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SEMINAR SEMINAR – 2008 – 2008 Common Rail Direct Common Rail Direct Injection Injection Engine Engine Presented By: JUNET BABU S7 MECHANICAL
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Page 1: CRDi

SEMINARSEMINAR – 2008– 2008

Common Rail Direct Common Rail Direct InjectionInjection EngineEngine

Presented By:

JUNET BABUS7 MECHANICAL

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What is CRDI ?What is CRDI ?• CRDI stands for CRDI stands for Common Rail Common Rail

Direct InjectionDirect Injection meaning, direct meaning, direct injection of the fuel into the injection of the fuel into the cylinders of an engine via a cylinders of an engine via a single, common line, called the single, common line, called the common rail which is connected common rail which is connected to all the fuel injectors. Instead of to all the fuel injectors. Instead of providing separate piston pumps providing separate piston pumps for fuel supply, the common rail for fuel supply, the common rail alone supplies high pressure fuel alone supplies high pressure fuel to each cylinder.to each cylinder.

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The TechnologyThe Technology• Whereas ordinary diesel direct fuel-Whereas ordinary diesel direct fuel-

injection systems have to build up pressure injection systems have to build up pressure anew for each and every injection cycle, anew for each and every injection cycle, CRDI engines maintain constant pressure CRDI engines maintain constant pressure regardless of the injection sequence. This regardless of the injection sequence. This pressure then remains permanently pressure then remains permanently available throughout the fuel line. The available throughout the fuel line. The electronic control unit (ECU) modifies electronic control unit (ECU) modifies injection pressure precisely as needed, injection pressure precisely as needed, based on data obtained from sensors on based on data obtained from sensors on the cam and crankshafts. ie compression the cam and crankshafts. ie compression and injection occur independently of each and injection occur independently of each other. This technique allows fuel to be other. This technique allows fuel to be injected as needed, saving fuel and injected as needed, saving fuel and lowering emissions.lowering emissions.

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PRINCIPLE OF CRDi IN DIESEL ENGINESPRINCIPLE OF CRDi IN DIESEL ENGINES

• Is named as GDI( Gasoline Direct Injection)Is named as GDI( Gasoline Direct Injection)• Introduced to remove the drawbacks of Introduced to remove the drawbacks of

carbureted and MPFI systemscarbureted and MPFI systems• Main advantage is that even petrol Main advantage is that even petrol

engines can be run under the very lean engines can be run under the very lean mixture ratio of 50:1mixture ratio of 50:1..

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FIGURE SHOWING THAT BY INTRODUCTION OF GDI IN FIGURE SHOWING THAT BY INTRODUCTION OF GDI IN PETROL ENGINES A LEAN MIXTURE OF A\F RATIO OF PETROL ENGINES A LEAN MIXTURE OF A\F RATIO OF 50:1 CAN BE BURNT50:1 CAN BE BURNT SUCESSFULLYSUCESSFULLY

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LAYOUT OF A TYPICAL CRDI LAYOUT OF A TYPICAL CRDI ENGINEENGINE

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DIFFERENCES BETWEEN DI AND CRDDIFFERENCES BETWEEN DI AND CRD

• Constant pressure regardless of the Constant pressure regardless of the injection sequence injection sequence

• Fuel is supplied directly to a common rail Fuel is supplied directly to a common rail from where it is injected directly onto the from where it is injected directly onto the cylinder head cylinder head

• High Pressure of about (1600 bar) , High Pressure of about (1600 bar) , Improved pulverizationImproved pulverization

• Electronic engine management system Electronic engine management system continually adjusts the peak fuel pressure continually adjusts the peak fuel pressure according to engine speed and throttle according to engine speed and throttle positionposition

• Compression and injection occur Compression and injection occur independently of each other independently of each other

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CIRCUIT DIAGRAMCIRCUIT DIAGRAM

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Electronic Control UnitElectronic Control Unit• ECU monitors Engine variables such ECU monitors Engine variables such

as Temperature , intake pressure , as Temperature , intake pressure , RPM , air mass intake and demand RPM , air mass intake and demand for power (from accelerator) and for power (from accelerator) and provides real time control and provides real time control and modifies injection pressure precisely modifies injection pressure precisely as needed , based on data obtained as needed , based on data obtained from cam and crankshaft.from cam and crankshaft.

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Electronic Fuel InjectorElectronic Fuel Injector• electromagnet electromagnet

moves the plunger - moves the plunger - opening rapid opening rapid solenoid valvesolenoid valve

• Injector pulse width Injector pulse width controlled by ECUcontrolled by ECU

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CHARACTERISTICSCHARACTERISTICS

• Spiral shaped Intake port for optimum Spiral shaped Intake port for optimum swirl of air entering cylinder – spiral port swirl of air entering cylinder – spiral port induces optimum swirl in the intake air induces optimum swirl in the intake air leading to more efficient mixing and leading to more efficient mixing and combustion of fuel inside cylinder combustion of fuel inside cylinder

• Integrated port at cylinder head for Integrated port at cylinder head for exhaust gas recycling – building up input exhaust gas recycling – building up input air temperature, reducing vibrations and air temperature, reducing vibrations and cooler exhaustcooler exhaust

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• air-flow meter located in front of the air-flow meter located in front of the turbocharger's compressor permitting an turbocharger's compressor permitting an exact analysis of the air-mass that is being exact analysis of the air-mass that is being taken in. taken in.

• Air mass alters depending on temperature or Air mass alters depending on temperature or atmospheric pressure. atmospheric pressure.

• The microcomputer that controls engine The microcomputer that controls engine timing receives precise data. It is thus able to timing receives precise data. It is thus able to regulate exhaust-gas recycling according to regulate exhaust-gas recycling according to engine load and speed in the interest of engine load and speed in the interest of lowering nitrous oxide and particle emissionslowering nitrous oxide and particle emissions. .

Precise air flow meteringPrecise air flow metering

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Multiple Pilot and post injectionMultiple Pilot and post injection

• Leading to smoother compression and Leading to smoother compression and expansion - reducing noise levelsexpansion - reducing noise levels

• More efficient combustion and burning up More efficient combustion and burning up of fuel leading to quieter engine cyclesof fuel leading to quieter engine cycles

• Reduces unburnt HC , NOx and CO and Reduces unburnt HC , NOx and CO and particles in exhaust particles in exhaust

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CRDI - Future TrendsCRDI - Future Trends• Ultra-high pressure common-rail injection Ultra-high pressure common-rail injection

(1800 bar) generating ideal swirl in the (1800 bar) generating ideal swirl in the combustion chamber allowing the air/fuel combustion chamber allowing the air/fuel mixture to form a perfect vertical vortex - mixture to form a perfect vertical vortex - uniform combustion and greatly reduced uniform combustion and greatly reduced NOx emissionsNOx emissions

• CRDi and Particle Filter - To reduce particle CRDi and Particle Filter - To reduce particle emissions from exhaustemissions from exhaust

• CRDi and closed-loop control injection - CRDi and closed-loop control injection - Using ion Using ion sensor to provide real-time sensor to provide real-time combustion data for each cylinder such as combustion data for each cylinder such as temperature and pressure.temperature and pressure.

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PARTICLE FILTERPARTICLE FILTER

•Porous silicon carbide unit

•Decreases Particle emissions •Trapped particles burnt up into CO2 and water

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ADVANTAGES OF CRDIADVANTAGES OF CRDI• Reduced noise and vibrationReduced noise and vibration• Reduced smoke , particulates and exhaustReduced smoke , particulates and exhaust• Increased fuel economyIncreased fuel economy• Higher power output even at lower rpmHigher power output even at lower rpm

• Increased Cost due to high pressure Increased Cost due to high pressure pump and electronic control unitpump and electronic control unit

• Technology cannot be employed in Technology cannot be employed in present enginespresent engines

DISADVANTAGEDISADVANTAGESS

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Hyundai Accent CRDiHyundai Accent CRDi

Pioneering new generation CRDiengines in India

• 3 Cylinder 1.5 litre and 4 cylinder 2 litre 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

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CONCLUSIONCONCLUSION• cuts fuel consumption by 20%cuts fuel consumption by 20%• doubles torque at low engine speeds doubles torque at low engine speeds • increases power by 25%.increases power by 25%.• It also brings a significant reduction in the noise and It also brings a significant reduction in the noise and

vibrations of conventional diesel engines.vibrations of conventional diesel engines.• In emission, greenhouse gases (CO2) is reduced by In emission, greenhouse gases (CO2) is reduced by

20%. At a constant level of NOx, carbon monoxide (CO) 20%. At a constant level of NOx, carbon monoxide (CO) emissions are reduced by 40%, unburnt hydrocarbons emissions are reduced by 40%, unburnt hydrocarbons (HC) by 50%, and particle emissions by 60%.(HC) by 50%, and particle emissions by 60%.

• CRDI principle not only lowers fuel consumption and CRDI principle not only lowers fuel consumption and emissions possible; it also offers improved comfort emissions possible; it also offers improved comfort and is quieter than modern pre-combustion engines. and is quieter than modern pre-combustion engines. Common-rail engines are thus clearly superior to Common-rail engines are thus clearly superior to ordinary motors using either direct or indirect fuel-ordinary motors using either direct or indirect fuel-injection systems. injection systems.

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THE ENDTHE END