Sensorless control of electromagnetic fuel injectors

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Westport Innovations Inc. is a Canadian company and world leader in natural gas engine technology and vehicles. Westport's natural gas technology has been developed and integrated into a variety of automobile applications that range from small passenger vehicles to large commercial semi-trailer tractors. Increasingly stringent emissions standards and volatile gasoline and diesel fuel prices are allowing Westport's natural gas alternatives to flourish. Westport's high pressure direct injection (HPDI) injector is a leading-edge technology that uses high speed electromagnetic actuators to open or close a hydraulic valve, which in turn drives the injection needle. However, Westport's HPDI injectors lack the ability to control intermediate needle positioning since the actuator can only be operated in an on/off state, due to the infeasibility of being able to integrate a position sensor. This proposal details a 42 month collaborative research project with Westport Innovations Inc. and the University of British Columbia (UBC). The proposed project aims to developing a novel sensorless control strategy and a constant air gap solenoid actuator to allow for intermediate position control. With intermediate position control, one can not only achieve soft seating which reduces parasitic injections, wear and acoustic noise, but new needle lift and rate-shaping strategies can be implemented that will decrease fuel consumption and harmful emissions. The success of this project will result in the world's first commercially feasible HPDI injector capable of robust intermediate positioning. Through this research, natural gas engine technology will be made more viable. Furthermore, this research will help make Canada a leader in natural gas engine technology while reducing greenhouse gas emissions and its dependence on conventional fossil fuels.