Supplemental Fuel Control With Baseline ECU Integration
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Solution Overview
Problem
Existing aftermarket dual injection systems for engines struggle to accurately adjust fuel delivery due to lack of integration with the baseline ECU, leading to inefficiencies and poor engine operation under varying conditions, particularly at low load scenarios, and cannot compensate for changes in fuel properties without reprogramming.
Innovation Solution
The system reorders calculations to make the supplemental fraction a dependent variable, using real-time data from the baseline ECU to determine precise fuel delivery through supplemental injectors, adjusting dynamically based on current engine conditions rather than relying on pre-programmed tables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If DI injectors are used to increase power output, then fuel delivery capacity is improved, but dynamic operating ability deteriorates at low load scenarios
Solution Approach 1:
The fuel injection system is segmented into two independent injection systems: direct injection (DI) injectors for high power delivery and port injection (PI) injectors for low load operation. Each injector type operates independently based on engine conditions, allowing the system to leverage the strengths of both injection methods without compromise.
Solution Approach 2:
The system dynamically switches between DI and PI injection modes based on real-time engine operating conditions. The ECU constantly monitors engine parameters and automatically adjusts which injection system is active, enabling seamless adaptation from high power to low load scenarios without manual intervention or performance loss.
2Adaptability or versatility
If auxiliary controllers are added to manage PI injectors, then fuel delivery flexibility is improved, but system integration and control accuracy deteriorate
Solution Approach 1:
The auxiliary controller for PI injectors is merged with the baseline ECU into a single integrated control unit. This unified controller has direct access to all engine sensors and parameters, eliminating communication delays and ensuring both injection systems are coordinated by a single brain that understands the complete engine state, thereby maintaining high control accuracy.
Solution Approach 2:
The integrated controller implements continuous feedback loops that monitor actual fuel delivery from both DI and PI injectors against target values. Real-time corrections are applied based on feedback from oxygen sensors and engine performance parameters, ensuring accurate fuel metering adapts dynamically to changing conditions without requiring separate control loops.
3Device complexity
If pre-programmed fuel delivery tables are used, then system simplicity is maintained, but adaptability to changing conditions deteriorates
Solution Approach 1:
The fuel delivery system transitions from static pre-programmed tables to dynamic real-time calculations. The integrated ECU continuously computes optimal fuel delivery based on current sensor readings, engine load, and operating conditions, allowing the system to adapt instantly to changing conditions while maintaining computational efficiency through optimized algorithms.
Solution Approach 2:
The system changes its control parameters dynamically based on operating conditions. Instead of relying on fixed lookup tables, the controller adjusts injection timing, duration, and split between DI and PI injectors in real-time based on measured parameters such as manifold pressure, temperature, and oxygen feedback, enabling continuous optimization without requiring complex user calibration.
Data Source
AI summary
An auxiliary controller operates in combination with a baseline ECU in a primary fuel (PF) system to determine a fueling level for supplemental fuel (SF) injectors. The auxiliary controller receives PF injector on time from the baseline ECU and determines a PF fuel mass and a PF fueled air mass for the primary fuel system. The auxiliary controller calculates a SF fueled air mass from a total engine air mass and the PF fueled air mass and then calculates a SF fuel mass and a SF injector on time. The auxiliary controller sequentially repeats the process for all of the cylinders in the engine and communicates the SF injector on times to the SF injectors for the cylinders.