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The dynamic response of fuel injectors has a direct impact on injection accuracy, combustion efficiency, and emission performance in modern engine systems. Due to the strong coupling between hydraulic, electromagnetic, and mechanical subsystems, accurately modeling injector transient behavior remains a complex challenge. This study presents a co-simulation method that integrates AMESim and MATLAB to analyze the dynamic response process of fuel injectors with high accuracy and flexibility.

AMESim is employed to build a detailed physical model of the injector, including the high-pressure fuel circuit, control valve, needle motion, and electromagnetic actuator. The hydraulic dynamics, such as pressure wave propagation, flow restriction, and fuel compressibility, are modeled using validated component libraries. Meanwhile, MATLAB/Simulink is used to develop the injector control logic and signal processing algorithms, enabling precise control of drive current profiles and real-time analysis of system response.

The two platforms are coupled through a co-simulation interface, allowing data exchange at each simulation time step. Key variables such as coil current, needle lift, injection pressure, and flow rate are transferred bidirectionally. This approach combines the high-fidelity physical modeling capability of AMESim with the powerful control and numerical computation features of MATLAB, achieving both accuracy and computational efficiency.

Simulation results show that the co-simulation method can accurately capture transient phenomena during injector opening and closing, including response delay, overshoot, and oscillation. The influence of different drive current waveforms on needle dynamics is systematically analyzed. Compared with single-platform simulation, the co-simulation approach reduces modeling simplifications and improves prediction accuracy for injection timing and injected fuel quantity.

Furthermore, the method enables rapid evaluation of control strategy optimization. By adjusting current rise rate, holding current level, and shutdown slope in MATLAB, the dynamic performance of the injector can be optimized without modifying the physical model in AMESim. The results indicate that optimized control parameters can reduce opening delay by up to 15% and suppress needle rebound during closing.

In conclusion, the AMESim–MATLAB co-simulation method provides an effective and reliable tool for analyzing injector dynamic response and optimizing control strategies. It offers strong support for injector design, calibration, and performance improvement, and can be extended to other electro-hydraulic components in advanced fuel injection systems.