Fuel injector having algorithm controlled look-ahead timing for injector-ignition operation

• US RE45,644 E1
• Filed: 03/12/2013
• Issued: 08/04/2015
• Est. Priority Date: 03/31/2006
• Status: Expired due to Fees

• Current Assignee: EcoMotors, Inc
• Original Assignee: Transonic Combustion, Inc.
• Inventors: Cheiky, Michael C
• Primary Examiner(s): Cronin, Stephen K
• Assistant Examiner(s): Bacon, Anthony L
• Application Number:
  US13/797,196
• Time in Patent Office: 875 Days
• Field of Search: 123/27.R, 123/297, 123/304, 123525-527, 123/538, 123/549, 123/557, 123/558, 123/478, 123/480, 123/670, 701101-106, 239/88, 239/135, 239/136
• US Class Current: 1/1
• CPC Class Codes: F02B 2275/14 Direct injection into combustion chamber
• CPC Class Codes: F02B 23/0624 Swirl flow
• CPC Class Codes: F02B 23/0669 having multiple fuel spray jets per injector nozzle
• CPC Class Codes: F02B 3/06 with compression ignition compression ignition engines using air or gas for blowing fuel into compressed air in cylinder F02B13/02
• CPC Class Codes: F02B 31/00 Modifying induction systems for imparting a rotation to the charge in the cylinder air intakes or induction systems for internal-combustion engines F02M35/10
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02M 27/02 by catalysts
• CPC Class Codes: F02M 51/0671 the armature having an elongated valve body attached thereto
• CPC Class Codes: F02M 53/06 with fuel-heating means, e.g. for vaporising
• CPC Class Codes: F02M 57/00 Fuel-injectors combined or associated with other devices
• CPC Class Codes: F02M 69/047 injectors with air chambers, e.g. communicating with atmosphere for aerating the nozzles F02M69/325 takes precedence
• CPC Class Codes: G06F 16/583 using metadata automatically derived from the content
• CPC Class Codes: G06F 17/30247 based on features automatically derived from the image data pattern recognition G06K9/00
• CPC Class Codes: Y02T 10/123 Fuel injection
• CPC Class Codes: Y02T 10/146 Charge mixing enhancing outside the combustion chamber
• CPC Class Codes: Y02T 10/16 Energy recuperation from low temperature heat sources of the ICE to produce additional power

Abstract

The present invention provides an injector-ignition fuel injection system for an internal combustion engine, comprising an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a next fuel charge, wherein the ECU uses a one firing cycle look-ahead algorithm for controlling fuel injection. The ECU may further incorporate a look-up table, auto-tuning functions and heuristics to compensate for the rapid rotational de-acceleration that occurs near top dead center in lightweight small ultra-high compression engines as may be used with this invention. The ECU may further ramp heat input to the injector in response to engine acceleration requests and, under such circumstances, may extend its look-ahead for up to four firing cycles.

Claims

1. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, the fuel charge comprising a mixture of approximately 65% heptane, 25% cetane, and 10% ethanol by volume and wherein the ECU uses an algorithm for controlling fuel injection.

2. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the fuel charge is catalyzed using a catalyst selected from the group consisting of nickel, nickel-molybdenum, alpha alumina, aluminum silicon dioxide, other air electrode oxygen reduction catalysts, and other catalysts used for hydrocarbon cracking and wherein the ECU uses an algorithm for controlling fuel injection.

3. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm that estimates time to the next firing for controlling fuel injection.

4. The fuel injection system of claim 3, wherein the algorithm comprises a computer software program residing on the ECU, the software program comprising machine readable or interpretable instructions for controlling fuel injection.

5. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm that compares a current throttle input to prior engine data and determines a fuel load and an estimated time to the next firing for controlling fuel injection.

6. The fuel injection system of claim 5, wherein the prior engine data comprises a last throttle input, an engine load, an RPM value, and an air inlet temperature.

7. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, wherein the algorithm adjusts energy input into the fuel injector such that the fuel is heated to a selected temperature more rapidly at higher throttle settings than at lower throttle settings.

8. The fuel injection system of claim 7, wherein the algorithm allows up to four firing cycles of fuel to build up in the hot section to increase fuel heating exposure time during rapid acceleration.

9. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, wherein the ECU includes a supplemental input for receiving fuel mixture information to accommodate a range of fuels and fuel mixtures.

10. The fuel injection system of claim 9, wherein the fuel mixture information is provided using a direct entry scheme at fueling or using an on-board analyzer which samples the fuel on board and communicates engine operating parameters to the ECU.

11. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, and, wherein the ECU utilizes pattern recognition heuristics to fine tune ignition delay drift due to compression braking.

12. The fuel injection system of claim 11, wherein the pattern recognition heuristics provide for the identification of a steady state throttle and load condition.

13. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection;

wherein the heated catalyzed fuel injector comprises;

an input fuel metering system for dispensing a fuel charge into a pressurizing chamber;

a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber in the presence of a catalyst; and

an injector nozzle for injecting the heated catalyzed fuel charge into the combustion chamber of the internal combustion engine, wherein the injector nozzle opens after a pre-determined hold time and the pressurization ram pushes the fuel charge into the combustion chamber such that the pressurization ram reaches a full displacement position.

14. The fuel injection system of claim 13, wherein the pre-determined hold time is back projected from a next top dead center event.

15. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection and wherein a next firing cycle involves retracting the pressurization ram, which allows the input fuel metering system to dispense an aerosol of liquid fuel into the pressurization chamber;

wherein the heated catalyzed fuel injector comprises;

an input fuel metering system for dispensing a fuel charge into a pressurizing chamber;

a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber in the presence of a catalyst; and

an injector nozzle for injecting the heated catalyzed fuel charge into the combustion chamber of the internal combustion engine.

16. The fuel injection system of claim 15, wherein the pressurization ram then pressurizes the fuel in a two step cycle, including protecting the fuel injector while the fuel is heating and vaporizing, and pressurizing the fuel to a target injection pressure and temperature.

17. The fuel injection system of claim 15, wherein the fuel is vaporized to reach the target injection pressure and temperature.

18. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, wherein the algorithm identifies appropriate pre-oxidizer hold time settings in an ECU database based upon a predetermined fuel mixture in use.

19. The fuel injection system of claim 18, wherein the ECU database contains a pre-loaded table spanning a range of fuel octane ratings and oxygenator additives that may be encountered.

20. The fuel injection system of claim 19, wherein the oxygenator additives are selected from the group consisting of MTBE, ethanol, other octane and cetane boosters, and other fuel oxygenator agents.

21. The fuel injection system of claim 19, wherein the ECU continuously tunes its operation over the range of fuel octane ratings by sensing ignition delay.

22. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection and adjusts an injector fire signal to compensate for rapid rotational deceleration that occurs just before top dead center in high compression engines.

23. The fuel injection system of claim 22, wherein the ECU includes an engine look-up table which corrects for engine deceleration over a predetermined operating map including RPM, engine load, and engine load trend.

24. The fuel injection system of claim 23, wherein the engine look-up table is pre-loaded with a learning algorithm to measure the error in predicted top dead center versus actual top dead center for a particular class of engine geometry.

25. The fuel injection system of claim 23, wherein the engine look-up table is dynamically adjusted in operation through use of a learning algorithm which continually adjusts table entries by computing the difference between an injection pin location indicator and an absolute top dead center indicator.

26. The fuel injection system of claim 25, wherein the adjustment is refined using knock sensor input, or using an in cylinder pressure sensor which detects absolute fire position versus top dead center.

27. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, the fuel charge comprising a mixture of approximately 65% heptane, 25% cetane, and 10% ethanol by volume and wherein the ECU uses an algorithm for controlling fuel injection.

28. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, wherein the ECU uses an algorithm that compares a current throttle input to prior engine data and determines a fuel load and an estimated time to the next firing for controlling fuel injection.

29. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, wherein the ECU includes a supplemental input for receiving fuel mixture information to accommodate a range of fuels and fuel mixtures.

30. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection, and, wherein the ECU utilizes pattern recognition heuristics to fine tune ignition delay drift due to compression braking.

31. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection;

wherein the heated fuel injector comprises;

an input fuel metering system for dispensing a fuel charge into a pressurizing chamber;

a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber; and

an injector nozzle for injecting the heated fuel charge into the combustion chamber of the internal combustion engine, wherein the injector nozzle opens after a pre-determined hold time and the pressurization ram pushes the fuel charge into the combustion chamber such that the pressurization ram reaches a full displacement position.

32. An injector-ignition fuel injection system for dispensing fuel into a combustion chamber of an internal combustion engine, the fuel injection system comprising:

an ECU controlling a heated fuel injector for heating a fuel charge, wherein the ECU uses an algorithm for controlling fuel injection and wherein a next firing cycle involves retracting the pressurization ram, which allows the input fuel metering system to dispense an aerosol of liquid fuel into the pressurization chamber;

wherein the heated fuel injector comprises;

an input fuel metering system for dispensing a fuel charge into a pressurizing chamber;

a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber; and

an injector nozzle for injecting the heated fuel charge into the combustion chamber of the internal combustion engine.