"Fundamentals of the Common Rail System"

8th Session:INJECTOR CONSTRUCTION AND OPERATION

In the last session the rail was discussed. The rail receives constant, high-pressure fuel from the supply pump, and provides fuel at a common pressure to each injector. This session will describe the injectors installed in each engine cylinder. Injectors function as the final step in the fuel injection system.

1 OUTLINE
The injector injects high pressure fuel from the rail into the engine combustion chamber at the optimal injection timing, injection quantity, injection rate, and atomization in accordance with signals from the engine ECU. Injection control is performed by the TWV (Two-Way Valve) and orifice opening and closing. The TWV controls the beginning and completion of injection by governing the pressure of the control chamber. The command piston transfers pressure from the control chamber to the nozzle needle, which opens and closes the nozzle. When the nozzle needle valve is open, the nozzle atomizes the fuel and injects it.

TWV (Two-Way Valve)

Rail Pressure Sensor

Orifice Engine ECU Control Chamber Rail Command Piston

Supply Pump

Nozzle Needle

Nozzle

<Injector>

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"Fundamentals of the Common Rail System"

2 CONSTRUCTION AND OPERATION

1 Injector Construction
The injector is comprised of a nozzle similar to the conventional (nozzle body and nozzle needle), a TWV (Two-Way Valve) that controls the injection quantity, an orifice that controls the injection rate, and a command piston. The latest type of injector is designed to withstand high pressure, causing an increase in sealability and resistance to high pressure wear. Further, high-speed operability has increased, enabling higher precision injection control and multiple injections.
To Fuel Tank Connector

TWV (Two-Way Valve)

From Rail Command Piston

Nozzle Spring Pressure Pin

Nozzle Body Nozzle Nozzle Needle Leak Path Seat Orifice

Reference
In order to reduce exhaust gas and lower running noise, one injection is divided into a maximum of five separate injections.
Ex: Five Injection Pattern Main Injection Injection Quantity Pilot Injection Pre Injection After Injection Post Injection

Time

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"Fundamentals of the Common Rail System"

2 Injector Operation

The injector controls injection according to fuel pressure in the control chamber. The fuel pressure within the control chamber is governed by using the TWV to regulate fuel leakage from the control chamber. The following explains injector operation in detail. (For the sake of simplicity the nozzle needle has been included with the nozzle portion in the diagram below.)

Non-injection
When the TWV is not energized, the TWV keeps the control chamber leak path shut, causing both the fuel pressure in the control chamber and the fuel pressure exerted on the bottom of the nozzle are the same as rail pressure. The diameter of the control chamber command piston is larger than the diameter of the lower portion of the nozzle. As a result, the nozzle is pushed down and no injection occurs.

Injection
When the TWV is energized the valve lifts, opening a leak path for fuel to escape from the control chamber. When the leak path opens fuel leaks from the control chamber, decreasing control chamber pressure. As a result, the force pushing up on the nozzle becomes greater than the force exerted on the control chamber command piston. This lifts the nozzle, and injection begins. Excess fuel is returned to the fuel tank via the path displayed in the illustration below.

Injection Complete
When the TWV is de-energized the valve lowers, closing the leak path from the control chamber. When the leak path closes, the pressure in the control chamber returns to rail pressure. This closes the nozzle and stops injection.

Solenoid TWV

Leak Path

To Fuel Tank

Actuation Current

Actuation Current TWV

Actuation Current

Rail Outlet Orifice Inlet Orifice Control Chamber Pressure Control Chamber Pressure Control Chamber Pressure

Command Piston Nozzle Injection Rate Injection Rate Injection Rate

Non-Injection

Injection

Injection Complete

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3 OTHER COMPONENTS
1 Injector with Correction Resistor
Correction Resistor Terminal Solenoid Terminal

The injector with correction resistor has a resistor built into the connector portion used to reduce the injection quantity variation between cylinders. The engine ECU calculates the proper correction injection quantity by measuring the variation in resistance between injectors and reflecting this quantity in the output signal.

Injectors with QR Codes

QR (Quick Response) codes are employed to improve injection quantity precision. Injection correction data is reflected in the QR codes, and the data from the QR codes is written to the engine ECU. Using QR codes drastically increases injection quantity correction points, causing improved injection quantity precision.

Correction Points Derived from QR Code Pressure Parameters

QR Code
10EA01EB 13EA01EB 0300 0000 0000 BC

Injection Quantity Q

ID Code Actuation Pulse Width TQ

Reference Handling Injectors with QR Codes The engine ECU performs corrections by recognizing the capabilities of each individual injector with QR codes. In light of this, when replacing an injector(s) or the engine ECU, it is necessary to register the ID code information into the engine ECU.
When replacing injectors It is necessary to register the ID code information of replaced injectors to the engine ECU. When replacing the engine ECU It is necessary to re-register the ID code of every injector installed in the vehicle to the engine ECU.
"No correction resistance, electrical recognition impossible"

Spare Injector

Engine ECU Necessary to register ID code to engine ECU

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