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Fuel injectors are critical components in modern internal combustion engines, directly influencing fuel atomization quality, combustion efficiency, and exhaust emissions. As injection pressure and control precision continue to increase, understanding the dynamic behavior of fuel injectors under variable operating conditions has become increasingly important. This study focuses on the dynamic response characteristics of fuel injectors and their impact on injection accuracy.

The injector operation process involves complex interactions between electromagnetic force, hydraulic pressure, spring force, and friction. During high-speed engine operation, the injector needle must open and close within extremely short time intervals, making dynamic response performance a key factor affecting fuel delivery accuracy. Delayed needle opening or unstable closing can result in injection quantity deviation and spray inconsistency.

To investigate these effects, a dynamic model of the fuel injector is established, incorporating electromagnetic actuation, needle motion, and fuel flow behavior. Simulation results indicate that injection pressure significantly influences needle lift dynamics. At higher pressures, increased hydraulic force accelerates needle opening but also intensifies impact forces during closure, potentially increasing wear on the sealing surface.

The study further examines the influence of control signal parameters, including energizing time and current rise rate, on injector performance. Results show that optimized current profiles can reduce opening delay and stabilize needle motion, leading to improved injection repeatability. Compared with conventional square-wave control signals, shaped current strategies demonstrate better adaptability to high-speed injection demands.

Experimental validation is conducted using a high-pressure common rail test bench. Measured injection rate curves confirm the simulation findings, showing reduced cycle-to-cycle variation when optimized control parameters are applied. Spray observation tests also reveal improved atomization consistency, contributing to more uniform air–fuel mixing.

Overall, the results demonstrate that dynamic behavior optimization is essential for achieving precise fuel injection in modern engines. By coordinating injector structural design and control strategy, injection accuracy and durability can be significantly improved. This study provides valuable insights for the development of next-generation fuel injectors with enhanced performance and reliability.