Process for Operating a Fuel Injection Device

The invention is based on a method, known from U.S. Pat. No. 5,197,438, for operating a fuel injection system, in which the fuel is fed at high pressure into a high-pressure reservoir whose pressure is controlled by a pressure control valve, and from which fuel is withdrawn for injection via electrically controlled injection valves. In the fuel injection system operated in the known manner, it can happen that the high-pressure fuel reservoir system is no longer intact, which is especially critical, particularly in view of the high injection pressures for injecting fuel in self-igniting internal combustion engines.

Moreover, it can also happen that because of a malfunction the fuel quantity actually delivered to the high-pressure reservoir is not equal to the quantity that is intended for fuel injection and is required for pressure regulation.

With the method according to the invention for operating a fuel injection system of this generic type, it is now possible to ascertain in an exact way whether a malfunction is present in such a known high-pressure system, in particular in the high-pressure portion, such as in the vicinity of the high-pressure reservoir and the fuel injection valve. If a thus-detected malfunction should occur, then advantageously a warning can be given or a suitable intervention into the fuel injection system can be made directly in order to avert further damage.

In an especially advantageous way, and as recited in claim 2, the outflowing fuel required for regulating the fuel pressure in the high-pressure reservoir is detected in terms of its quantity by means of a flow quantity control device. Thus for a known delivery, detected by the quantity control device, of fuel brought to high pressure to the high-pressure fuel reservoir, and when there is a fuel injection quantity via the injection valves that is known from control parameters of the control unit, an exact balance for the delivered and withdrawn fuel is obtained, which now has a deviation only if a malfunction is involved.

Advantageously, a leakage quantity occurring in the high-pressure portion can be detected, and monitored whether the controlled fuel injection quantity in fact matches the actually injected fuel quantity.

In addition, instead of direct measurement of the high-pressure quantity delivered to the high-pressure reservoir, the quantity fed can easily be ascertained indirectly from the drive rpm of the fuel pump and its constant feed quantity per revolution of the drive shaft, and linked with the signals already needed for controlling the fuel injection valves and corresponding to the injected fuel quantity.

An exemplary embodiment of the invention is shown in schematic form in the drawing and will be described in further detail in the ensuing description .

Shown in the drawing is a high-pressure fuel reservoir 1, which is supplied with fuel that is brought to high injection pressure via a feed line 2 from a fuel pump 3, which aspirates fuel from a fuel tank 4. This involves pressures that are substantially above 1000 bar. The pressure in the high-pressure fuel reservoir is detected by a pressure transducer 6, whose signal is delivered to an electronic control unit 7, by means of which, if a fixedly set or desired pressure is exceeded, which pressure may be dependent on an applicable operating state of the associated internal combustion engine, a pressure control valve 9 connected to the high pressure fuel reservoir is triggered by a suitable signal. This valve is located in a fuel return line 10 from the high-pressure fuel reservoir to the fuel tank 4. Also leading away from the high-pressure fuel reservoir are pressure lines 11, which are each connected to one fuel injection valve 14, by way of which at the appropriate time a desired fuel quantity can be injected into different cylinders of the engine. The control of the fuel injection quantity in terms of timing and quantity is also effected via the control unit 7, which for this control purpose receives control signals corresponding to the rpm and load at which the associated engine is to be operated. The control of this fuel injection quantity is effected for instance in a known manner by magnet valves, which control the communication between the high-pressure reservoir and the fuel injection valve. Any fuel control quantities that may occur and flow back into the tank can also be returned to the tank via the return line 10.

The fuel pump is driven, for instance in synchronism with the engine operated by the fuel injection system, or in other words at an rpm that is already detected for controlling the injection. Alternatively, however, the fuel pump can be operated separately by a special drive mechanism, and then the respective drive rpm of the fuel pump can also be detected, for instance by an rpm transducer 15. With the aid of this drive rpm and of the fact that the fuel pump feeds a constant feed quantity per revolution, it is now possible indirectly, with the aid of this rpm, to detect the fuel quantity delivered to the high-pressure fuel reservoir, so that a flow quantity control device for directly measuring the fuel quantity supplied can be dispensed with. But even if for certain reasons the fuel feed pump has a variable feed volume, the fuel quantity fed by it can still be detected from the control signals, or advantageously by means of a quantity control device 22.

Since in the operation of the fuel injection system at very high pressures it is critical if leaks occur in the high-pressure system, especially the high-pressure reservoir 1, it is necessary that the intactness of this reservoir be monitored. Since the supply of high-pressure fuel in this injection system takes place not intermittently but rather from a constantly filled high-pressure reservoir, it is furthermore also highly important to ascertain whether the fuel injection valves are functioning properly, because otherwise considerable engine damage can occur. With the aid of the fuel quantity delivered via the feed pump 3 and the fuel quantity withdrawn via the fuel injection valves 14, in conjunction with the fuel quantity withdrawn to regulate the fuel pressure in the high-pressure reservoir and the control quantities that may occur for the injection system, a balance for the delivered fuel and the withdrawn fuel can now be established. To that end, however, the fuel quantity diverted via the pressure control valve 9 must be measured by means of a flow quantity control device 17 in the fuel return line 10. The signal corresponding to this quantity, added to a signal corresponding to the total fuel injection quantity in the unit of time, the latter signal being outputtable by the control unit, is now compared, with the aid of a comparison device 18, with the correspondingly processed signal for the feed quantity of the feed pump 3 based on the rpm signal. If the fuel quantity delivered and the fuel quantity withdrawn again differ, then by means of the control unit 7a, tripped by the comparison device 18, a signal is output for a display 20 or for an intervention into the operation of the fuel injection system. With this signal, the drive of the fuel pump 3 can for instance be turned off, or the entire fuel injection system in the engine can be shut down or reduced to an emergency mode.

If the indirect measurement of the fuel quantity delivered to the high-pressure reservoir is replaced by a direct measurement, as mentioned above, then where there is an high-pressure reservoir assumed to be intact, not only high-pressure lines but also the function of the fuel injection valves can be monitored. To that end, a flow quantity control device 22, shown in dashed lines in the drawing, is again inserted into the feed line 2; it can be called the first flow quantity control device, in contrast to the second flow quantity control device 17 in the fuel return line 10. This produces an actual value for the fuel quantity injected. This value is compared with the set-point injection quantity specified to the control unit. From the result of the comparison it can be found whether the fuel injection valves are functioning without error, and if needed a correction value for the control unit can be formed.

As the flow quantity control device 17, in a manner known per se, a throttle inserted into the fuel return line 10 can be provided and the pressures upstream and downstream of the throttle can be compared with one another so as to form a quantity signal therefrom. Such flow quantity control devices are described for instance in conjunction with injection systems in German Patent Application DE-A 37 22 264. It is also possible to use other suitable sensors. For instance, a sensor already used for some other purpose can advantangeously be used economically, an example being sensors that are also used for measuring the air flow rate and that are known in terms of their physical design from German Patent Application DE-A 29 19 433.

The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.