COMMON RAIL DIRECT INJECTION

Dr. K. C. Vora
Head, ARAI Academy The Automotive Research Association of India, Pune

CONTENTS

Introduction System Types & Generation

Common Rail & Emission Strategy

System Validation & Tests Project Milestones

INTRODUCTION
TECHNOLOGY DRIVERS Emission regulations (Exhaust gas and Noise) Further fuel economy improvements

Further improvements in
Reliability Durability of engine/vehicles Competitive costs and prices

FUEL INJECTION SYSTEM - FUNCTIONS

To meter the quantity of fuel to be injected.

To inject fuel at the right time in the cycle. This implies accurate timing
of injection as a function of engine speed and load. To mix fuel with air effectively in the short period of time available. This means that the fuel has to be introduced at very high energy levels All the above have to happen consistently cycle by cycle, cylinder to cylinder and over a period of time.

FUEL INJECTION SYSTEM - FUNCTIONS

Main Functions of Diesel Fuel Injection System

Injection Timing Control

Atomization and Penetration

Injection Quality Control

FUEL INJECTION SYSTEM - FUNCTIONS

Fuel Injection Pump Fuel quantity delivered Injection Timing Rate of Injection Idle & Max speed Governing Injector Injection pressure Spray pattern Filter Removal of contamination from fuel Protect Fuel Injection equipment

CAM DRIVEN FIE

Cam driven FIE

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Pressure generation and injection are coupled

DEVELOPMENT TRENDS IN CAM DRIVEN FIE

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COMMON RAIL & EDC FIP

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PRESSURE GENERATION AND FIE

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INJECTION PRESSURES 1600 - 2000 BAR

TECHNOLOGY DRIVERS-EMISSION

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TECHNOLOGY DEMANDS ON FIE

High pressure potential (> 2000 bars) Realisation of the ideal rate of injection via pressure modulation alone Capability of realising staged (boot) as well as pilot injection where pilot is separated from the main injection Flexibility of selecting start of injection as well as end of injection Moderate initial rise of main injection

Sharp cut off of the injection end

Flexibility of selecting peak injection pressure Provide option to automatically change rate shape according to

engine speed and load

COMMON RAIL SYSTEM

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COMMON RAIL SYSTEM

What is a Common Rail? Common Rail is a 1. Modular, 2. Electronic Controlled, 3. Diesel Fuel Injection System

COMMON RAIL SYSTEM

Special Characteristics

1. Injection Pressure is produced and governed relatively .independent of the Engine Speed and can be selected freely within a wide range. 2. Injection begin and Injection Quality can be freely selected (EDC function).

COMMON RAIL SYSTEM

How are the main characteristics of CR system achieved?

1. CR uses and intermediate High Pressure Accumulator (Rail)

2. Uses Electronic Control of Injectors (use of Electro-magnetic valves)

COMMON RAIL SYSTEM

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COMMON RAIL SYSTEM

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COMMON RAIL SYSTEM

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COMPONENTS OF CRDI SYSTEM

Filter Sedimenter Low Pressure Side Priming Pump (Pear Type) Low pressure pipes with quick fit couplers

HP Pump CR System High Pressure Side

Rail

Injectors (set of 4)
HP Pipes (set of 5)

ECU Electronics Sensors

COMMON RAIL SYSTEM

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COMMON RAIL SYSTEM

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ELECTRONIC DIESEL CONTROL

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CRS- ELECTRONIC CONTROL UNIT (ECU)

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CRS- ELECTRONIC CONTROL UNIT (ECU)

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CRS- ELECTRONIC CONTROL UNIT (ECU)

ECU mounting Hints Boundary condition influencing installation of ECU Wiring harness: 150mm from ECU Vibration: 4 plane screwing points Temperature: < 60C Humidity: Away from water splash Chemical resistance: Away from battery

SENSORS FOR CRDI ENGINE

Fuel Temp On CR System Rail Pressure Water Sensor Barometric Sensor Engine Speed (Crankshaft) Engine Phase (Cam Shaft) Knock Sensor On Engine Water Temp Intake Air Temp and Boost Pressure Air Mass Flow Cruise Control On Vehicle Vehicle Speed Throttle Pedal

Sensors

SENSORS ON CRDI ENGINE

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ORIENTATION ON CRS COMPONENT: COMMON RAIL

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ORIENTATION ON CRS COMPONENT: COMMON RAIL

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HIGH PRESSURE PUMP OF COMMON RAIL SYSTEM

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INJECTOR

Servo valve principle Solenoid actuator 200 - 1600 bar operating pressure pilot quantity 1-3 mm3 Extremely fast response Low leakage system Capable of multiple injections

COMMON RAIL SYSTEM

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CRS ADVANTAGES
Separation of pressure generation and injection allowing flexibility in controlling both the injection rates and timing. Fuel pressure does not depend on the engine speed and load conditions (This feature differentiates the common rail from conventional injection systems) High injection pressures and good spray preparations are possible even at low engine speeds and loads. Capability to deliver stable, small pilot injections can be used for decreased NOx emissions and noise. Option for post injections may be used together with such emission control technologies as particulate filters, lean NOx catalysts, or NOx adsorbers. Fuel pump operates with low drive torque.

CONTENTS

Introduction completed System Types & Generation

Common Rail & Emission Strategy

System Validation & Tests Project Milestones

SYSTEM TYPES

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SYSTEM TYPES

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COMMON RAIL SYSTEM

1600bar with CP1H, Gear pump (feed), Metering unit, Injector, Rail, ECU

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COMMON RAIL SYSTEM

1600bar with CP1H, Gear pump (feed), Metering unit, Injector, Rail, ECU

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COMMON RAIL SYSTEM- COMMERCIAL VEHICLE (CRSN)

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CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM

CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM

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SYSTEM COMPONENTS : CRS

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SYSTEM MANAGEMENT

CONTENTS

Introduction completed System Types & Generation completed

Common Rail & Emission Strategy

System Validation & Tests Project Milestones

COMMON RAIL SYSTEM & EMISSION

COMMON RAIL SYSTEM & EMISSION

SYSTEM VARIABILITY REDUCTION

Dispersion management is one of the great challenges. Low variation and high precision are required during the entire vehicle life
Euro 4

Enabling technologies:
Fast/Precise fuel injection systems

PM (g/km)

Fuel injection control strategies Combustion sensors

Euro 6 Proposal
Future dispersio n

Euro 5

Performing EGR components

NOx (g/km)

CONTENTS

Introduction completed System Types & Generation completed

Common Rail & Emission Strategy completed

System Validation & Tests Project Milestones

VALIDATION TESTS ON SYSTEM, ENGINE, VEHICLE

System endurance test on bench Load collective measurement on vehicle Low pressure circuit measurement on vehicle Temperature measurement on vehicle Vibration measurements on engine and vehicle Fault monitoring and diagnostics on vehicle Endurance test on engine Mileage accumulation on vehicle Summer, winter, altitude test on vehicle

COMMON RAIL SYSTEM LOAD COLLECTIVE MEASUREMENTS

CONTENTS

Introduction completed System Types & Generation completed

Common Rail & Emission Strategy completed

System Validation & Tests completed Project Milestones

PROJECT MILESTONES

CUSTOMER PROJECTS : INTERFACE & INVOLMENTS

COMMON RAIL SYSTEM & DIAGNOSIS

PROJECT TEAMS

COMMON RAIL SYSTEM & FUEL

CONCLUSIONS

Thank You!

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