System and methods for electronic control of an accumulator fuel system

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of referencel;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• startup activation means for generating a repeated series of said pump control signals to activate at least one of said first and second pumping chambers to pressurize the accumulator during engine startup, prior to a time when said engine position sensor means begins to provide an accurate indication of engine angular position;
• and
• control means including memory means for storing a program, and a micrprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for;
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator,
• wherein said microprocessor receives said position signals at standard intervals during rotation of the engine and, depending on the angular position of the engine at each said interval, selectively actuates (1) a valve timer function for generating said solenoid valve control signal after a programmed elapsed time and (2) a pumping timer function for generating one of said pump control signals after a programmed elapsed time.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times upon activation of an electrically controlled solenoid valve, through a distributor and a rate shaping means positioned between said electrically controlled solenoid valve and said individual combustion chambers for dynamically varying the pressure of fuel delivered to the combustion chamber during an injection event, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator;
• and
• rate shaping control means associated with the control means and connected to said rate shaping means, for generating control signals to dynamically vary the pressure of fuel delivered to the combustion chamber during an injection event.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• back EMF detection means connected to said solenoid valve actuating means for electrically detecting initiation and cessation of mechanical movement of the solenoid valve based on driving current flow to the solenoid valve;
• and
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, said back EMF detection means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal, comprising multiple level boost means for selectively providing one of three voltage levels to a coil of the solenoid valve:
• a first level which is provided upon receipt of the valve control signal;
• a second level lower than said first level which is substituted for said first level prior to the opening of the valve, with said second level established at a voltage which does not saturate the coil, and a third level lower than said second level which is substituted for said second level after opening of the solenoid valve to hold said solenoid valve in an open position;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• and
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers upon activation of an electrically controlled solenoid valve at selected times, through a distributor and a plurality of fuel lines between the distributor and the individual combustion chambers at least two of which have different lengths, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator, and storing a value associated with each combustion chamber varying with fuel line length between the distributor and that combustion chamber, and varying the valve control signal to compensate for the different fuel line lengths.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal, and further comprising pre-bias means for selectively providing one of two current levels to a coil of the solenoid valve:
• a first current level less than a pull-in current of the solenoid valve which is applied to the coil during a time immediately prior to an anticipated activation of said solenoid valve, and a second current level equal to or greater than the pull-in current which is applied to the coil in response to the valve control signal indicating that fuel injection is desired;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• and
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator.

An integrated electronic control system for an internal combustion engine fuel injection system in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator;
• and
• pump operation monitoring means connected to the control means for storing at least one previous measured accumulator pressure value associated with one of said first and second pumping chambers and comparing said previous value to a current accumulator pressure value associated with the other of said first and second pumping chambers, and providing an indication if the difference between said current and previous values exceeds a predetermined stored value.

An integrated electronic control system for an internal combustion engine fuel injection system driving a fixed load in which at least first and second pumping chambers selectively supply fuel to a high pressure accumulator, and in which fuel flows from the high pressure accumulator to individual combustion chambers at selected times through a distributor upon activation of an electrically controlled solenoid valve, comprising:

• engine position sensor means for generating a position signal indicating the angular position of engine rotation relative to a point of reference;
• accumulator pressure sensor means for generating a pressure signal indicative of fuel pressure in said high pressure accumulator;
• pressure transfer actuating means for selectively enabling the supply of fuel to said high pressure accumulator from said first and second pumping chambers, respectively, in response to pump control signals;
• solenoid valve actuating means for opening said electrically controlled solenoid valve in response to a valve control signal;
• a control line connected to said solenoid valve actuating means for carrying said valve control signal;
• control means including memory means for storing a program, and a microprocessor having electrical inputs and outputs and connected to said memory means to read and execute said program, with said control means connected to said engine position sensor means, said accumulator pressure sensor means, said pressure transfer actuating means, and through said control line to said solenoid valve actuating means, for:
• monitoring said engine rotation angular position and monitoring said accumulator pressure synchronously with said angular position and selectively generating a plurality of said solenoid valve control signals for a plurality of the combustion chambers respectively and transmitting said plurality of solenoid valve control signals over said control line at calculated times synchronous with said angular position when injection of fuel into one of the combustion chambers is required, and selectively generating a plurality of said pump control signals synchronously with said angular position to maintain a desired pressure range in said accumulator;
• speed control means associated with the control means for varying fueling levels to maintain a constant engine speed in response to application and removal of the fixed engine load;
• operator input means connected to the control means for receiving an indication that the fixed load is being applied;
• and
• load event response means associated with the control means for electronically increasing fueling levels to the engine in response to the indication that the fixed load is being applied.