duration that initiates movement of the solenoid armature from an initial air gap position toward a final air gap position. After the pull-in duration, the current level is dropped to a hold in level for the remaining duration of the actuation event. The solenoid may be used for fuel injector control and/or pump control, such as to control fuel injection and pumping events respectively.