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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.