Development of a Fuel Injector Driver for Accelerated Testing

This paper presents the design of a cost-effective fuel injector driver designed for accelerated testing of injectors. The driver simulates injection patterns across a wide range of vehicle operating conditions and can be programmed with injection maps for different engines, test cycles based on drawing specifications, pre-defined engine running profiles, and manual control, where the user defines PWM frequency and duty cycle. It also enables remote operation through a Wi Fi access point. An injector driver-based test setup was developed to study wear and evaluate leakage tendency in an injector design. To simulate extended field usage in a short timeframe, an accelerated operating cycle was derived using telematics data. Injector samples were tested with periodic leak rate measurements. Conducting such tests at vehicle level or on engine test bench would involve significant time and cost. This setup is an effective tool for rapid comparative analysis across supplier design, enabling data driven product selection. It can also be used for quick evaluation of design improvement features introduced in injectors. The flexible architecture and remote operability make it a valuable tool for future injector development and validation.