Using the Injection System as a Sensor to Analyze the State of the Electronic Automotive System

This paper presents a novel diagnostic method that employs the fuel injection system as a sensor for monitoring internal combustion engine pressure, analysing series resistance to detect connector degradation, and evaluating needle movement within the injector’s magnetic core. Experimental results showed that reducing the injector needle opening from 100% to 20% of its maximum displacement caused up to a 35% reduction in peak current amplitude and a 0.2 ms delay in coil charging. Increasing fuel pressure from 0.3 bar to 2.5 bar resulted in a rise in peak current by approximately 35% and an extension of coil charging delay by 0.4 ms. Furthermore, increasing the series resistance from 0.2 Ω to 2.0 Ω reduced the current amplitude by nearly 50% and significantly distorted the waveform, simulating connector oxidation or wear. Comparative analysis of reference and fault current waveforms confirmed that variations in electrical parameters correlate with injector needle displacement, fuel pressure, and resistance changes. Finally, an automated diagnostic system was developed that achieved over 90% accuracy in independently detecting injector faults based on current waveform characteristics.