Optical device for measuring the injectors opening in common rail systems

Since the needle displacement exerts a fundamental influence on the operation of Common Rail injection systems, accurate measurements of the control piston position can be crucial for a more thorough analysis of the behaviour of injectors, in particular when multiple injections are employed. Eddy current sensors have traditionally been used in lab activities to measure the control piston position inside injectors; apart from the high cost, the scientific literature clearly shows their inadequacy, which is mainly due to the presence of electromagnetic disturbance: the current pulse, which controls the opening of the injector, generates electromagnetic fields which strongly affect the acquisition of data. Many attempts have recently been made either to solve the interference occurring during such measurements or to propose alternative displacement transducers whose operation is not influenced by electromagnetic interference. In this paper, a new device for measuring the injector opening is proposed: it is an optical transducer characterized both by simple and very cheap construction and by a reliable physical principle for measuring the control piston lift. The reliability of the proposed sensor is assessed by a thorough experimental campaign and by comparing the experimental results with the numerical predictions achieved by a Common Rail injector model. Since the assembly of the optical sensor does not affect the injector operation, it can efficiently be used both for experimental tests and for on-board diagnosis and monitoring of the injector operation.