Unit-Injector Test Bench with Angle Sensor
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Solution Overview
Problem
Existing test devices for cam-driven fuel injection systems require extensive reconfiguration and time to adapt to different types of injection systems, leading to potential errors due to the need for precise setting of cam angles and lifts for solenoid valve activation, resulting in high costs from the necessity of separate devices for each system type.
Innovation Solution
A test device equipped with an angle of rotation sensor that assigns specific cam lifts to camshaft angles, allowing for pre-assembly and storage of these associations during manufacturing, enabling the lever and fastening device to adjust for different operating positions, eliminating the need for repeated setup and reducing conversion time between systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the test device is configured for a specific injection system type with fixed cam angle settings, then testing accuracy is improved, but adaptability to different injection system types deteriorates
Solution Approach 1:
The camshaft is made adjustable with variable angular positioning capability, allowing the test device to adapt to different cam profiles and injection system types while maintaining accurate testing through controlled dynamic reconfiguration
Solution Approach 2:
The device allows changing of camshaft angular position parameters and lever positioning parameters to match different injection system specifications, enabling accurate testing across multiple system types through parameter adjustment rather than device replacement
2Measurement precision
If the camshaft and lever are fixed in specific positions for precise testing, then measurement precision is improved, but the time required to reconfigure for different systems increases
Solution Approach 1:
Multiple camshaft positioning options and lever positions are pre-configured during device assembly, allowing operators to quickly switch between different injection system types by selecting pre-prepared configurations rather than performing time-consuming adjustments
Solution Approach 2:
The positioning system is divided into discrete, pre-defined angular positions for the camshaft and discrete positions for the lever, enabling rapid switching between configurations through simple selection rather than continuous adjustment
3Adaptability or versatility
If manual adjustment and setting procedures are used for each injection system type, then adaptability is improved, but the risk of setting errors increases
Solution Approach 1:
Manual measurement and calculation procedures are replaced with an electronic control system that automatically determines the correct camshaft angular position and lever position based on the selected injection system type, eliminating human error in setting procedures
Solution Approach 2:
The system incorporates sensors to detect the actual positions of the camshaft and lever, providing feedback to the control device which automatically adjusts positions to match the required specifications for the being-tested injection system
Data Source
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AI summary
A test device (10) is used to test cam-driven fuel injection systems (12). It comprises a camshaft (80) which can act, at least indirectly, on a piston (26) of the fuel injection system (12) via a lever (60). It is proposed to provide a rotation angle sensor (82) on the camshaft (80) and to record and store the rotation angles (ϕi) corresponding to different strokes (H;) after the test device has been mounted. This prevents incorrect settings during operation of the test device and significantly reduces setup times when changing from one fuel injection system to another.