The present application relates generally to fuel supply pumps, including methods and systems for controlling a high pressure fuel pump. In some embodiments, the application relates to a pump, a pump arrangement, and methods to reduce noise emitted from a high pressure pump for use with internal combustion engines wherein valve movement is rotational and without reciprocating impact.
Direct-injection engines inject fuel at high pressure directly into the engine's combustion chambers. The fuel may be injected via a common fuel rail. The fuel may be pressurized using a high pressure fuel pump, sometimes referred to as a supply pump. The high pressure fuel pump can be a source of undesired engine noise. In particular, the high pressure fuel pump can produce a ticking noise. Research and test data show that the ticking noise occurs as the pump's magnetic solenoid valve (MSV) opens and closes, resulting in an armature-to-stopper impact at closing, or suction valve-to-seat impact at opening. This impact energy not only excites the pump itself but may also be transmitted to the cylinder head through the pump mount. Furthermore, the energy may also travel to other engine components, e.g. the engine block, oil pan, cam covers, front cover, intake and exhaust manifolds. This may have the effect of amplifying the unwanted noise, making it more noticeable especially during engine idle conditions when these other engine components are relatively quiet.
Attempts have been made to reduce the noise emitted from high pressure fuel supply pumps. For example, US Patent Application #20120000445 to BORG et al. discloses a method and control apparatus for controlling a high-pressure fuel supply pump. The disclosed approach decreases a control current of a normally-closed type solenoid-actuated intake valve so that the movement in the opening direction can be decelerated by means of a biasing force at the time of hitting a mechanical stop at the fully-opened position, thereby reducing the impact noise.
The inventors have recognized several potential issues with these approaches. For example, although this approach may reduce impact it may still be great enough to add to unwanted engine noise. Further, it is believed that the decelerated motion may become less synchronized with the moment of impact as the impacted surfaces age and deform over time, and unwanted noise may consequently increase.
In view of these issues, the inventors have taken an approach that reduces valve-to-valve seat impact and may completely eliminate the impact at pump close and open events. Embodiments in accordance with the present disclosure may comprise a valve arrangement including a rotatable disk configured to separate a fuel supply chamber from a pump chamber. There may be one or more holes through the disk designed to correspond to one or more holes in the valve housing. When the valve is at an open position, the disk holes may be configured to align with the valve housing holes to allow fuel flow from the fuel supply chamber to the pump chamber, and vice versa. Since the disk valve may influence fuel flow by rotation, impact between the disk and the valve housing is avoided. In this way the process may generate significantly less noise, and by eliminating any ticking noises the fuel pump may operate almost silently.
Additional examples as per the present disclosure may include a passage separating first and second chambers of the valve arrangement, such as a wall separating a supply chamber and pump chamber. The rotatable disk may be in a sealing arrangement with the wall, and may have one or more holes corresponding to one or more holes in the wall. Gear teeth may be present on at least part of the disk perimeter capable of meshing with a worm screw or similar driving element. The worm may be actuated by a controller and/or a cam or other mechanism.
These embodiments may incorporate methods of establishing a pressure differential between the fuel supply and pump chamber to influence fuel flow when the disk is aligned to allow fuel to pass through. The pump chamber may include a plunger which increases or decreases pressure within the chamber. By adjusting pressure the plunger may also assist in compressing fuel and/or pushing it towards a combustion chamber.
Methods of operation as described may include a controller, attached to a driving element, triggering rotation of the disk based on pre-selected engine operation conditions. Embodiments driven by a worm gear or similar element may have rotation sequences which are influenced by the positioning of a cam. The cam may be responsive to different engine operation conditions, such as engine fuel and/or fuel pressure demand, and may also influence movement of a plunger within the pump chamber.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
The following description relates to a pump arrangement including a high pressure fuel pump for use with an internal combustion engine systems, and methods of operation of said pump arrangement.
Engine 10 of the vehicle system 100 may include a fuel system 20. Fuel system 20 may include a fuel rail 102, a high pressure (HP) fuel pump or supply pump 104, and fuel injectors 106. Fuel rail 102 may provide a chamber for holding fuel for subsequent injection into cylinders 16 through fuel injectors 106. In the depicted example, the fuel rail 102 may provide pressurized fuel to fuel injectors 106 of the bank 14 along high-pressure injector passages 108. Fuel rail 102 may also include one or more fuel rail pressure sensors/switches 126 for sensing fuel rail pressures (Pfuel
Fuel may be pressurized by high pressure fuel pump 104 and transferred to the fuel rail 102 along high-pressure rail passage 110. In one example, high pressure fuel pump 104 may be driven by the rotation of engine 10, such as by an engine crankshaft and/or an engine camshaft. Alternatively, high pressure fuel pump 104 may be driven by an optional electric motor. The example shown here schematically illustrates a cam 160 in contact with a plunger 162 configured to regulate a pressure inside the fuel pump 104. The coupling of the engine operation to the motion of the plunger 162 is illustrated with a dashed line 164. Alternatively, or in addition to, the coupling 164 of the engine 10 to the plunger 162 and/or cam 160 to the movement of the plunger 162 may be coupled with the controller 12 as illustrated with a dashed line 165. In some cases the plunger 162 may be actuated and/or controlled by other means.
A low pressure feed pump 112 may be configured to draw low-pressure fuel from fuel tank 114 and feed it into supply pump 104 for subsequent pressurization and injection. In one example, fuel tank 114 may include a fuel type sensor (not shown) for determining a type of fuel in the tank. Low pressure fuel drawn by feed pump 112 may be transferred to high pressure fuel pump 104 along low pressure passage 116.
Fuel rail 102 may also be configured to return fuel, and thereby reduce fuel pressure, into low pressure recirculation passage 120 via rail return flow passage 122. A pressure reducing valve at the rail outlet (not shown) may regulate the return flow of fuel from the fuel rail 102 into recirculation passage 120. Similarly, fuel returned from injectors 106 may also be fed into recirculation passage 120 via injector return flow passage 124. High pressure fuel pump 104 may also be configured to return fuel, and thereby reduce fuel pressure into recirculation passage 120 via pump return flow passage 130. A pressure reducing valve at the pump's outlet (not shown) may regulate the return flow of fuel from the supply pump into the recirculation passage 120. As such, the fuel returned from the supply pump 104, injectors 106, and/or rail 102 may hereinafter also be referred to as the return fuel.
The low pressure fuel passage 116 may include a fuel filter 118 that may be located downstream from the fuel tank 114. The low pressure fuel pump 112 may be configured to pull fuel from the fuel tank 114 to direct it through the fuel filter 118 and further direct it towards the high pressure fuel pump 104. In some cases the pump 112 may be located within the fuel tank 114. The fuel filter 118 may also be located upstream from the fuel tank 114.
In some embodiments, a return flow valve may be included at the outlet of the injectors 106 to regulate the flow of injector return fuel into the recirculation passage 120. In alternate embodiments, a throttle may be used to regulate the flow of injector return fuel into the recirculation passage 120. A fuel cooler (not shown) may be optionally included in recirculation passage 120 for cooling the return fuel.
While the depicted example shows a single fuel filter 118, in alternate embodiments two or more filters may be included. Each filter may receive return fuel from respective recirculation branch passages. In one example, flow through each passage may be regulated by respective thermal recirculation valves. A pressure of fuel at the filter may be communicated to the engine controller 12 by a filter pressure sensor/switch (not shown) positioned at the outlet of the filter. Additional sensors, such as a fuel temperature sensor may also be included.
Feed pump 112, low pressure passage 116, recirculation passage 120, return flow passages 122, injector return flow passage 124, pump return flow passage 130, and first fuel filter 118 may constitute a low pressure section of the fuel system 20. Similarly, high pressure fuel pump 104, supply passages 110, high pressure injector passages 108, fuel rails 102, and injectors 106 may constitute a supply section of the fuel system 20. Other components may be included but may not be shown or described here.
Engine controller 12 may be coupled to various sensors and may be configured to receive a variety of sensor signals from said sensors. The sensors may include a vehicle speed sensor, a throttle opening-degree sensor, an engine rotational speed sensor, a battery state of charge sensor, an ignition switch sensor, a brake switch sensor, a gear sensor, and a driver request sensor. These sensors may also include temperature sensors such as an engine coolant temperature sensor, fuel rail temperature sensor 128, fuel rail pressure regulator, intake temperature sensor, and exhaust temperature sensor, in addition to various pressure sensors/switches including a fuel rail pressure sensor/switch 126 and a filter pressure sensor/switch. The engine controller 12 may also be coupled to various actuators of the vehicle system 100 and may be further configured to control the operation of the various actuators, including the fuel injectors 106, high pressure fuel pump 104, and a thermal recirculation valve.
The high pressure fuel pump 104 may include a supply chamber 166 and a pump chamber 168. There may be a passage 170 from the supply chamber 166 to the pump chamber 168. The pump 104 may also include a disk 172 that may have a hole or plurality of holes 174 therethrough. The disk 172 may be rotatable to place the hole or holes 174 in the disk 172 in varying degrees of alignment with the passage 170 to allow respective varying amounts of fuel to flow through the passage 170. The disk 172 may be configured to rotate about an axis 176. The flow of fuel may be from the supply chamber 166 to the pump chamber 168 or from the pump chamber 168 to the supply chamber 166. There may be a wall 178 separating the supply chamber 166 from the pump chamber 168. The passage 170 may be a hole or plurality of holes 170 in the wall 178. The disk 172 may be configured to rotate relative to the wall 178 and may be journaled for rotation on the wall 178. Collectively the wall 178 and the disk 172 may be referred to as a valve 179.
The controller 12 may be configured to control the rotational movement of the disk 172 in accordance with preselected operating conditions of the internal combustion engine 10. The controller 12 may therefore be configured to adjust the degrees of alignment of the hole or holes 174 and the passage 170 in accordance with one or more preselected operation conditions of the engine 10.
The pump 104 may include, or may be coupled with, a one-way valve 180 which may allow fuel to flow in a direction away from the pump chamber 168 during the delivery stroke as indicated by arrow 182. Arrow 182 may also indicate fuel flow towards a combustion chamber (located within cylinder 16 of the internal combustion engine 10 as shown in
The pump arrangement 104 may include, or may be coupled with, a driving element 184 such as a stepper motor, DC motor, brushless DC motor or the like configured to rotate the disk 172. The driving element 184 may be coupled with the disk via a coupling 186 such as a shaft, gear arrangement, or other component. A position sensor 187 may be included to detect the position of the coupling 186, and/or the driving element 184.
As shown previously in
The pump arrangement 104 may include an exit port 181 (
The fuel pump 104 may include a housing 198 which may be configured to enclose one or both of the supply chamber 166 and pump chamber 168 and may be configured to enclose part, or all, of the disk 172 and or part, or all, of the worm 196. For example,
Returning to
As shown in
When receiving a trigger signal, the driving element 184 may rotate the disk 172 to put the valve 179 in open and closed positions. The timing of the trigger signal may be calculated from one or more predetermined positions of the cam 160 and/or may be based on engine fuel, fuel pressure demand, and/or another determination. Similarly, controller 12 may control the triggering and/or timing of the driving element 184 so as to rotate the disk 172. The controller 12 may thereby adjust the degrees of alignment of the holes of the disk 174 and the passage holes 170 in accordance with one or more preselected operation conditions of the engine.
The specific routines described herein may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various actions, operations, or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the features and advantages of the example embodiments described herein, but is provided for ease of illustration and description. One or more of the illustrated actions, functions, or operations may be repeatedly performed depending on the particular strategy being used. Further, the described operations, functions, and/or acts may graphically represent code to be programmed into computer readable storage medium in the control system
Further still, it should be understood that the systems and methods described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are contemplated. Accordingly, the present disclosure includes all novel and non-obvious combinations of the various systems and methods disclosed herein, as well as any and all equivalents thereof.
This application claims priority to U.S. Patent Application No. 61/665,206 filed on Jun. 27, 2012, the entire contents of which are hereby incorporated herein by reference for all purposes.
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Number | Date | Country | |
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20140003966 A1 | Jan 2014 | US |
Number | Date | Country | |
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61665206 | Jun 2012 | US |