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WEL

COM

E

common rail direct FUEL INJECTION

Team members:-

ASHWIN KUMAR.M – 4MH08ME402

SUMAN.M.S – 4MH08ME414

INTRODUCTION

CLASSIFICATION

WHAT IS CDRFI ?

THE TECHNOLOGY

WORKING OF CRDFI

HOW MUCH IS 1600 BAR

CRS BLOCK DIAGRAM

ELECTRONIC CONTROL UNIT

ADVANTAGES AND DISADVANTAGES OF CRDFI

CONCLUSION

Contents:

INTRODUCTION:Fuel Injection in the CI Engine

For the compression ignition engine, it is very important to promote a means of injecting fuel into the cylinder at the proper time in the cycle.

This is so because the injection system starts and controls the combustion process

Fuel Injection Systems

CLASSIFICATIONS FOR FUEL-INJECTION SYSTEMS

Air injection Solid (or airless) injection

Individual pump system

Distribution system

Common rail

system

Individual pump system: This consists of a separate metering and compression pump for each cylinder.

Distribution system: This consists of a single pump for compressing the fuel, plus a delivery device for distributing the fuel to the cylinders

Common rail system:A single pump for compressing the fuel, plus a metering element for each cylinder.

What is CRDI ?CRDI stands for Common Rail Direct Injection meaning, direct

injection of the fuel into the cylinders of an engine via a

single, common line, called the common rail which is

connected to all the fuel injectors. Instead of providing

separate piston pumps for fuel supply, the common rail alone

supplies high pressure fuel to each cylinder.

The TechnologyWhereas ordinary diesel direct fuel-injection systems have to build up

pressure anew for each and every injection cycle, CRDI engines

maintain constant pressure regardless of the injection sequence. This

pressure then remains permanently available throughout the fuel

line. The electronic control unit (ECU) modifies injection pressure

precisely as needed, based on data obtained from sensors on the

cam and crankshafts. i.e. compression and injection occur

independently of each other. This technique allows fuel to be injected

as needed, saving fuel and lowering emissions.

Piezo injectors

VCV & PCV

EGR valve

Turbo ActuatorGlow plugs

A/C Compressor Clutch Relay

Radiator Cooling Fan

relay

Check Engine Lamp

Atmosphericpressure

Clutch Switch

Brake Switch

Battery Voltage

Engine Coolant Temp

Fuel temp

Fuel pressure

Boost air Temp + Pressure

Mass air flow

Vehicle speed

Accelerator Pedal

Position A/C SwitchCrank shaft

Position(+ RPM)

Cam shaftPosition

ECU STATUS CONTROL Sensors

Actuators

Working of CRDFi System

CRDFi System

Sensors ECU Actuators status control

LAYOUT OF A TYPICAL CRDI ENGINE

Working of CRDFi System

Working of CRDFi System

Common rail System incorporates higher injection pressure up to 1600 bars.

Injection timing, duration and pressure is independent of engine load and rpm’s.

A Micro controller (Electronic Control Unit - ECU) is used to define and carry out the injection of fuel in a system.

Based on the demand of power from driver through pedal input, ECU calculate actual torque needed taking into consideration all parameters provided by sensors.

The calculated quantity is injected by command to piezo injectors which are supplied by the Rail.

How much is 1,600 barEquivalent to the water pressure at an ocean depth of 16,000 meters deeper than the Mariana Trench, the world’s deepest ocean bottom.

ITP

Exhaust gasAir

Low pressure fuel

High pressure fuel

Legend

VNT PWMVGT TURBO

AIR FILTERSi-MAF

INTERCOOLER

CAT

FUEL TEMPSENSOR

FUEL TANK

FUEL RETURN LINE FLYWHEEL CRANK POS. SENSOR

CAM POS. SENSOR

GLOW PLUG(S)

EGR VALVE

FUEL PR. SENSOR

HP FUEL RAIL

COOLANT TEMP.SENSOR

INJECTOR(S)

ECU

Feed Pump

Boost Pressure Sensor

EGR ValveActuator

VCV

Fuel Filter

PCV

SV

HPP

CRS Block Layout

Engine Control Unit –ECUThe engine control unit (ECU) checks all processes which are necessary for controlling the engine system.

It computes the necessary output data for the engine (e.g. fuel injection quantity, exhaust gas recirculation rate, etc) in accordance with driver’s requirements and the engine and vehicle data (e.g. engine speed, vehicle speed, engine coolant temperature, intake air mass, et cetera).

FUEL SUPPLY SYSTEM

1. High-pressure fuel sensor

2. Rail (high-pressure storage)

3. High-pressure pipe to the pump

4. High-pressure pipes to the injectors

High Pressure Joints

DCP High Pressure

PumpCommon

Rail

Cylinder

Injection Nozzles

Fuel Pump Assembly

H P P

V C V

P C V

Inlet Return

Supply

Inlet

Return

Supply

The DCP is driven by camshaft rear through a drive belt and has NO timing arrangement.

It is capable of generating the high pressure up to 1600 bars at higher rpm.

V C V

Fuel Pump Components

ITP

HPP

PCV

HPP

HPP

VCV

PPCV

SV

Edge Filter

To Rail

Return

Fuel Feed

a Fuel Feed

ITP

VCV

HPP

PCV

C

b

PPCV

To Rail

5

4

6

2

2

2

3

Return

SV

1

Components of Piezo Injector

1. High- pressure connection

2. Fuel return

3. ECU Connector (140 V)

4. Piezo actuator

5. Valve piston

6. Valve mushroom

7. Control piston

8. Nozzle needle

9. High- pressure chamber nozzle

10. Spray holes (100microns) (8 No's)

Advantages of Piezo technology

The piezo effect is 30 times faster than a coil actuation

Start and quantity of injections is eligible, independent of engine

speed

High pressure injection up to 1600 bar

Finest adjustment of pressure to operating state

Consistency of injection-pressure during the whole process

Reduction of combustion noise during injection

Very fast and precise dosage of diesel is possible

Reduction in exhaust gases

CRDI - Future Trends

Ultra-high pressure common-rail injection (1800 bar)

generating ideal swirl in the combustion chamber

allowing the air/fuel mixture to form a perfect vertical

vortex - uniform combustion and greatly reduced NOx

emissions

CRDi and Particle Filter - To reduce particle emissions

from exhaust

CRDi and closed-loop control injection - Using ion

sensor to provide real-time combustion data for each

cylinder such as temperature and pressure.

ADVANTAGES OF CRDI

Reduced noise and vibrationReduced smoke , particulates and exhaustIncreased fuel economyHigher power output even at lower rpm

disadvantages OF CRDI Increased Cost due to high pressure pump and

electronic control unitTechnology cannot be employed in present engines

new generation CRDiengines in India3 Cylinder 1.5 liter and

4 cylinder 2 liter engines

81 bhp and 187 NM max torque at 2700 rpm , max 4000 rpm

5 speed gear box ,

0 – 100 in 13 sec , max speed 170 km/hr

26.2 kmpl in highway ,

12 kmpl town riding

CONCLUSION Cuts fuel consumption by 20% Doubles torque at low engine speeds Increases power by 25%. It also brings a significant reduction in the noise and vibrations of conventional diesel engines. In emission, greenhouse gases (CO2) is reduced by 20%. At a constant level of NOx, carbon monoxide (CO) emissions are reduced by 40%, unburnt hydrocarbons (HC) by 50%, and particle emissions by 60%. CRDI principle not only lowers fuel consumption and emissions possible; it also offers improved comfort and is quieter than modern pre-combustion engines. Common-rail engines are thus clearly superior to ordinary motors using either direct or indirect fuel- injection systems.