1. Field of the Invention
The present invention relates to a fuel-injector for an internal-combustion engine and methods of controlling the fuel-injector, and more particularly to a fuel injection system for a direct fuel-injection engine (also referred to as direct injection engine) which supplies fuel directly into the combustion chamber by use of a fuel-injector (also referred to as injector). The present invention also relates to a control circuit unit for the fuel injection system.
2. Description of the Related Art
With a conventional technique disclosed in JP-A-2000-170629, a voltage applied to a piezoelectric element is controlled so as to change the stroke of an injector valve. Further, swirl generation mechanisms having fuel passages corresponding to each stroke are provided so that different fuel spray shapes are obtained with different swirl mechanisms.
With the above-mentioned conventional technique, a plurality of swirl mechanisms are required in an upstream fuel passage of a sheet section. The problem with this is that the fuel spray shape varies for each injector because of processing error or assembly error of the swirl mechanisms, and this technique is thus not suitable for commercial production.
An object of the present invention is to provide an injector that can change the fuel spray shape according to engine operating conditions and methods for controlling the injector, i.e., an injector having a small number of parts and methods of controlling the injector with little variation in fuel spray shape.
The above-mentioned object of the present invention is attained by an injector of an internal-combustion engine, comprising: at least one fuel injection hole; a sheet surface located on an upstream side of the fuel injection hole; a valve which controls opening and closing of a fuel passage leading to the fuel injection hole by the valve touching and separating from the sheet surface; and an electromagnetic drive unit which operates the valve; wherein the valve is maintained to any desired opening position between a fully-opened position and a fully-closed position at which the valve comes in contact with the sheet surface depending on the magnitude of the power supplied to the electromagnetic drive unit.
Specifically, the above-mentioned object is attained by controlling the time period of power distribution to the electromagnetic drive unit or an electromagnetic solenoid forming the electromagnetic drive unit to control the fuel injection quantity; and at the same time controlling at least either one of the rising slope and the peak value of the power to control at least either one of the penetration, the fuel spray angle, and the fuel spray density of injected fuel.
Further, preferably, the above-mentioned object is attained by the electromagnetic drive unit comprising: an electromagnetic solenoid; a magnetostrictive element whose amount of expansion/contraction varies with electromagnetic force generated by the electromagnetic solenoid; and a displacement transmission mechanism that transmits the displacement of expansion/contraction of the magnetostrictive element to the valve.
In accordance with the present invention having the above-mentioned configuration, it is possible to provide an injector suitable for mass production having a small number of processed parts affecting the fuel spray shape and accordingly little variation in fuel spray shape among injectors. Further, since there is little variation, the variation can be absorbed through control.
The present invention will be explained in detail below with reference to embodiments shown in the accompanying drawings.
The present embodiment is configured based on a fundamental principle shown below.
A change rate (rising slope) or peak value of a supply current applied to an injector using a giant magnetostrictive element as an actuator and a solenoid for magnetic field generation which displaces the giant magnetostrictive element are controlled according to requests of an engine. The steeper the rising slope of the supply current to the solenoid, the higher becomes a lifting speed of a plunger and the initial speed of a fuel spray, and the longer the penetration can be. The gentler the rising slope thereof, the lower becomes the lifting speed of the plunger and the initial speed of the fuel spray, and the shorter the penetration can be. Further, the larger the peak value of the supply current to the solenoid, the larger the lift amount of the plunger can be and the larger becomes the fuel flow rate, allowing an increase in fuel spray density (resulting in a fuel spray that is not easily crushed). The smaller the peak value of the supply current, the smaller becomes the fuel flow rate, allowing a decrease in fuel spray density (resulting in a fuel spray that is easily crushed).
Since the shape of a fuel spray injected can be controlled by changing the rising slope and the peak value of the current waveform which drives the giant magnetostrictive injector, it is possible to inject a fuel spray according to engine operating conditions. This makes it possible to realize various fuel spray shapes according to operation conditions of a direct injection engine, thus improving the exhaust gas performance and fuel efficiency.
An example of a direct injection engine according to the present invention is shown in
An engine 100 comprises a cylinder 101 and a cylinder head 102. An ignition plug 2b is provided at the center of the cylinder head 102 in such a way to protrude into a combustion chamber 103.
A suction passage 4 and an exhaust passage 5 are formed in the cylinder head 102 such that an ignition coil 2 is sandwiched therebetween, each passage being connected to the combustion chamber 103 in the cylinder 101.
A suction valve 8 is provided at a connecting section between the suction passage 4 and the cylinder 103.
An exhaust valve 9 is provided at a connecting section between the exhaust passage 5 and the cylinder 103.
In the cylinder, a piston 3 is arranged so as to perform reciprocating motion with which the volume of the combustion chamber 103 changes.
The fuel injector (hereinafter referred to as injector) 1 is provided in the middle of two suction valves 8 (one is not shown) on the side of the suction passage 4 of the cylinder to inject fuel directly into the combustion chamber 103 in the cylinder 101.
An independent ignition type ignition coil 2 integrated with an igniter 2a is provided in an attachment hole of the ignition plug 2b.
An injector 1 is controlled through a drive circuit 6 based on signals of an engine control unit (ECU) 7.
The ignition coil 2 is controlled through the igniter 2a based on signals of the engine control unit (ECU) 7.
Input into the engine control unit (ECU) 7 are an output signal Qa of an intake air quantity sensor (not shown) provided in the suction passage 4, a signal Ne of an engine rotational speed sensor (not shown) provided in the vicinity of the revolving shaft of the engine, a signal Tw of an engine cooling water temperature sensor (not shown) provided in the cylinder section of the engine, a signal O2 of an air-fuel ratio sensor (O2 sensor, not shown) provided in the exhaust passage 5, and a signal θTH of a throttle opening sensor (not shown) for detecting the opening of a throttle device provided in the suction pipe.
Control signals of the injector 1 and the ignition coil 2 are obtained based on these input signals.
As shown in
The injector is composed of the solenoid 10 for magnetic field generation, the giant magnetostrictive element 11, a plunger 12, a valve opening/closing plunger 13, and an orifice plate 14.
When a fuel injection signal from the ECU 7 is inputted to the injector drive circuit 6 and a drive current is inputted from the injector drive circuit to the injector 1 to be mentioned later in detail, a magnetic field is generated by the solenoid 10 shown in
Since the giant magnetostrictive element 11 rapidly responds to a current change applied to the solenoid 10 for magnetic field generation, it is possible to precisely control the by the lift behavior of the valve opening/closing plunger 13 by use of the current applied to the solenoid 10.
That is, change characteristics of the current flowing in the solenoid almost correspond to response characteristics of the plunger. Therefore it can be said that the response speed of the plunger is dependent on the rising speed of the current.
Further, the stroke of the plunger almost corresponds to the magnitude of the current applied to the solenoid, i.e., the larger the current, the larger becomes the stroke. The smaller the current, the smaller becomes the maintained stroke position.
Therefore, if the magnitude of the current applied to the solenoid is linearly changed, it is possible to linearly change cross-sectional areas A1 and A2 of fuel passages between a valve V and a sheet surface S provided at an end of the plunger 13.
If a current waveform 15 having a steep rising slope as shown in
On the other hand, if a current waveform 16 having a gentle rising slope of
With the above-mentioned methods, the penetration can be controlled by the rising slopes of the supply current applied to the solenoid 10.
When a supply current 17 having a large peak value is applied to the solenoid 10 as shown in
On the other hand, if a supply current 18 having a small peak value is applied to the solenoid 10 as shown in
With the above-mentioned methods, it is possible to control the density (resistance to being crushed) or the fuel spray angle of the fuel spray by the peak values of the supply current applied to the solenoid 10.
The operation region (i) represents an operating condition in which engine rotational speed is high and mixing effect by the piston is strong. Therefore the evaporation rate of the air-fuel mixture can be increased by widely distributing the fuel spray in the cylinder, making it possible to improve output power and fuel efficiency. For this reason, as a supply current applied from the drive circuit 6 to the injector 1, a supply current 19 having a steep rising slope and a large peak value as shown in
In the operation region (ii), it is necessary to inject much fuel at one time in the suction stroke because of homogeneous combustion and high load. However, the engine operates under conditions of weak mixing effect by the piston because of low rotational speeds. Therefore, in the operation region (ii), a supply current 20a having a gentle rising slope and a large peak value as shown in
In the operation region (iii), improved fuel efficiency is realized by performing stratified combustion. In the operation region (iii), for example, fuel injection is split into two: one in the suction stroke and the other in the compression stroke. In this case, the spread of flame is ensured by forming a homogeneous lean premixed air-fuel mixture with suction stroke injection. Further, a dense air-fuel mixture for ignition is formed in the vicinity of the ignition plug with compression stroke injection immediately before ignition. The operation region (iii) represents an operation condition with rotational speeds ranging from high to low. Under the operating condition of low rotational speeds, the mixing effect by the piston is weak. Therefore a current waveform 21a having a gentle rising slope and a middle peak value as shown in
In the operation region (iv), improved combustion is realized by stratified combustion. However, because of a small load, fuel injection quantity is small making it difficult to split injection. Therefore, in the operation region (iv), fuel injection is performed once in the compression stroke, and a dense compact air-fuel mixture is distributed around the ignition plug to realize stratified combustion. Hence, a current waveform 22 having a steep rising slope and a middle peak value as shown in
In the operation region (v), fuel injection is performed once in the suction stroke in order to perform homogeneous combustion with low load and low rotational speed. In the operation region (v), in order to ensure the exhaust performance, a supply current 23a having a gentle rising slope and a middle peak value as shown in
As shown in
Based on a physical phenomenon that displacement characteristics of a giant magnetostrictive element are closely related to a change of a current applied to a solenoid for magnetic field generation which displaces the giant magnetostrictive element, the present embodiment makes it possible to control the penetration, spread angle, and density of the fuel spray injected from an fuel injection hole on a downstream side of a sheet with simple components (a valve and the sheet member) by controlling the valve opening speed or stroke of the injector.
As a result, it has become possible to accurately fine-adjust the shape of the fuel spray injected by the giant magnetostrictive injector according to operating conditions, resulting in a favorable exhaust gas emission and improved fuel efficiency.
The present invention is applicable to a hole nozzle type injector, a plate nozzle type injector, a multi-hole type injector, etc., in addition to a solid fuel spray type injector and an injector with a swirler explained in the embodiments.
Further, the present invention is applicable to piezoelectric element type and magnetostrictive element type injectors and also to a solenoid-driven injector if the response speed is increased by an improved magnetic circuit.
Further, as an internal-combustion engine, the present invention is not influenced by the attachment position of the injector. Therefore, the present invention can be applied to a direct fuel injection engine wherein an injector is provided on a side surface of the cylinder block and the cylinder head and also to a direct fuel injection engine of a center injection type wherein an injector is provided at the top of the cylinder head. Further, the present invention can also be applied to an injector of an internal-combustion engine which injects fuel to a suction port.
Number | Date | Country | Kind |
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2007-048375 | Feb 2007 | JP | national |