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An add-on module to ECU for extending the functionalities of EFI tune-up process: An electronic device which extends the lifetime of fuel injectors

The paper presents the ideology, procedures followed in order to implement, and the experimental results of an electronic device developed to extend the functionalities of an Electronic Control Unit (ECU) employed in the automobiles equipped with Electronic Fuel Injection (EFI) technology. The EFI system is empowered with a computing unit, ECU. A key responsibility of a typical ECU is to manipulate the fuel delivery for efficient combustion to optimize the engine's performance while minimizing the fuel wastage and emissions. Further, it is expected to self-adjust to fulfill the above requirements relying on several input sensors including a feed-back sensor. But, due to various reasons the objective is not fully achieved, therefore need to be rectified time to time. The process is called EFI Tune-up. Sensor malfunction and decayed fuel injectors are the major reasons for the incapability of ECU to control the situation. The especially developed add-on module was designed to assist the ECU when it loses its tolerance because of decayed fuel injectors and once the feedback sensor is beyond its range of operation. The strategy followed was to modify the Injector Pulse Width, a Pulse Width Modulated (PWM) control signal generated by the ECU to regulate the fuel release of fuel injectors, based on an analysis done regarding the emissions containing in exhaust gas. The experimentally obtained evaluation records conclude that the involvement of the introduced add-on module could reduce the fuel wastage and release of toxic emissions up to 70%, depending upon the condition of the fuel injector.