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Accurate prediction of injector transient dynamics is essential for achieving precise fuel metering and stable combustion in modern engine systems. The injector dynamic response involves complex interactions among electromagnetic actuation, hydraulic flow, and mechanical motion, which are difficult to represent using a single simulation environment. To address this challenge, a hybrid simulation approach combining AMESim and MATLAB is proposed to analyze injector transient behavior under various operating conditions.

In this method, AMESim is primarily used to represent the physical behavior of the injector system. Detailed submodels are constructed for the fuel supply channel, control chamber, needle valve, and return circuit, enabling accurate description of pressure variation, flow resistance, and fuel compressibility. Special attention is given to transient hydraulic effects, such as pressure wave reflection and damping, which strongly influence injector response time and stability.

MATLAB is employed to implement advanced signal generation and numerical analysis functions. The injector drive signal, including current shaping, dwell control, and shut-off strategy, is generated in MATLAB and transmitted to AMESim in real time. At the same time, key response variables such as needle displacement, injection rate, and control chamber pressure are fed back to MATLAB for post-processing and performance evaluation.

The co-simulation framework operates with synchronized time steps, ensuring numerical stability and consistency between the two platforms. This configuration allows rapid modification of control parameters without changing the injector’s physical model, significantly improving simulation efficiency. The dynamic response characteristics under different injection pressures and drive strategies are systematically investigated using this framework.

Simulation results demonstrate that the hybrid approach effectively captures injector opening delay, closing lag, and transient oscillations that are difficult to observe experimentally. The results also reveal that improper current shut-off timing can induce pressure rebound in the control chamber, leading to secondary injection or unstable needle motion. By optimizing the current decay profile through MATLAB, these undesired effects can be significantly reduced.

Compared with standalone simulation methods, the AMESim–MATLAB hybrid approach provides higher modeling fidelity and greater flexibility in control strategy development. It enables a clear separation between physical modeling and control logic, making it particularly suitable for injector design optimization and electronic control unit calibration.

In summary, the proposed hybrid simulation method offers an efficient and reliable tool for investigating injector transient dynamics. It supports performance evaluation, control strategy refinement, and system-level optimization of fuel injection systems, contributing to improved engine efficiency and emission performance.