Accumulator fuel injection apparatus compensating for injector individual variability

• US 20060090733A1
• Filed: 11/01/2005
• Published: 05/04/2006
• Est. Priority Date: 11/01/2004
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Fujii, Hiroto
• Granted Patent: US 7,552,709 B2
• Time in Patent Office: Days
• US Class Current: 123/446
• CPC Class Codes: F02D 2250/04 Fuel pressure pulsation in common rails
• CPC Class Codes: F02D 41/2438 Active learning methods
• CPC Class Codes: F02D 41/247 Behaviour for small quantities
• CPC Class Codes: F02D 41/3809 Common rail control systems common rail apparatus F02M55/025, F02M63/0225
• CPC Class Codes: F02D 41/403 with pilot injections
• CPC Class Codes: F02M 47/027 Electrically actuated valves draining the chamber to release the closing pressure
• CPC Class Codes: F02M 63/0225 Fuel-injection apparatus having a common rail feeding several injectors F02M63/0003 takes precedence; Means for varying pressure in common rails; Pumps feeding common rails

Abstract

A common rail injection system for internal combustion diesel engines is provided which is designed to correct a limit of width of an ineffective injection command pulse signal which is to be applied to each fuel injector, but causes the injector to produce no spray of fuel in order to minimize a variation in quantity of fuel injected to the engine between the injectors arising from the individual variability or aging of the injectors. The system works to changes the width of a pilot injection command pulse signal to search a value thereof when an engine operation variation such as a change in speed of the engine exceeds or decreases below a threshold at which the injector may be viewed as having sprayed the fuel actually or stopped spraying the fuel actually and determines the limit of width of the ineffective injection command pulse signal using the searched value.

Claims

1. An accumulator fuel injection system for an internal combustion engine comprising:

a common rail working to accumulate fuel at a given pressure;

an injector which injects the fuel supplied from said common rail to an internal combustion engine; and

an injector controller working to output an injection pulse signal to actuate said injector, said injector controller determining a required injection quantity as a function of a given operating condition of the engine to define an effective injection pulse width and adding the effective injection pulse width to an ineffective injection pulse width to determine an injection pulse width that is a width of the injection pulse signal, the effective injection pulse width defining a duration for which the injector actually injects the fuel into the engine, the ineffective injection pulse width being given as a function of a time lag in operation of said injector,

wherein said injector controller is designed to perform (a) an injection pulse width changing function to change the injection pulse width from a smaller value at which said injector is insensitive to the injection pulse signal to produce no spray of the fuel to a greater value at which said injector is sensitive to the injection pulse signal to spray the fuel actually, (b) a pressure amplitude measuring function to measure an amplitude of pulsations of pressure of the fuel within said common rail a given period of time after the injection pulse signal, as changed in the injection pulse width by said injection pulse width changing function, is outputted to said injector, and (c) an ineffective injection pulse width determining function to determine the ineffective injection pulse width based on the injection pulse width, as having been changed by said injection pulse width changing function and outputted to said injector when the amplitude measured by said pressure amplitude measuring function has exceeded a preselected level.

2. An accumulator fuel injection system as set forth in claim 1, wherein said injector controller is designed to perform a multi-injection mode in which a main injection of the fuel into the engine is made and a pre-injection of fuel into the engine is made before the main injection, said injector controller outputting a main injection pulse signal to said injector to initiate the main injection and a pre-injection pulse signal to said injector to initiate the pre-injection, said injector controller performing an injection pulse width setting function to set an injection pulse width that is a width of the main injection pulse signal to a value causing the engine to produce torque required to maintain running of the engine, and wherein the injection pulse width changing function works to change the injection pulse width of the pre-injection pulse signal.

3. An accumulator fuel injection system as set forth in claim 2, wherein said injection pulse width setting function works to determine the injection pulse width of the main injection pulse signal to lie within a period of time during which the pulsations of pressure of the fuel within said common rail appear.

4. An accumulator fuel injection system as set forth in claim 1, wherein said injector includes a valve member, a fuel sump, a control chamber, a valve urging member, and a solenoid valve, the valve member working to open or close a spray hole through which the fuel is sprayed into a combustion chamber of the engine, the fuel sump having the fuel supplied from said common rail act on the valve member in a valve open direction to open the spray hole, the control chamber having the fuel supplied from said common rail act on the valve member in valve closing direction to close the spray hole, the valve urging member working to urge the valve member in the valve-closing direction, the solenoid valve working to drain the fuel, which is supplied from said common rail to the control chamber, to a lower-pressure side of a fuel system to move the valve member in the valve open direction.

5. An accumulator fuel injection system for an internal combustion engine comprising:

a common rail working to accumulate fuel at a given pressure;

an injector which injects the fuel supplied from said common rail to an internal combustion engine; and

an injector controller working to output an injection pulse signal to actuate said injector, said injector controller determining a required injection quantity as a function of a given operating condition of the engine to define an effective injection pulse width and adding the effective injection pulse width to an ineffective injection pulse width to determine an injection pulse width that is a width of the injection pulse signal, the effective injection pulse width defining a duration for which the injector actually injects the fuel into the engine, the ineffective injection pulse width being given as a function of a time lag in operation of said injector,

wherein said injector controller is designed to perform (a) an injection pulse width changing function to change the injection pulse width from a greater value at which said injector is sensitive to the injection pulse signal to spray the fuel actually to a smaller value at which said injector is insensitive to the injection pulse signal to produce no spray of the fuel, (b) a pressure amplitude measuring function to measure an amplitude of pulsations of pressure of the fuel within said common rail a given period of time after the injection pulse signal, as changed in the injection pulse width by said injection pulse width changing function, is outputted to said injector, and (c) an ineffective injection pulse width determining function to determine, as the ineffective injection pulse width, the injection pulse width, as having been changed by said injection pulse width changing function and outputted to said injector, when the amplitude measured by said pressure amplitude measuring function has dropped below a preselected level.

6. An accumulator fuel injection system as set forth in claim 5, wherein said injector controller is designed to perform a multi-injection mode in which a main injection of the fuel into the engine is made, and a pre-injection of fuel into the engine is made before the main injection, said injector controller outputting a main injection pulse signal to said injector to initiate the main injection and a pre-injection pulse signal to said injector to initiate the pre-injection, said injector controller performing an injection pulse width setting function to set an injection pulse width that is a width of the main injection pulse signal to a value causing the engine to produce torque required to maintain running of the engine, and wherein the injection pulse width changing function works to change the injection pulse width of the pre-injection pulse signal.

7. An accumulator fuel injection system as set forth in claim 6, wherein said injection pulse width setting function works to determine the injection pulse width of the main injection pulse signal to lie within a period of time during which the pulsations of pressure of the fuel within said common rail appear.

8. An accumulator fuel injection system as set forth in claim 5, wherein said injector includes a valve member, a fuel sump, a control chamber, a valve urging member, and a solenoid valve, the valve member working to open or close a spray hole through which the fuel is sprayed into a combustion chamber of the engine, the fuel sump having the fuel supplied from said common rail act on the valve member in a valve open direction to open the spray hole, the control chamber having the fuel supplied from said common rail act on the valve member in valve closing direction to close the spray hole, the valve urging member working to urge the valve member in the valve-closing direction, the solenoid valve working to drain the fuel, which is supplied from said common rail to the control chamber, to a lower-pressure side of a fuel system to move the valve member in the valve open direction.

9. An accumulator fuel injection system for an internal combustion engine comprising:

a common rail working to accumulate fuel at a given pressure;

an injector which injects the fuel supplied from said common rail to an internal combustion engine; and

an injector controller working to output injection pulse signals to actuate said injector, said injector controller determining a required injection quantity as a function of a given operating condition of the engine to define an effective injection pulse width and adding the effective injection pulse width to an ineffective injection pulse width to determine an injection pulse width that is a width of each of the injection pulse signals, the effective injection pulse width defining a duration for which the injector actually injects the fuel into the engine, the ineffective injection pulse width being given as a function of a time lag in operation of said injector,

wherein said injector controller is designed to perform (a) a multi-injection function in each operation cycle of a cylinder of the engine to perform a multi-injection mode in which a main injection of the fuel into the engine is made and a pre-injection of fuel into the engine is made before the main injection and to output one of the injection pulse signals as a main injection pulse signal to said injector to initiate the main injection and one of the injection pulse signals as a pre-injection pulse signal to said injector to initiate the pre-injection, (b) an injection pulse width setting function to set a main injection pulse width that is a width of the main injection pulse signal to a value causing the engine to produce torque required to maintain running of the engine, (c) an injection pulse width changing function to change a pre-injection pulse width that is a width of the pre-injection pulse signal from a smaller value at which said injector is insensitive to the pre-injection pulse signal to produce no spray of the fuel to a greater value at which said injector is sensitive to the pre-injection pulse signal to spray the fuel actually, (d) an engine operation variation measuring function to measure a preselected engine operation variation within a given period of time after the pre-injection pulse signal, as changed in the pre-injection pulse width by said injection pulse width changing function, is outputted to said injector, and (e) an ineffective injection pulse width determining function to determine the ineffective injection pulse width based on the pre-injection pulse width, as having been changed by said injection pulse width changing function and outputted to said injector when the engine operation variation, as measured by the engine operation variation measuring function, has reached a preselected value.

10. An accumulator fuel injection system as set forth in claim 9, wherein said injector controller also works to perform an interval determining function to determine a non-injection interval between the pre-injection and the main injection so that the non-injection interval lie within a period of time during which pulsations of pressure of the fuel within said common rail appear.

11. An accumulator fuel injection system as set forth in claim 9, wherein the engine operation variation measuring function, as performed by said injector controller, works to measure instantaneous speeds of a piston of the cylinder of the engine when the pre-injection pulse signal, as changed in the pre-injection pulse width by the injection pulse width changing function, has been outputted to said injector, but said injector has produced no spray of the fuel and when the pre-injection pulse signal, as changed in the pre-injection pulse width by the injection pulse width changing function, has been outputted to said injector, and said injector has produced a spray of the fuel actually, and wherein the engine operation variation measuring function works to determine a difference between the instantaneous speeds measured by the engine operation variation measuring function as the engine operation variation.

12. An accumulator fuel injection system as set forth in claim 9, wherein said injector includes a valve member, a fuel sump, a control chamber, a valve urging member, and a solenoid valve, the valve member working to open or close a spray hole through which the fuel is sprayed into a combustion chamber of the engine, the fuel sump having the fuel supplied from said common rail act on the valve member in a valve open direction to open the spray hole, the control chamber having the fuel supplied from said common rail act on the valve member in valve closing direction to close the spray hole, the valve urging member working to urge the valve member in the valve-closing direction, the solenoid valve working to drain the fuel, which is supplied from said common rail to the control chamber, to a lower-pressure side of a fuel system to move the valve member in the valve open direction.

13. An accumulator fuel injection system for an internal combustion engine comprising:

a common rail working to accumulate fuel at a given pressure;

an injector which injects the fuel supplied from said common rail to an internal combustion engine; and

an injector controller working to output injection pulse signals to actuate said injector, said injector controller determining a required injection quantity as a function of a given operating condition of the engine to define an effective injection pulse width and adding the effective injection pulse width to an ineffective injection pulse width to determine an injection pulse width that is a width of each of the injection pulse signals, the effective injection pulse width defining a duration for which the injector actually injects the fuel into the engine, the ineffective injection pulse width being given as a function of a time lag in operation of said injector,

wherein said injector controller is designed to perform (a) a multi-injection function in each operation cycle of a cylinder of the engine to perform a multi-injection mode in which a main injection of the fuel into the engine is made and a pre-injection of fuel into the engine is made before the main injection and to output one of the injection pulse signals as a main injection pulse signal to said injector to initiate the main injection and one of the injection pulse signals as a pre-injection pulse signal to said injector to initiate the pre-injection, (b) an injection pulse width setting function to set a main injection pulse width that is a width of the main injection pulse signal to a value causing the engine to produce torque required to maintain running of the engine, (c) an injection pulse width changing function to change a pre-injection pulse width that is a width of the pre-injection pulse signal from a greater value at which said injector is sensitive to the pre-injection pulse signal to spray the fuel actually to a smaller value at which said injector is insensitive to the pre-injection pulse signal to produce no spray of the fuel, (d) an engine operation variation measuring function to measure a preselected engine operation variation within a given period of time after the pre-injection pulse signal, as changed in the pre-injection pulse width by said injection pulse width changing function, is outputted to said injector, and (e) an ineffective injection pulse width determining function to determine the ineffective injection pulse width based on the pre-injection pulse width, as having been changed by said injection pulse width changing function and outputted to said injector when the engine operation variation, as measured by the engine operation variation measuring function, has reached a preselected value.

14. An accumulator fuel injection system as set forth in claim 13, wherein said injector controller also works to perform an interval determining function to determine a non-injection interval between the pre-injection and the main injection so that the non-injection interval lie within a period of time during which pulsations of pressure of the fuel within said common rail appear.

15. An accumulator fuel injection system as set forth in claim 13, wherein the engine operation variation measuring function, as performed by said injector controller, works to measure instantaneous speeds of a piston of the cylinder of the engine when the pre-injection pulse signal, as changed in the pre-injection pulse width by the injection pulse width changing function, has been outputted to said injector, but said injector has produced no spray of the fuel and when the pre-injection pulse signal, as changed in the pre-injection pulse width by the injection pulse width changing function, has been outputted to said injector, and said injector has produced a spray of the fuel actually, and wherein the engine operation variation measuring function works to determine a difference between the instantaneous speeds measured by the engine operation variation measuring function as the engine operation variation.

16. An accumulator fuel injection system as set forth in claim 13, wherein said injector includes a valve member, a fuel sump, a control chamber, a valve urging member, and a solenoid valve, the valve member working to open or close a spray hole through which the fuel is sprayed into a combustion chamber of the engine, the fuel sump having the fuel supplied from said common rail act on the valve member in a valve open direction to open the spray hole, the control chamber having the fuel supplied from said common rail act on the valve member in valve closing direction to close the spray hole, the valve urging member working to urge the valve member in the valve-closing direction, the solenoid valve working to drain the fuel, which is supplied from said common rail to the control chamber, to a lower-pressure side of a fuel system to move the valve member in the valve open direction.