DE102022119512A1 - Fuel injection control systems and methods - Google Patents

Abstract

A multi-fuel injector assembly in one embodiment includes a first fuel injector assembly to deliver a first fuel type and a second fuel delivery system to deliver a second fuel type. The first fuel injector includes a first nozzle, at least one first needle, and at least one first actuator configured to move the at least one first needle. The at least one first actuator moves the at least one first needle into a first fueling configuration corresponding to a first fuel mixture composition and into a second fueling configuration corresponding to a second fuel mixture composition.

Description

BACKGROUND

This application is a continuation in part of that filed on April 10, 2019 U.S. Patent Application No. 16/380,727 entitled "Systems and Methods for Fuel Injector Control" and claims priority thereto, which in turn is a follow-up to those filed on June 29, 2016 U.S. Patent Application No. 15/197,038 entitled "Systems and Methods for Fuel Injector Control" and claims priority thereto. The entire contents of application 15/197,038 and application 16/380,727 are hereby incorporated herein by reference in their entirety.

BACKGROUND

Engines, such as internal combustion engines, may use a piston that reciprocates within a cylinder. In various direct injection engines, a fuel-air mixture can be ignited for combustion by a spark, by diesel pilot injection, or by another ignition source (e.g., laser, plasma, etc.). However, the initial rate at which fuel energy is released in the cylinder may be faster than desired, resulting in a high rate of pressure rise that, due to structural limitations (e.g., peak cylinder pressure limit), may act to limit engine operation for high loads.

SHORT DESCRIPTION

In one embodiment, a fuel injector assembly is provided that includes a nozzle, at least one needle, and at least one actuator. The nozzle includes at least one cavity in fluid communication with nozzle orifices. The at least one needle is movably arranged within the at least one cavity and, in a closed position, prevents flow through the nozzle openings. The at least one actuator is configured to move the at least one needle within the cavity. The at least one actuator is configured to move the at least one needle into at least a first fueling configuration and a second fueling configuration (e.g., at different times of a combustion cycle). A first amount of fuel is delivered through the nozzle orifices (eg, at a first fuel delivery rate) with the at least one needle in the first fuel delivery configuration, and a second amount of fuel is delivered through the nozzle orifices with the at least one needle in the second fuel delivery configuration (e.g., at a second fuel delivery rate). .

In another embodiment, a method is provided that includes moving at least one needle in at least one cavity of a nozzle with at least one actuator from a closed position to a first fuel delivery configuration to deliver a first fuel amount (e.g., at a first fuel delivery rate) in the first fuel delivery configuration to deliver through openings of the nozzle to a cylinder. Fluid is prevented from flowing through the openings of a nozzle in the closed position. The method also includes moving the at least one needle within the at least one cavity with the at least one actuator from the first fueling configuration to a second fueling configuration to deliver a second amount of fuel at a second fueling rate through the openings.

In another embodiment, an engine system is provided that includes a cylinder of an engine, a fuel injection assembly, and at least one processor. The fuel injector assembly is configured to deliver fuel to the cylinder and includes a nozzle, at least one needle, and at least one actuator. The nozzle includes at least one cavity in fluid communication with nozzle orifices. The at least one needle is movably arranged within the at least one cavity and, in a closed position, prevents flow through the nozzle openings. The at least one actuator is configured to move the at least one needle within the cavity. The at least one actuator is configured to move the at least one needle into at least a first fueling configuration and a second fueling configuration. (It should be noted that additional fueling configurations may be used in various embodiments.) A first amount of fuel is delivered through the nozzle openings at a first fueling rate with the at least one needle in the first fueling configuration, and a second amount of fuel is delivered through the nozzle openings at a second fueling rate being delivered with the at least one needle in the second fuel delivery configuration. The at least one processor is operatively coupled to the at least one actuator and configured to control the actuator to move the at least one needle between the closed position, the first fueling configuration, and the second fueling configuration.

character list

• 1 1 is a schematic block diagram of an engine system according to various embodiments.
• 2A illustrates a fuel injector assembly of FIG 1 in a closed position.
• 2 B illustrates the fuel injector assembly of FIG 1 in a first fueling configuration.
• 2C illustrates the fuel injector assembly of FIG 1 in a second fueling configuration.
• 3 12 illustrates a top view of a fuel injector assembly according to various embodiments.
• 4A 12 illustrates a fuel injector assembly in a closed position according to various embodiments.
• 4B illustrates the fuel injector assembly of FIG 4A in a first fueling configuration.
• 4C illustrates the fuel injector assembly of FIG 4A-B in a second fueling configuration.
• 5A 12 illustrates a fuel injector assembly in a closed position according to various embodiments.
• 5B illustrates the fuel injector assembly of FIG 5A in a first fueling configuration.
• 5C illustrates the fuel injector assembly of FIG 5A-B in a second fueling configuration.
• 6A 12 illustrates a fuel injector assembly in a closed position according to various embodiments.
• 6B illustrates the fuel injector assembly of FIG 6A in a first fueling configuration.
• 6C illustrates the fuel injector assembly of FIG 6A-B in a second fueling configuration.
• 7 FIG. 1 provides a flowchart of a method of operating an engine according to various embodiments.
• 8th 12 is a schematic block diagram of a multi-fuel injector assembly according to various embodiments.
• 9 1 is a schematic block diagram of an engine system according to various embodiments.
• 10 FIG. 1 provides a flowchart of a method of operating an engine according to various embodiments.

DETAILED DESCRIPTION

Various embodiments will be better understood when read in conjunction with the accompanying drawings. To the extent that the figures depict functional block diagrams of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuits. Thus, for example, one or more of the functional blocks (e.g., processors, controllers, or memory) may be implemented in a single piece of hardware (e.g., general purpose signal processor or random access memory, hard disk, or the like) or multiple pieces of hardware. Likewise, any programs can be independent programs, can be integrated into an operating system as subroutines, can be functions in an installed software package and the like. It goes without saying that the various embodiments are not limited to the arrangements and means shown in the drawings.

As used herein, the terms "system," "device," or "module" can include a hardware and/or software system that operates to perform one or more functions. For example, a module, unit, or system may include a computer processor, controller, or other logic-based device that performs operations based on instructions stored on a tangible and non-transitory computer-readable storage medium, such as computer memory. Alternatively, a module, unit, or system may include a hardwired device that performs operations based on hardwired logic of the device. The modules or units shown in the accompanying figures may represent the hardware operating based on software or hard-wired instructions, the software directing the hardware to perform the operations, or a combination thereof. The hardware may include electronic circuitry that includes and/or is coupled to one or more logic-based devices such as microprocessors, processors, controllers, or the like. These devices may be commercially available devices suitably programmed or instructed to perform operations described herein from the instructions described above. Additionally or alternatively, one or more of these devices may be hardwired to logic circuitry to perform these operations.

As used herein, an element or step named in the singular and preceded by the word "a" or "an" should be understood to mean the plural of elements or does not exclude steps, unless such exclusion is expressly stated. Furthermore, references to "one embodiment" should not be construed as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, unless expressly stated otherwise, embodiments that "comprise" or "have" an element or plurality of elements having a particular property may contain additional such elements that do not have that property.

In general, for example, various embodiments provide for shaping the rate at which the energy of a fuel is released in one or more cylinders of an internal combustion engine by controlling the rate at which the mass of fuel is injected directly through one or more fuel injectors. Various combinations of needles, cavities, and actuators are used in various embodiments to provide two or more fuel delivery configurations (e.g., a first fuel delivery configuration to deliver fuel in a lesser amount or at a lower rate, and a second fuel delivery configuration to deliver fuel at a greater quantity or at a higher rate). In various embodiments, a first fueling configuration is used to provide a smaller amount of fuel during an initial phase of an injection event to maintain the amount of energy released and the corresponding pressure rise rates within desirable operating levels consistent with engine speed and load. Additionally, in various embodiments, the injection rate is modified throughout the injection event to achieve, for example, better combustion phasing, controlling the rate of pressure rise, and optimizing overall engine performance and emissions.

At least one technical effect of various embodiments includes improved control of pressure rise rates and peak cylinder pressures. At least one technical effect of various embodiments includes improved combustion phasing, engine performance, and/or emissions levels. At least one technical effect of various embodiments includes simplifying structural requirements by enabling similar or better engine performance at lower cylinder pressures. At least one technical effect of various embodiments includes improved reliability and durability, and/or reduced life cycle costs (e.g., due to engine operation at lower cylinder pressures and/or pressure rise rates). At least one technical effect of various embodiments includes reduced emissions (eg, due to improved combustion phasing and/or reduced cylinder pressure).

1 1 is a schematic block diagram of an engine system 100 configured in accordance with various embodiments. As in 1 1, the engine system 100 depicted includes a cylinder 110, a processing unit 120, and a fuel injector assembly 130. In general, the fuel injector assembly 130 provides fuel to the cylinder 110 for combustion to provide work output to the crankshaft (via rotating the crankshaft 190). In the illustrated embodiment, an intake flow 101 of air is provided to a combustion chamber 112 of the cylinder 110 via an intake valve 102 and combusted along with fuel from the fuel injector assembly 130 . After combustion, an exhaust stream 103 is evacuated from the combustion chamber 112 via an exhaust valve 104 . Combustion in combustion chamber 112 produces mechanical work that reciprocally drives a piston 114 to rotate crankshaft 190 . The fuel injector assembly 130 includes a nozzle 140 through which fuel nozzles 105 deliver fuel into the combustion chamber 112 with the amount of fuel being controlled by movement of an actuator 160 of the fuel injector assembly 130 . As used herein, an amount of fuel provided or delivered to the combustion chamber 112 may be understood as a fueling rate or a volume or mass of fuel per unit time. In general, the processing unit 120 controls various aspects of the engine system 100 to control the amount of fuel and air provided to the combustion chamber 112 and the timing of providing fuel and air to the combustion chamber 112 . For example, the illustrated processing unit 120 transmits control or drive signals to control the actuator 160 to synchronize the delivery of fuel(s) with intake valve 102 and exhaust valve 104 movements. It should be noted that various embodiments may or may not include additional components (e.g., additional cylinders or other engine components). 1 may include components shown. It should also be noted that certain aspects of the system 100 described in 1 shown as separate blocks, may be incorporated into a single physical entity, and/or aspects incorporated into 1 shown as a single block may be divided or shared by two or more physical entities. It should be noted that in dual-fuel engines, part of the fuel can be supplied with an intake air charge.

The fuel injector assembly 130 discussed herein is configured to deliver fuel to the cylinder 110 . 2A-2C provide an enlarged view of the fuel injector assembly 130 in various fuel delivery configurations - 2A illustrates the fuel injector assembly 130 in a closed position 210, 2 B illustrates the fuel injector assembly 130 in a first fuel delivery configuration 220, and 2C 12 illustrates fuel injector assembly 130 in a second fueling configuration 230. As shown in FIGS 1 , 2A , 2 B and 2C 1, the fuel injector assembly 130 depicted includes the nozzle 140, a needle 150, and the actuator 160. While in FIGS 1 , 2A , 2 B and 2C While only a single nozzle, needle, cavity, and actuator are illustrated, it should be understood that two or more nozzles, needles, cavities, and/or actuators may be used in various embodiments as discussed herein.

How best in the 2A , 2 B and 2C As can be seen, the nozzle 140 includes a cavity 142 and nozzle openings 144. The needle 150 is movably disposed within the cavity 142 with the needle 150 in the closed position 210 (see FIG 2A) flow through the nozzle openings 144 is prevented. The actuator 160 moves the needle 150 within the cavity 142. For example, in the illustrated embodiment, the actuator 160 can be used to move the needle 150 to the first fuel delivery configuration 220 (see FIG 2 B) and the second fueling configuration 230 (see 2C ) to move. It should also be pointed out here that the 2A-C The specific example shown is illustrative and includes only a single needle and actuator for the sake of clarity; however, multiple needles and/or cavities and/or actuators may be used in various embodiments, with different needle positions or configurations for one or more needles defining the first and second fuel delivery configurations. Further, in various embodiments, additional fueling configurations beyond the first and second fueling configurations may be used. In general, the first fueling configuration 220 is used to provide fuel at a relatively lower rate during the beginning of combustion and the second fueling configuration 230 is used to provide fuel at a relatively higher rate later during combustion. In various embodiments, a first quantity of fuel is delivered through nozzle openings 144 with fuel injector nozzle assembly 130 (e.g., needle 150 and/or other needles) in first fuel delivery configuration 220, and a second quantity of fuel is delivered along with the first quantity of fuel through nozzle openings 144 with fuel injector nozzle assembly 130 (eg, needle 150 and/or other needles) in second fueling configuration 230. For example, in some embodiments, the first fuel delivery configuration 220 may define a first fuel path (in 2B-2C not shown, see eg 5 and related discussion), and the second fueling configuration 230 may define a second fuel path (in 2 B - 2C not shown, see eg 5 and related discussion). In the first fueling configuration 220, fuel is only delivered along the first fuel path and not the second fuel path, while in the second fueling configuration 230, fuel is delivered along both the first fuel path and the second fuel path. (See e.g 5 and the related discussion.)

Like for example in 2A As can be seen, the needle 150 is fully inserted into the cavity 142 and obstructs the nozzle openings 144 in the closed position 210. A spring or other mechanism may be used to urge the needle 150 toward the closed position 210, with a force is required from actuator 160 to move needle 150 from closed position 210 . In 2 B At this point, the actuator 160 has moved the needle away from the bottom of the cavity 142 allowing a first quantity of fuel 290 to flow through the nozzle openings 144 . For example, the first amount of fuel 290 may be selected to provide a desired amount of fuel at the beginning of a combustion cycle. In 2C When the actuator 160 moves the needle 150 further away from the bottom of the cavity 142 , an additional second quantity of fuel 292 can flow through the nozzle openings 144 in addition to the first quantity of fuel 290 . It may be noted that in various embodiments, additional nozzle openings 144 may be used to allow the second amount of fuel 292 to flow in addition to the first amount of fuel 290 in the second fueling configuration 230 . (See e.g 5 and related discussion.) Additionally or alternatively, one or more additional needles and/or cavities may be used to enable the additional second quantity of fuel 292 .

Various modifications or alternative arrangements to the illustrated example of FIG 1 and 2A-C be used. At for example, more than one jet per cylinder may be used, with a first jet providing the first quantity 290 and a second jet providing the second quantity 292. As another example, more than one cavity can be used per nozzle and/or more than one needle can be used per cavity. In addition, more than one actuator can be used to move a corresponding needle (or needles). It may be noted that in some embodiments, the first fueling configuration 220 and/or the second fueling configuration 230 may define a fixed or single position that defines a fixed amount of fuel, while in other embodiments they include a series of positions to provide a variable or adjustable one Allow fuel quantity in one or more fuel delivery configurations. It should be noted that in various embodiments, a given actuator may be shared by or between two or more needles, or may be dedicated to a single needle. Additionally, in some embodiments, more than one actuator may be used for a given needle. Actuator 160 may include, for example, one or more solenoid or piezoelectric actuators along with associated components.

As discussed herein, different needle/cavity/actuator combinations may be used to provide different fueling configurations (eg, first fueling configuration 220 and second fueling configuration 230), with each fueling configuration delivering a different amount of fuel to cylinder 210 . For example, multiple cavities and multiple actuators are used in some embodiments. 3 FIG. 3 illustrates a top view of aspects of a fuel injector assembly 300 according to various embodiments. One or more of the example aspects of fuel injector assembly 300 depicted may be used, for example, in connection with FIG 1 and 2A-C discussed fuel injector assembly 130 can be used. As in 3 1, fuel injector assembly 300 includes a nozzle 310 having multiple cavities (first cavity 320, second cavity 322, third cavity 324, fourth cavity 326) along with a plurality of corresponding needles (first needle 330, second needle 332, third needle 334, fourth needle 336) and multiple corresponding actuators (first actuator 340, second actuator 342, third actuator 344, fourth actuator 346). It should be noted that the cavities 320, 322, 324, 326 are shown in a single nozzle 310 in the illustrated example; however, in various embodiments, one or more of the cavities 320, 322, 324, 326 may be located in a dedicated single cavity nozzle. The actuators 340, 342, 346, 348 in the illustrated embodiment are illustrated as solenoid coils disposed radially around at least a portion of a needle to be moved by a given solenoid. It should be noted that the in 3 The particular arrangement shown is meant to be exemplary for purposes of illustration and that other arrangements may be used in various embodiments. For example, a diesel injector may be positioned at the center of nozzle 310 in dual fuel embodiments.

In the illustrated embodiment, each needle is movably disposed within a respective cavity and configured to be moved by a respective actuator. As in 3 As can be seen, the first needle 330 is disposed in the first cavity 320 and is moved by the first actuator 340; the second needle 332 is disposed in the second cavity 322 and is moved by the second actuator 342; the third needle 334 is disposed in the third cavity 324 and is moved by the third actuator 344; and the fourth needle 336 is disposed in the fourth cavity 326 and is moved by the fourth actuator 346 . As discussed herein, a first quantity of fuel is delivered through the nozzle openings (e.g., nozzle openings 144) with fuel injector assembly 300 in a first fuel delivery configuration (e.g., first fuel delivery configuration 220), and a second quantity of fuel is delivered through the nozzle openings (e.g., nozzle openings 144) with fuel injector nozzle assembly 300 in a second fueling configuration (eg, second fueling configuration 230). Specifically, for the fuel injector assembly 300 depicted, the first fueling configuration includes opening a first group 350 of needles (and only opening first group 350), and the second fueling configuration includes first group 350 along with a second group 352 of needles that be opened. For the illustrated example, the first group 350 includes the first needle 340 and the third needle 344 , while the second group 352 includes the second needle 342 and the fourth needle 346 . Accordingly, the first group 350 contains two needles (first needle 340 and third needle 344) arranged symmetrically to each other (e.g. noon and 6 o'clock positions viewed from above), and the second group 352 contains two needles (second needle 342 and fourth needle 346) disposed symmetrically to each other (eg, at 3 o'clock and 9 o'clock positions viewed from above). In some embodiments, the second group 352 may have a relatively larger amount of fuel than the first Provide group 350 such that an initial amount of fuel provided by first group 350 is less than half of the total amount (eg, 10%) provided later in a combustion cycle. It may also be noted that an additional cavity, needle, and actuator (eg, in the center of nozzle 310) may be provided for use for diesel fuel injection in dual fuel embodiments.

It can be appreciated that other numbers, configurations, or combinations of needles to mold groups can be used in different embodiments. For example, one or more clusters can be formed with a single needle. As another example, more than two groups may be employed in some embodiments. Additionally, different needle positions (e.g., an intermediate position for a first fueling configuration and a fully open position for a second fueling configuration) for a given needle(s) may be employed in different embodiments. For example, in the above example, the first needle 340 and third needle 344 may be shifted to an intermediate position for the first fuel delivery configuration, while for the second fuel delivery configuration, the first needle 340 and third needle 344 may be shifted to a more open position than that If the intermediate position is shifted, the second group 352 (the second needle 342 and fourth needle 346) are also shifted to an open position. In the illustrated embodiment, each needle has its own dedicated actuator; however, it may be noted that in various embodiments, an actuator may be shared between two or more needles in the same group (where a group of actuators includes actuators that all bring open or close together), and/or one or more needles may be of be opened or closed by more than one actuator.

Other needle/lumen/actuator arrangements may be used in various embodiments. As an example, more than one actuator may be used to move a particular needle, using a first actuator to place the needle in the first fuel delivery configuration, and a combination of two or more actuators (e.g., the first actuator together with one or more additional actuators) that positions the needle in the second configuration of fuel delivery. The 4a-c provide schematic views of a fuel injector assembly 400 in various fuel supply configurations - 4A shows the fuel injector assembly 400 in a closed position 410, 4b 4 shows the fuel injector assembly 400 in a first fuel cut-off configuration 420 and 4C shows the fuel injector assembly 400 in a second configuration of the fuel supply 430. One or more of the illustrated example aspects of the fuel injector assembly 400 can, for example, in connection with the in connection with the 1 and 2A-C discussed fuel injector assembly 130 can be used. As in the 4a-c As can be seen, the fuel injector assembly 400 includes a first coil 440 and a second coil 442 around a common needle 450. The common needle 450 is disposed in a nozzle 460 having a cavity 462 in fluid communication with nozzle openings 464. Activation of the first coil 440 places the common needle 450 in the first fuel cutoff configuration 420 (to allow an initial amount of fuel to begin combustion) and activation of the second coil 442 along with the first coil 440 places the common needle 450 in the second fueling configuration 430 ( to allow an additional amount of fuel in addition to the initial amount). It may be appreciated that in some embodiments activation of the second coil 442 without activation of the first coil 440 may be used to place the common needle 450 in the second fueling 430 configuration or in another fuel delivery configuration.

As in 4a As can be seen, with the fuel injector assembly 400 in the closed position 410, the nozzle openings 464 are closed to fluid flow from a fuel source, and a reservoir 490 in fluid communication with the nozzle openings 464 has no fuel. In 4b the common needle 450 with the first coil 440 is activated (e.g., current allowed to flow through the first coil 440) in a partially open or partially raised position (which may also be referred to as partial flow), and the fuel injector assembly 400 is in the first Configuration of the fuel supply 420 placed. In the first configuration of the fuel supply 420, the nozzle openings 464 are open to flow, the volume of the reservoir 490 is increased relative to the volume of the reservoir 490 in the closed position 410, and liquid is in the reservoir 490 for delivery via the nozzle openings 464 available. In 4c with the first coil 440 and the second coil 442 activated (e.g. current allowed to flow through the first coil 440 and the second coil 442), the common needle 450 is in a fully open or maximum lift position (also referred to as maximum flow). may be used), and the fuel injector assembly 400 becomes the fuel in the second configuration supply 430 placed. In the second configuration of the fuel supply 430, the nozzle openings 464 are open to flow. The volume of reservoir 490 is increased relative to the volume of reservoir 490 in the first configuration of fuel supply 420 and liquid is present in reservoir 490 for delivery via nozzle openings 464 . It may be noted that in various embodiments associated with any of the figures discussed herein, one or more reservoirs discussed herein may have a different volume of liquid and/or different fuel types for each of the different fuel delivery configurations. The flow range provided by a particular configuration helps determine the injection rate and the time spent in an open state (along with the injection rate) determines the amount of fuel delivered. Pressure (rail or delivery pressure) also affects injection rate.

It can be appreciated that other arrangements can be used in alternative embodiments. For example, in some embodiments, only the first coil may be used to place the needle in the first fueling configuration and only the second coil may be used to place the needle in the second fueling configuration. As another example, more than two coils may be used to provide more than two fuel delivery configurations. Additionally, in some embodiments, three fueling configurations may be provided with two coils - namely, a first fueling configuration with only the first coil activated, a second fueling configuration with only the second coil activated, and a third fueling configuration with active and second coils activated.

It may further be noted that in various embodiments some nozzle openings may be closed in one configuration of fuel delivery for liquid flow, and opened in another configuration of fuel delivery for liquid flow. The 5A-C provide schematic views of a fuel injector assembly 500 in various fuel delivery configurations - 5A shows the fuel injector assembly 500 in a closed position 510, 5B 5 shows the fuel injector assembly 500 in a first fuel cut-off configuration 520, and 5c 12 shows fuel injector assembly 500 in a second configuration of fuel supply 530. One or more of the illustrated example aspects of fuel injector assembly 500 may be used, for example, in connection with FIG 1 and 2A-C discussed fuel injection assembly and / or in connection with the 4a-c discussed fuel injector assembly 400 can be used. The fuel injector assembly 500 includes a first coil and a second coil (not included in Figs 5a-c shown, see 4A-C for an example of first and second coils) placed around a common needle 550. The common needle 550 is disposed in a nozzle 560 having a cavity 562 in fluid communication with nozzle openings 564 . The nozzle orifices 564 include a first set 566 of the nozzle orifices and a second set 568 of the nozzle orifices, the first set 566 being positioned closer to a lower end 569 of the nozzle 560 than the second set 568. Activation of the first coil places the common needle 550 in the first fuel delivery configuration 520 (to allow an initial amount of fuel to begin combustion), and activation of the second coil along with the first coil places the common needle 550 in the second fuel delivery configuration 530 (to allow an additional amount of fuel in addition to the initial amount ). As in the 5B and 5c As can be seen, the first set 566 of nozzle orifices but not the second set 568 of nozzle orifices are open in the first fuel delivery configuration 520, and the first set 566 of nozzle orifices and the second 568 of nozzle orifices are in the second fuel delivery configuration 530 open. Accordingly, a first fuel delivery path may include the first set 566 of nozzle openings, while a second fuel delivery path may include both the first set 566 and the second set 568 of nozzle openings.

As in 5a As can be seen, the nozzle openings 564 (both the first set 566 and the second section 568) are closed with the fuel injection assembly 500 in the closed position 510 for liquid flow from a fuel source, and a reservoir 590 in liquid communication with the nozzle openings 564 has no fuel. In 5b With the first coil activated (e.g. current allowed to flow through the first coil) or the first fuel cutoff configuration 520 otherwise achieved, the common needle 550 is in a partially open or partially raised position (also referred to as partial flow may be used), and the fuel injector assembly 500 is placed in the first configuration of the fuel system 520 . In the first configuration of the fuel supply 520, with the needle 550 partially raised but still positioned distally below the second set 568 of nozzle orifices, the first set 566 of nozzle orifices (but not the second set 568) is opened to flow, the volume of the reservoir 590 is increased relative to the volume of the reservoir 590 in the closed position 510, and fluid is present in the reservoir 590 for delivery via the first set 566 of nozzle orifices. In 5c , with the first coil and the second coil activated (e.g. current allowed to flow through the first coil and the second coil) or the second fuel delivery configuration 530 otherwise achieved, the common needle 550 is in a fully open or maximum lift position (which also may be referred to as maximum flow) and the fuel injector assembly 500 is placed in the second fuel supply 530 configuration. In the second configuration of the fuel supply 530, with the needle 550 fully raised or distal above the second set 568 of nozzle orifices in 5c As can be seen, the nozzle openings 564 of the first set 566 and the second set 568 are open to flow, the volume of the reservoir 590 is increased relative to the volume of the reservoir 590 in the first configuration of the fuel supply 520, and fluid is in the reservoir 590 for delivery via the nozzle openings 564 of the first set 566 and the second set 568.

As another example of needle/lumen/actuator arrangements that can be used in various embodiments, more than one needle can be used in conjunction with a lumen. The 6A-C provide schematic views of a fuel injector assembly 600 in various configurations for fuel delivery - 6A shows the fuel injector assembly 600 in a closed position 610, 6b 6 shows the fuel injector assembly 600 in a first fuel delivery configuration 620, and 6c 12 shows fuel injector assembly 600 in a second fuel configuration 630. One or more of the illustrated example aspects of fuel injector assembly 600 may be used, for example, in the context of FIG 1 and 2A-C discussed fuel injector assembly 130 can be used. As in the 6a-c As can be seen, the fuel injector assembly 600 includes an outer needle 640 and an inner needle 642 that has been placed within a cavity 650 . Outer needle 640 is movably disposed within lumen 650 and inner needle 642 is movably disposed within outer needle 640 and lumen 650 . A distal tip 643 of inner needle 642 extends distally beyond a distal tip 641 of outer needle 640. While the actuators are not shown in the illustrated embodiment for clarity of illustration, it may be noted that the illustrated inner needle 642 and outer needle 640 can be moved to their respective closed positions by two separate actuators (e.g. each needle has an individual coil dedicated thereby) or by an actuator with one or two coils with different energy strategies.

The cavity 650 includes a first needle hub 652 that accepts the inner needle 642 when the inner needle 642 is closed (eg, as seen in FIG. 6A). In the closed position, the inner needle 642 prevents liquid delivery to a combustion chamber via the first nozzle openings 660. When the inner needle 642 is raised or opened from the first needle seat 652 (e.g., as shown in FIGS 6b and 6c 2), fuel is allowed to flow through the first nozzle openings 660. The cavity 650 also includes a second needle hub 654 that accepts the outer needle 640 when the outer needle 640 is in a closed position (e.g., as shown in FIGS 6A and 6b) . In the closed position, the outer needle 640 prevents liquid delivery to a combustion chamber via the second nozzle orifice 662. When the outer needle 640 is lifted or opened from the second needle seat 654 (e.g., as in FIG 6c 2), the fuel is allowed to flow through the second nozzle openings 662.

In the closed position 610 (as in 6a) Both the outer needle 640 and the inner needle 642 are closed, preventing fuel from being discharged through both the first nozzle openings 660 and the second nozzle openings. When the fuel injector assembly 600 is placed in the first configuration of the fuel system 620 as shown in FIG 6b As can be seen, the outer needle 640 remains closed, but the inner needle 642 is lifted off the first needle seat 652, allowing flow through the first nozzle openings 660 but not the second nozzle openings 662, thereby delivering a first quantity of fuel (eg an initial amount to start combustion). When the fuel injector assembly 600 is placed in the second configuration of the fuel system 630 as shown in FIG 6c As can be seen, the outer needle 640 is lifted from the second needle seat 654, allowing flow through the second nozzle openings 662, and the inner needle 642 is lifted from the first needle seat 652, allowing flow through the first nozzle openings 660 as well as the second nozzle openings 662, whereby a second amount of fuel (via the second nozzle openings 662) can be delivered along with the first amount of fuel (via the first nozzle openings 660).

In the illustrated embodiment, only one of the inner needle 642 and the outer Needle 640 open (in 6b the inner needle 642 is opened), and the other is (in 6b , the outer needle 640) is closed in the first configuration of the fuel supply 620, and both the inner needle 642 and the outer needle 640 are open in the second configuration of the fuel supply 630 (see FIG 6c ). Other arrangements or combinations can be used in different embodiments. For example, in some embodiments, the first configuration of fuel delivery may be achieved by raising the outer needle while leaving the inner needle closed. In various embodiments, in various embodiments, one or both of the inner and outer needles may be shifted to an intermediate position as part of the first fuel delivery configuration, with both the inner and outer needles being fully open in the second fuel delivery configuration. Accordingly, in various embodiments, a first fuel path may be defined with one of the open and the other of the inner needle and the other closed, and a second fuel path may be defined with both the inner and outer needles. Additionally, either or both inner or outer needles may have intermediate positions and/or continuous adjustment to provide additional fueling configurations (eg, more than two fueling configurations) and/or to enhance control or adjustability of the amount of fuel delivered.

Referring again to 1 the processing unit 120 of the illustrated embodiment is configured to control various aspects of the system 100, including the actuator 160 (e.g., to control the positioning of one or more needles 150 to bring the fuel injector assembly 130 into a desired fueling configuration at a desired time). . Processing unit 120 provides control signals for one or more aspects of system 100 . For example, the processing unit 120 controls activation and deactivation of the actuator 160. In various embodiments, the processing unit 120 controls the actuator to perform or provide different movements of one or more needles to or between fueling configurations. The movements to or from fueling configurations (eg timing of using fueling configurations in relation to combustion events) in various embodiments are controlled by the processing unit 120 to provide a desired fueling rate shaping. In some embodiments, processing unit 120 controls one or more actuators to move needles between a range of available positions for a given fueling configuration (or configurations) for more precise control and/or adjustment. The processing unit 120 receives feedback from one or more sensors (eg, sensor 170) configured to detect one or more parameters of the system 100 in various embodiments.

For example, in the illustrated embodiment, sensor 170 is operably coupled to processing unit 120 . The sensor 170 depicted is in fluid communication with the exhaust flow 103 from the cylinder 112, but may be located at other locations. For example, sensor 170 may additionally or alternatively communicate with one or more of the combustion chamber, fuel injector, or fuel system. In various embodiments, more than one sensor can be used. In the example depicted, sensor 170 may detect or determine (or provide information from which one or more parameter values are determined) the temperature of an exhaust gas (e.g., temperature entering an aftertreatment device) or the presence or amount of one or more materials in exhaust stream 130 can become). For example, sensor 170 may be one or more of a pressure sensor (eg, a cylinder pressure sensor and/or a fuel rail pressure sensor), a power sensor, a torque sensor, a speed sensor, a crank angle position sensor, a needle lift sensor, a temperature sensor, a strain gauge, a knock sensor, a NOx sensor, an oxygen sensor, a soot sensor, a particle sensor (PM) or a (unburned or partially burned) hydrocarbon sensor, among others. It should be noted that a combination of one or more of the above (or other) sensors may be used in various embodiments. The processing unit 120 is configured to perform at least one of moving the needle 150 (and/or other needles) to a first fueling configuration or moving the needle 150 (and/or other needles) to a second fueling configuration based on feedback received from the sensor 170 is provided to control. Movement of a given needle can be accomplished by controlling or adjusting the timing of a start of movement of the needle relative to a burn event (e.g., start of burn), controlling or adjusting a speed of movement of the needle, and/or controlling or adjusting the amount of time that the needle is at a given position can be controlled. Such precisely executed control of the needle be displacement can be used to provide a desired fuel injection rate into the engine cylinder (referred to as "injection rate shaping").

It should be noted that different types of movements to or between fueling configurations can be used. For example, moving needle 150 (and/or other needles) to the first fueling configuration (as well as moving needle 150 and/or other needles to a closed position) and/or the second fueling configuration may involve moving needle 150 (and/or other needles) in a series of steps. As another example, the needle 150 (and/or other needles) can be continuously moved (e.g., using a continuously variable/controllable solenoid actuator). As another example, moving needle 150 (and/or other needles) to the first fueling configuration, and/or the second fueling configuration (as well as moving needle 150 and/or other needles to a closed position) may involve moving needle 150 (and/or other spikes) in a series of discrete pulses (e.g. periods of movement between periods of stationary positioning).

The illustrated processing unit 120 includes processing circuitry configured to perform one or more tasks, functions, or steps discussed herein. The processing unit 120 of the illustrated embodiment is configured to perform one or more aspects discussed in connection with the methods or process flows disclosed herein. It should be noted that "processing unit" as used herein is not necessarily intended to be limited to a single processor or computer. For example, in various embodiments, the processing unit 120 may include multiple processors and/or computers that may be integrated into a common chassis or unit or that may be distributed across different units or chassis. It should be noted that operations performed by processing unit 120 (e.g., operations corresponding to process flows or methods discussed herein, or aspects thereof) may be sufficiently complex that the operations may not be possible for a human to perform within a reasonable time (e.g., sufficiently accurately, accurately and/or carried out repeatedly).

In the illustrated embodiment, processing unit 120 includes memory 122. Additionally, it should be appreciated that other types, numbers, or combinations of modules may be used in alternative embodiments. In general, the various aspects of processing unit 120 act individually or cooperatively with other aspects to perform one or more aspects of the methods, steps, or processes discussed herein. Memory 122 includes one or more computer-readable storage media. Furthermore, in various embodiments, the process flows and/or flowcharts (or aspects thereof) discussed herein represent one or more sets of instructions stored in memory 122 for directing operations of system 100 .

7 7 provides a flow diagram of a method 700 for operating an engine (eg, a reciprocating internal combustion engine) according to various embodiments. In various embodiments, the method 700 uses, for example, structures or aspects of various embodiments (eg, systems and/or methods) discussed herein. In various embodiments, certain steps may be omitted or added, certain steps may be combined, certain steps may be performed concurrently, certain steps may be performed concurrently, certain steps may be broken into multiple steps, certain steps may be performed in a different order, or specific steps or a series of steps may be repeated iteratively. In various embodiments, portions, aspects, and/or variations of method 700 are used as one or more algorithms to instruct hardware to perform operations described herein. In various embodiments, one or more processors (eg, processing unit 120) use portions, aspects, and/or variations of method 700 as one or more engine control algorithms.

At 702, an engine is started. In the illustrated embodiment, the engine is a fuel injected reciprocating internal combustion engine. In some embodiments, the engine may be a compression ignition engine (e.g., using diesel fuel at least at the beginning of a combustion cycle), while in other embodiments the engine may be a spark-ignition engine, while in still other embodiments the engine may use other ignition sources such as lasers, plasma, or other ignition sources to initiate combustion in the engine cylinder. In various embodiments, the engine may use one or more of gasoline, diesel, or natural gas (liquid and/or gas). In the illustrated example, the engine includes a cylinder with at least one fuel injector A sensor assembly configured to deliver fuel to the cylinder, the fuel injector assembly including at least one actuator configured to move at least one needle to open and close the fuel injector and to move the fuel injector to or between different fuel delivery configurations, to deliver variable amounts of fuel. For example, the illustrated method 700 may be used to provide rate shaping of fueling such that an initial amount of fuel provided at the beginning of combustion is less than a later amount of fuel provided later during combustion. It may be noted that the method 700 may be used to continuously control and/or vary the timing rate of injection of either a first fuel or a second fuel or both the first and second fuels, allowing a wide range of flexibility for the Rate shaping of the injection of fuels is provided.

At 704, at least one needle in at least one cavity of the engine is moved from a closed position (where fluid is prevented from flowing through orifices of a nozzle and fuel is not supplied) to a first fueling configuration. In the first fuel delivery configuration, a first amount of fuel is delivered through openings of the nozzle. The first amount in various embodiments is an amount configured for use at the beginning of combustion. The at least one needle is moved with at least one actuator, such as a solenoid coil, under the control of at least one processor (e.g., processing unit 120). In various embodiments, different cavity/needle/actuator combinations, as well as different numbers of fuel injector assemblies, may be used to provide the first fuel delivery configuration (as well as other fuel delivery configurations).

For example, at 706, in some embodiments, the at least one cavity includes multiple cavities, the at least one needle includes multiple corresponding needles, and the at least one actuator includes multiple corresponding actuators. Each needle is movably disposed in a respective cavity. To move the at least one needle to the first fueling configuration, a first set of needles is opened.

As another example, at 708 the at least one actuator includes a first coil and a second coil disposed about a common needle. Moving the at least one needle to the first fueling configuration includes activating the first spool to place the common needle to the first fueling configuration.

As another example, the at least one needle at 710 includes an outer needle and an inner needle, where the inner needle is movably disposed within the outer needle (e.g., at least a portion of the inner needle is radially surrounded by the outer needle). Moving the at least one needle to the first fueling configuration includes opening only one of the inner needle and the outer needle (e.g., opening the inner needle with a first solenoid coil while leaving the outer needle closed).

At 712, fuel is delivered with the fuel injection assembly (or assemblies) in the first fueling configuration. Fuel may be delivered from the first fuel delivery configuration at and/or near the start of combustion. In some embodiments, fuel may be delivered from the first fuel delivery configuration during an intake phase of a combustion cycle during which a piston is depressed and air is delivered to a combustion chamber of the cylinder. In some embodiments, fuel may be delivered simultaneously with one or more fuel injectors moving to or from a position of the first fueling configuration and/or at different positions of a series of positions of the first fueling configuration, for example to provide adjustability.

At 714, the at least one needle is moved within the at least one cavity of the engine from the first fueling configuration to a second fueling configuration. In the second fuel delivery configuration, a second amount of fuel is delivered along with the first amount of fuel through the orifices of the nozzle. The first amount and the second amount, in various embodiments, provide a combined amount configured for later use in combustion that is greater than the first amount provided by the first fueling configuration. The at least one needle is moved from the first fueling configuration with at least one actuator, which may include one or more actuators used in moving from the closed position to the first fueling configuration and/or one or more other actuators. In some embodiments, the nozzle includes a first set of nozzle orifices and a second set of nozzle orifices. The first sentence, but not that second set of nozzle openings may be open to flow in the first fuel delivery configuration while first and second set of nozzle openings are open to flow in the second fuel delivery configuration.

For example, at 716 in some embodiments (e.g., embodiments for which step 706 was performed), the at least one cavity includes multiple cavities, the at least one needle includes multiple corresponding needles, and the at least one actuator includes multiple corresponding actuators. Each needle is movably disposed in a respective cavity. To move the at least one needle into the second fueling configuration, a second group of needles is opened along with the first group of needles opened at 706 .

As another example, at 718 in some embodiments (e.g., embodiments for which step 708 was performed), the at least one actuator includes a first coil and a second coil disposed about a common needle. Moving the at least one needle to the second fueling configuration includes activating the second spool along with the first spool to place the common needle to the second fueling configuration. It should be noted that in some embodiments the first spool may be deactivated and the second spool activated to provide the second fueling configuration.

As another example, at 720 in some embodiments (e.g., embodiments for which step 710 was performed), the at least one needle includes an outer needle and an inner needle, wherein the inner needle is movably disposed within the outer needle (e.g., at least a portion is of the inner needle radially surrounded by the outer needle). Moving the at least one needle to the second fueling configuration includes opening both the inner needle and the outer needle (e.g., opening the outer needle with a second solenoid coil while leaving the inner needle open from step 710). It should be noted that in alternate embodiments, only one needle may be opened to achieve the second fueling condition. For example, a needle opened at 710 may be closed and another needle opened (e.g., at 710 an inner needle is opened while an outer needle is closed, and at 720 an outer needle is opened while an inner needle is closed). In some embodiments, two needles can be used to provide three configurations - a configuration in which only a first of the two needles is open, a second configuration in which only a second of the two needles is open, and a third configuration in which both needles are open. It may further be noted that when two pins are opened, they may be opened sequentially (e.g. a first pin opened and then a second pin opened without temporal overlap of the opening of the individual pins) or may be opened concurrently or concurrently (e.g. with partial or complete temporal overlap of the opening time of the individual needles).

At 722, fuel is delivered from the second fueling configuration. Fuel may be delivered from the second fuel delivery configuration after ignition. Because the second fueling configuration provides a second amount of fuel in addition to the first amount of fuel, more fuel is delivered (and/or a fueling rate is increased) at 722 than at 712. In some embodiments, fuel may be delivered concurrently with one or more fuel injectors located at or from one position of the second fueling configuration (e.g., during transition from the first fueling configuration to the second fueling configuration) and/or at different positions of a series of positions of the second fueling configuration, for example to provide adjustability. It should be noted that in some embodiments, movement to or from either the first fueling configuration and/or the second fueling configuration may be accomplished in a series of steps or, as another example, in a series of discrete pulses. It may be further noted that in various embodiments, the fuel may be liquid and gaseous at various different times, and the method 700 may be used to control the rate shaping differently for each liquid and gaseous mode of operation. Additionally, it may be noted that in various embodiments, the amount of fuel delivered at one or more fueling configurations may be modified by adjusting a position of one or more needles while in the given fueling configuration. Accordingly, adjustments to fuel quantity or fueling rate may be controlled to, for example, achieve better combustion phasing, control pressure rise rate, and/or optimize overall engine performance and emissions.

At 724, one or more characteristics or aspects of engine operation are sensed using one or more sensors. In According to various embodiments, one or more parameters are sensed to confirm, retune, or reconfigure movement of one or more needles at 704 and/or 714 . For example, in some embodiments, one or more characteristics of an exhaust flow from the engine are sensed using a sensor. For example, feedback from the sensor may be used to control movement of the at least one needle toward the first fueling configuration and/or the second fueling configuration. For example, based on the one or more sensed characteristics (e.g., pressure/temperature/flow of the exhaust stream, torque, instantaneous power generated, knock sensor output, constituents of the exhaust (such as NOx, oxygen, soot, particulate matter, hydrocarbons (unburned or partially burned)) or the like)) the amount of fuel delivered in one or more fueling configurations may be adjusted (eg, as determined by at least one processor such as processing unit 120) to improve performance. It may be noted that, additionally or alternatively, in-cylinder conditions may be sensed, an aspect of operation of one or more fuel injectors may be sensed, and/or an aspect of operation of a fuel system may be sensed. For example, parameters such as fuel rail pressure and/or needle lift may be sensed. In various embodiments, an ECU recommended (or calibration commanded) parameter value may be compared to a sensed parameter value and the difference may be used to drive corrective actions for injector needle movements.

At 726, it is determined whether the engine should remain in operation for additional combustion cycles. If so, method 700 proceeds to 728 where the fuel injector assembly (or assemblies) of the engine are moved to the closed position and the nozzle (or nozzles) of the fuel injector assemblies are closed, for example, after a desired total amount of fuel is released and during an exhaust portion of a combustion cycle. If the engine is to be stopped, method 700 ends at 730.

In some embodiments, fuel injector assemblies disclosed herein may be used in conjunction with multi-fuel systems (e.g., systems that use more than one type of fuel). For example, an internal combustion engine may use a mixture of two types of fuel. Various embodiments disclosed herein provide for precise control and/or alteration of the proportion of two or more fuels used by an internal combustion engine.

For example, is 8th FIG. 8 is a schematic block diagram of a multi-fuel injector assembly 800 configured in accordance with various embodiments. In the illustrated example, the multiple fuel injector assembly is discussed in the context of a dual fuel system that uses two different types of fuels, each associated with a respective fuel injector assembly (or fuel delivery system) configured for use with that particular type of fuel. However, it should be noted that in other embodiments, the multi-fuel injector assembly may use more than two different types of fuels and/or may use more than two fuel injection (or other fuel delivery) arrangements.

in the in 8th In the example illustrated, the multi-fuel injector assembly includes a first fuel injector assembly 810 and a second fuel delivery system 820. The first fuel injector assembly is configured to deliver a first type of fuel and the second fuel delivery system is configured to deliver a second, different type of fuel. The first fuel injector assembly and the second fuel delivery system, in various embodiments, are configured to control the proportion of the first fuel type and the second fuel type, respectively, delivered to a cylinder 801 . For example, the ratio between the first fuel type and the second fuel type may be varied to account for different operating conditions and/or different availability of one or more fuel types. The first fuel injection arrangement and the second fuel delivery arrangement may be controlled by one or more processors (e.g., processing unit 120 operating in conjunction with 1 discussed.)

As in 8th 1, the first fuel injector assembly includes a first nozzle 830, at least one first needle 840, and at least one first actuator 850. In general, in various embodiments, the first fuel injector assembly includes one or more aspects of fuel injector assemblies described in connection with the 1-7 were discussed. For example, the first nozzle in the in 8th In the illustrated embodiment, there is at least one first cavity 832 in fluid communication with first nozzle openings 834. In various embodiments, ver different numbers of first cavities and first nozzle openings can be used. In the illustrated example, a first cavity is shown. In general, the first type of fuel is delivered to a cylinder (either directly or indirectly) via a passage through the first nozzle openings. When the flow through the first nozzle openings is completely blocked, the first type of fuel is not supplied to the cylinder.

in the in 8th illustrated example, only a first needle is shown. However, it should be appreciated that additional first needles may be used in various embodiments. The illustrated first needle is movably disposed within the first cavity. When the first needle is in a closed position of the first fuel injector arrangement, as shown in FIG. 8, flow of the first fuel type through the first nozzle openings is prevented. The first needle is moveable from the closed position to allow a controlled amount of the first fuel type to flow through the first nozzle openings.

The example shown by 8th also shows a first actuator. However, it should be noted that additional actuators may be used in various embodiments. The first actuator depicted is configured to move the at least one first needle within the first cavity. By moving the first needle, the first actuator controls the amount of first fuel provided (eg, over a given period of time) and/or the rate at which the first fuel is provided by the first fuel injector assembly. The first actuator depicted moves the first needle between different positions corresponding to different fuel delivery configurations for the first fuel injector assembly. For example, the first actuator moves the first needle to a first delivery configuration corresponding to a first fuel mixture composition and also to a second fuel delivery configuration corresponding to a second fuel mixture composition. In various embodiments, additional fuel delivery configurations and fuel blend compositions may be used. Each fuel blend composition specifies a certain percentage or proportion of each type of fuel used. For example, in the illustrated example, the first fuel mixture composition may include X% of the first fuel type and (100-X)% of the second fuel type, and the second fuel mixture composition may include Y% of the first fuel type and (100-Y)% of the second fuel type , where X and Y range from 0 to 100 and are different from each other. A first quantity of the first fuel type is delivered through the first nozzle openings with the first needle in the first fuel delivery configuration and a second quantity of the first fuel type is delivered through the first nozzle openings with the first needle in the second fuel delivery configuration. As used herein, an amount of fuel provided or delivered may be understood to include a volumetric amount, a specified amount over time, and/or a specified rate at which fuel is provided.

Various different arrangements and techniques for providing different fuel delivery configurations supported by the first fuel injector assembly of FIG 8th can be used in conjunction with the 1-7 discussed. For example, the first actuator, as well as in more detail in connection with the 4A-4C discussed, include a first coil and a second coil disposed about a common needle, wherein activation of the first coil places the common needle in the first fueling configuration and activation of the coil together with or in place of the first coil places the common needle in placed the second fuel delivery configuration. As another example, as detailed in connection with the 5A-5C discussed, in some embodiments, the first nozzle includes a first set of nozzle orifices and a second set of nozzle orifices. The first set of nozzle openings, but not the second set of nozzle openings, is open to flow in the first fuel delivery configuration, and the first set of nozzle openings and the second set of nozzle openings are open to flow in the second fuel delivery configuration. As another example, the first needle, as more fully described in connection with FIGS 6A-6C will comprise an outer needle and an inner needle movably disposed within the outer needle. Other arrangements may be used in alternative embodiments.

The second fuel delivery system may be arranged generally similar to the first fuel injector assembly (e.g. including aspects discussed in connection with 1-7 discussed) or alternatively may be arranged differently (eg, using various different known conventional fuel injector components and/or assemblies). As another example, in some embodiments, the second fuel delivery system includes one or more carburetors. The second fuel delivery system can deliver fuel directly to the cylinder (e.g. similar to those in 8th illustrated first fuel injection nozzle arrangement) or in other executions tion forms deliver fuel indirectly to the cylinder. In the example illustrated, the second fuel delivery system indirectly delivers fuel to the cylinder by first providing the fuel to an intake assembly 890 . The illustrated intake arrangement receives fuel from the second fuel delivery system and delivers the received fuel to the cylinder along with an intake airflow. The intake assembly, in various embodiments, includes a duct, an intake manifold, and/or an intake port (eg, a port formed in a cylinder head). The second fuel delivery system may deliver the fuel to the intake assembly at different locations. For example, the second fuel delivery system may include a port injector that injects fuel into an intake port of a cylinder. As another example, the second fuel delivery system may include a shared center injector or carburetor used in conjunction with a bank of multiple cylinders. The second fuel delivery system may use an open/close valve in some embodiments or a variable flow continuous flow valve in others. As another example, the second fuel delivery system may vary pressure to control the flow of the second type of fuel.

The second fuel delivery system depicted includes a second nozzle 860, at least one second needle 870, and at least one second actuator 880. The exemplary second fuel delivery system includes a single second nozzle, a single second needle, and a single second actuator. It should be noted that different numbers of one or more components may be used in alternative embodiments. It should also be noted that while the injectors depicted use needles, in other embodiments a poppet or other device may be used to open and close a valve.

The illustrated second nozzle includes at least one second cavity 862 (one is in 8th 8, but additional second cavities may be used in other embodiments) that is in fluid communication with second nozzle openings 864. The second type of fuel is supplied to the cylinder (either directly or indirectly) through the second nozzle openings. For example, in some embodiments, the second nozzle openings are in fluid communication with an inlet arrangement or port, and the second fuel is delivered from the second fuel delivery system to the inlet arrangement or port, where the second fuel is allowed to mix with air before being discharged from the Inlet arrangement is supplied to the cylinder.

The second needle is movably disposed with the second lumen. In 8th the second needle is shown in a closed position of the second fuel delivery system in which the second needle prevents flow through the second nozzle openings. The second needle can be moved to positions other than the closed position to provide a controlled amount of the second fuel type. The second actuator is configured to move the second needle within the second cavity (e.g., move the second needle to a predetermined position to provide a desired amount of the second fuel type and/or move the second needle to the closed position of the second fuel delivery system, to prevent the delivery of the second type of fuel).

In various embodiments, the second fuel delivery system (e.g., second needle position) is controlled in conjunction with the first fuel injector assembly (e.g., first needle position) to provide desired amounts of each type of fuel relative to one another to achieve a desired fuel mixture composition ( e.g., a fuel mixture containing a desired percentage of the first fuel type and a desired percentage of the second fuel type).

Accordingly, as discussed herein, in various embodiments, the multi-fuel injector assembly is controlled to provide different fuel mixtures (e.g., mixtures containing different amounts or proportions of two or more fuels). For example, as also discussed above, the first fuel injector assembly and the second fuel delivery system may be controlled to provide a first fuel mixture composition (including X% of the first fuel type and (100-X)% of the second fuel type), and then controlled (e.g., the first and second actuators are controlled to move the first and second needles, respectively) to provide a second fuel mixture composition (containing Y% of the first fuel type and (100-Y)% of the second fuel type). As indicated above, X and Y range from 0 to 100 and are different from each other.

It should be noted that X or Y can be 0 or 100 in various embodiments. One of the first fuel injector assembly or the second fuel delivery system may be placed in the closed position to provide flow (or 0%) flow different fuel type for different fuel delivery configurations. For example, the composition of the first fuel mixture may be 100% of the first fuel type, with the second fuel delivery system being in the second fuel delivery system closed position when the first fuel injector assembly is in the first fuel delivery configuration corresponding to the first fuel mixture composition. Similarly, the composition of the second fuel mixture may include 100% of the second fuel type when the first fuel injector assembly is in the closed position when the first fuel injector assembly is in the second fueling configuration corresponding to the second fuel mixture composition. In other words, the second fueling configuration of the first fuel injector assembly may be the closed position when the composition of the second fuel mixture is 100% the second fuel type. It may further be noted that the multiple fuel injector assembly may have multiple fuel delivery configurations, each with the second needle in the closed position, each composition being 100% the first fuel type, and only the total amount (or rate) of that delivered first fuel varies between the configurations based on the position of the at least one first needle of the first fuel injector assembly. Similarly, the multiple fuel injector assembly may have multiple fuel delivery configurations with the first needle in the closed position for each, the composition for each being 100% the second fuel type, and only the total amount (or rate) of the second fuel delivered varies between the configurations based on the position of the at least one second needle of the second fuel delivery system. In other fuel delivery configurations, both the first needle and the second needle are removed from their closed positions and a non-zero amount of each fuel type is delivered. The particular fuel mixture composition selected may be selected based on desired engine performance (eg, fuel mixture composition may be varied based on engine speed and/or engine power) and/or available fuel amounts.

In some embodiments, the first fuel type may be used to facilitate ignition. In some embodiments, the first fuel type is diesel fuel. Further, in some embodiments, the second fuel type includes at least one of hydrogen, ethanol, methanol, gasoline, diesel, ammonia, natural gas, or methane.

As discussed above, in some embodiments, both the first fuel injector assembly and the second fuel delivery system deliver fuel directly to a cylinder. In other embodiments, one or both fuel injector assemblies deliver fuel indirectly to a cylinder (eg, via an intake assembly). 9 FIG. 9 illustrates an embodiment of an engine assembly 900 that utilizes fuel that is initially provided to an intake assembly.

As in 9 1, the engine assembly depicted includes a cylinder 910, an intake assembly 920, a first fuel injector assembly 930, and a second fuel delivery system 940. In the illustrated embodiment, the intake assembly includes an intake port into which fuel is injected directly. However, as also discussed above, other fuel delivery modes (eg, carburetion) and/or other fuel delivery locations may be used for the second fuel type. Various aspects of the system of 1 and/or the multiple fuel injector assembly of US Pat 8th can in the motor arrangement of the 9 to be built in. For example, the first fuel injector assembly of 9 all or part of the first fuel injector assembly of 8th include, and the second fuel supply system of 9 may be all or part of the second fuel delivery system 8th contain. In general, the first fuel injector assembly provides a first fuel flow 950 of a first fuel type directly to the cylinder (eg, directly into a combustion chamber 912 of the cylinder), and the second fuel delivery system provides a second fuel flow 960 to the cylinder indirectly via the intake assembly. Combustion in the cylinder is used to provide work (e.g. on a crankshaft). In the illustrated embodiment, an intake flow 970 of air is provided via the intake assembly, where the intake air flow combines with the second flow of fuel to provide a fuel-air mixture 980 that is provided to the combustion chamber of the cylinder (eg, via an intake valve). Injecting fuel into an intake assembly or an aspect thereof (eg, an orifice) allows for the use of lower pressure injectors for the second fuel delivery system in various embodiments.

As in 9 As can be seen, the inlet assembly is operatively in fluid communication with the Cylinder coupled to supply air to the cylinder. In some embodiments, the intake assembly may be formed as or include an orifice formed in the cylinder (eg, in a cylinder head 914 ), with flow from the intake assembly to the combustion chamber being controlled by an intake valve 922 . The first fuel injector assembly configured to deliver a first type of fuel directly to the cylinder is positioned towards an upper portion of the cylinder in the example illustrated. However, it should be noted that the first fuel injector assembly may be positioned elsewhere, such as along one side of the cylinder for embodiments that use opposed pistons in a common cylinder. The second fuel delivery system, configured to deliver a second type of fuel to the intake assembly, is positioned proximate to and in fluid communication with the intake assembly at a location upstream of the cylinder. The first type of fuel, which is supplied directly to the cylinder, is used in various embodiments to facilitate ignition in the combustion chamber and can be, for example, diesel. The second type of fuel provided via the inlet assembly, in various embodiments, includes one or more of hydrogen, ethanol, methanol, gasoline, ammonia, natural gas, or methane. Accordingly, the engine arrangement provides 9 for injecting a first type of fuel for ignition directly into the cylinder and injecting a second type of fuel into the intake assembly for enhanced mixing with air prior to combustion, with accurate and versatile metering of fuel via the fuel injector assemblies.

10 10 provides a flow diagram of a method 1000 for operating an engine (eg, a reciprocating internal combustion engine) according to various embodiments. In various embodiments, the method 1000 uses, for example, structures or aspects of various embodiments (e.g., systems and/or methods, including in connection with 7 method discussed 700) discussed herein. In various embodiments, certain steps may be omitted or added, certain steps may be combined, certain steps may be performed concurrently, certain steps may be performed concurrently, certain steps may be broken into multiple steps, certain steps may be performed in a different order, or certain steps or series of steps can be repeated iteratively. In various embodiments, portions, aspects, and/or variations of method 1000 are used as one or more algorithms to instruct hardware to perform operations described herein. In various embodiments, one or more processors (eg, processing unit 120) use portions, aspects, and/or variations of method 1000 as one or more engine control algorithms. In general, method 1000 is used to provide a first fuel type via a first fuel injector assembly and a second fuel type via a second fuel delivery system. It should be noted that the use of two types of fuel in connection with the in 10 illustrated exemplary method is discussed. However, in other embodiments, additional types of fuels and additional fuel injector assemblies may be used.

At 1002 the engine is started. At 1004, at least a first needle is moved from a closed position to a first fueling configuration corresponding to a first fuel mixture composition. The at least one first needle is moved with at least one first actuator of the first fuel injector assembly and is moved within at least one cavity of a first nozzle. Movement of the at least one first needle to the first fuel delivery configuration facilitates delivery of a first quantity of the first fuel type through first openings of the first nozzle to the cylinder. When the first fuel injector assembly is in the closed position, fluid is restricted from flowing through the first openings.

At or about the same time as the movement of the at least one first needle to the first fuel delivery configuration, the second fuel delivery system is controlled (e.g., a needle of a fuel injector is actuated) at 1006 to provide a first quantity of the second fuel type corresponding to the first fuel mixture composition. when the first fuel injector assembly is in the first fueling configuration. For example, at least one second actuator may move at least a second needle of the second fuel delivery system. Accordingly, in some embodiments, the actuators of the first and second fuel injector assemblies can be used to move respective needles to provide a desired amount of each of the first and second fuel types to provide a desired or target fuel mixture composition having a desired proportion or proportion of each fuel type having. As another example, a carburetor, variable flow valve, and/or pressure supplied to the second fuel delivery system are arranged to be adjusted to provide a different quantity of the second type of fuel.

At 1008, the at least one first needle is moved with the at least one first actuator within the at least one first cavity from the first fueling configuration to a second fueling configuration. The second fueling configuration corresponds to a second fuel mixture composition to deliver a second amount of fuel through the first openings. For example, the at least one first needle may be moved to provide the first fuel type at a lower rate in the second fueling configuration relative to the first fueling configuration. For example, if the first fuel type is used for ignition, a greater relative amount of the first fuel type may be used during an initial warm-up period, or a greater relative amount of the first fuel type may be used during a portion of the engine cycle associated with the ignition of a fuel-air -Mixture in the cylinder corresponds.

At or about the same time as the movement of the at least one first needle to the second fueling configuration of the first fuel injector assembly, at 1010 the second fueling system is controlled to provide a second quantity of the second fuel type corresponding to the second fuel mixture composition when the first fuel injector assembly is in the second fueling configuration. Accordingly, the percentage or proportion of each fuel type in a fuel mixture can be accurately and reliably varied to accommodate different desired performance characteristics and/or different amounts of fuel available.

In some embodiments, the first fuel type and the second fuel type may be initially delivered to different parts of an engine before mixing in a combustion chamber of a cylinder. For example, in the illustrated embodiment, the first fuel type is delivered directly to the cylinder via the first fuel injector assembly and the second fuel type is delivered to an intake assembly via the second fuel delivery system.

As used herein, a structure, boundary, or element that is "configured" to perform a task or operation is specifically structurally shaped, constructed, or adapted in a manner consistent with the task or operation. For the sake of clarity and for the avoidance of doubt, an object that can only be modified to perform the task or operation is not "configured" to perform the task or operation as used herein. Instead, as used herein, the use of "configured for" denotes structural adjustments or properties and denotes structural requirements of any structure, constraint or element described as "configured" to perform the task or operation. For example, a processing unit, processor, or computer that is "configured" to perform a task or operation may be understood to be particularly structured to perform the task or operation (e.g., having one or more stored thereon or any programs or instructions used in connection therewith that are tailored or intended to perform the task or operation and/or with an arrangement of processing circuitry that is tailored or intended to perform the task or operation). For the sake of clarity and for the avoidance of doubt, a general purpose computer (which, if appropriately programmed, can be "configured" to perform the task or operation) is not "configured" to perform any task or operation unless, or until, it specially programmed or structurally modified to perform the task or operation.

It should be noted that the specific arrangement of components (e.g., number, types, placement, or the like) of the illustrated embodiments may be modified in various alternative embodiments. For example, different numbers of a particular module or unit may be used in different embodiments, a different type or types of a particular module or unit may be used, a number of modules or units (or aspects thereof) may be combined, a a specific module or unit may be divided into multiple modules (or sub-modules) or units (or sub-units), one or more aspects of one or more modules may be shared between modules, a specific module or unit may be added or a particular module or unit may be omitted.

It should be noted that the various embodiments can be implemented in hardware, software, or a combination thereof. The various embodiments and/or components, for example the modules or components and controllers therein, may also be part of one or more computers or processors are implemented. The computer or processor may include, for example, a computing device, an input device, a display unit, and an interface for accessing the Internet. The computer or processor may include a microprocessor. The microprocessor can be connected to a communication bus. The computer or processor may also include memory. The memory may include random access memory (RAM) and read only memory (ROM). The computer or processor may further include a storage device, which may be a hard disk drive or a removable storage drive such as a solid state drive, optical drive, and the like. The storage device can also be another similar means for loading computer programs or other instructions into the computer or processor.

As used herein, the terms "computer", "controller" and "module" can each include any processor-based or microprocessor-based system, including systems that use microcontrollers, reduced instruction set computers (RISCs), application specific integrated circuits (ASICs), logic circuits, GPUs, FPGAs and other circuits or processors capable of performing the functions described herein. The above examples are exemplary only and are therefore not intended to limit the definition and/or meaning of the term "module" or "computer" in any way.

The computer, module, or processor executes a set of instructions stored in one or more memory elements to process input data. The storage elements can also store data or other information as desired or needed. The storage element may be in the form of an information source or a physical storage element within a processing machine.

The set of instructions may include various instructions that direct the computer, module, or processor as a processing engine to perform particular operations, such as the methods and processes of the various embodiments described and/or illustrated herein. The instruction set can be in the form of a software program. The software may be in various forms such as system software or application software, and may be embodied in tangible and non-transitory computer-readable media. Furthermore, the software may be in the form of a collection of separate programs or modules, a program module within a larger program, or a portion of a program module. The software may also include modular programming in the form of object-oriented programming. The processing engine may process input data in response to operator commands, or in response to results of previous processing, or in response to a request from another processing engine.

As used herein, the terms "software" and "firmware" are interchangeable and include any computer program stored in memory for execution by a computer, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile memory RAM (NVRAM) memory. The above memory types are only exemplary and therefore do not limit the memory types that can be used to store a computer program. The individual components of the various embodiments may be virtualized and hosted by a cloud-type computing environment, for example, to enable dynamic allocation of computing power without user input to the computer system's location, configuration, and/or specific hardware.

It is to be understood that the above description is intended to be illustrative and not restrictive. For example, the embodiments described above (and/or aspects thereof) may be used in combination with one another. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Dimensions, material types, orientations of the various components, and the number and locations of the various components described herein are intended to define parameters of particular embodiments and are in no way limiting and merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will become apparent to those skilled in the art upon reading the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "including" and "in which" are used as the plain language equivalents of the respective terms "comprising" and "wherein". Furthermore, in the following claims, the terms "first,""second," and "third," etc. are used as labels only and are not intended to impose any numerical requirements on their objects. Furthermore, the Limitations of the following claims are not written in means-plus-function format and are not to be interpreted on the basis of 35 USC §112(f) unless and until such claim limitations expressly include the phrase "means for" followed by a statement of function without use more structure.

This written description uses examples to disclose the various embodiments and also to enable any person of ordinary skill in the art to practice the various embodiments, including making and using any devices or systems and performing any integrated methods. The patentable scope of the various embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or the examples include equivalent structural elements with insubstantial differences from the literal language of the claims.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• US16380727 [0001]
• US15197038 [0001]

Claims (10)

A multi-fuel injector assembly comprising: a first fuel injector assembly configured to deliver a first type of fuel, the first fuel injector assembly comprising: a first nozzle including at least a first cavity in fluid communication with first nozzle openings; at least one first needle movably disposed in the at least one first cavity, the at least one first needle preventing flow through the first nozzle openings in a closed position of the first fuel injector nozzle assembly; and at least one first actuator configured to move the at least one first needle within the first cavity, the at least one first actuator configured to move the at least one first needle into at least one first fuel delivery configuration corresponding to a first fuel mixture composition, and move a second fuel delivery configuration corresponding to a second fuel mixture composition, wherein a first quantity of the first fuel type is delivered through the first nozzle openings with the at least one first needle in the first fuel delivery configuration, and a second quantity of the first fuel type is delivered through the first nozzle openings with the at least delivering a first needle in the second fueling configuration; and a second fuel delivery system configured to deliver a second type of fuel. Multi-fuel injector assembly claim 1 wherein the first fuel injector assembly is configured to inject the first type of fuel directly into a cylinder, and wherein the second fuel delivery system is configured to deliver the second type of fuel into an intake assembly. Multi-fuel injector assembly claim 1 , wherein the first fuel type comprises diesel fuel. Multi-fuel injector assembly claim 1 , wherein the second type of fuel comprises at least one of hydrogen, ethanol, methanol, gasoline, ammonia, natural gas, or methane. Multi-fuel injector assembly claim 1 wherein the first fuel blend composition comprises 100 percent of the first fuel type, and wherein the second fuel delivery system is in the second fuel delivery system closed position when the first fuel injector assembly is in the first fuel delivery configuration. Multi-fuel injector assembly claim 1 wherein the second fuel blend composition comprises 100 percent of the second fuel type, and wherein the first fuel injector assembly is in the first fuel injector assembly closed position when the first fuel injector assembly is in the second fueling configuration. Multi-fuel injector assembly claim 1 wherein the at least one first actuator includes at least a first coil and a second coil disposed about a common needle, wherein activation of the first coil places the common needle in the first fueling configuration and activation of the second coil together with or instead the first coil places the common needle in the second fueling configuration. Multi-fuel injector assembly claim 1 , wherein the first nozzle comprises a first set of nozzle openings and a second set of nozzle openings, wherein the first set of nozzle openings but not the second set of nozzle openings are open to flow in the first fuel delivery configuration, and wherein the first set of nozzle openings and the second set of nozzle openings are open to flow in the second fuel delivery configuration. Multi-fuel injector assembly claim 1 , wherein the at least one first needle comprises an outer needle and an inner needle. wherein the outer needle is movably arranged in a lumen of the at least one first lumen, the inner needle is movably arranged in the outer needle. An engine assembly comprising: a cylinder; an intake assembly operably coupled to the cylinder; a first fuel injector assembly configured to deliver a first fuel type directly to the cylinder, the first fuel injector assembly comprising: a first nozzle including at least a first cavity in fluid communication with first nozzle openings; at least one first needle movably disposed in the at least one first cavity, the at least one first needle preventing flow through the first nozzle openings in a closed position of the first fuel injector nozzle assembly; and at least one first actuator configured to move the at least one first needle within the first cavity, the at least one first actuator configured to move the at least one first needle into at least a first fuel delivery configuration corresponding to a first fuel mixture composition, and a second fuel delivery configuration corresponding to a second fuel mixture composition, wherein a first quantity of the first fuel type is delivered through the first nozzle openings with the at least one first needle in the first fuel delivery configuration, and a second quantity of the first fuel type is delivered through the first nozzle openings with the delivering at least a first needle in the second fueling configuration; and a second fuel delivery system configured to deliver a second type of fuel to the intake assembly.

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