Production Intent DME Fuel Production Intent DME Fuel System DesignSystem Design

Design ApproachDesign Approach

• Designed for CNC Manufacture-Avoids Capital Investment

• 35% Fewer Parts-Low Cost, Improved Reliability

• Higher Pressure Capability (400 Bar +)

• Poppet Solenoid, Low Leakage

• 75 HP/Cylinder Capability

Design Features-PumpDesign Features-Pump

• 5-Cyl. Pump (vs 7)

• Ø10.5 Plungers (vs Ø12.5)

• 5 cc/rev (vs 11.7cc/rev)

• Bolt-on Cam w/Cermet Insert

• Machined Housings-No Castings

• 8-Bolt Pattern-No Special Seals Needed

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Pump AssemblyPump Assembly

Pump Assembly ProcedurePump Assembly Procedure

Common Rail FeaturesCommon Rail Features

• Vacuum Brazed Tube & Block

• No Secondary Operations (Grinding or Straightening)-Proven Process

• Integral Poppet Solenoid (Zero Leak)

• No Solenoid O-Rings

• Screw-In Fittings for Tubes

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Common Rail AssemblyCommon Rail Assembly

Fuel Injector FeaturesFuel Injector Features

• Ø17mm Primary Diameter

• Ø25mm Maximum Diameter

• Axi-symmetric Design

• No Leak-Vent Needed

• Simple to Manufacture

• Low Cost

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Injector AssemblyInjector Assembly

Control ModuleControl Module

• Similar to Previous Design

• Housing Modified for Bolt-On Bracket

• New Rail Pressure Valve (Lower Cost)

• Electronic Backpressure Valve Will Be Replaced w/Passive Valve

• New, Low Cost Internal Filter

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Pressure Control Module Ass’y.Pressure Control Module Ass’y.

Prototype & Low Volume Prototype & Low Volume Production (2000 Units/Year)Production (2000 Units/Year)

• AFT Can Produce Housings, Shafts, Cylinders, Semi Finished Plungers, Guide Plates, Injectors, Covers & Modules

• Have Ordered State of Art CNC Equipment-Delivery in 6 Weeks

• Outsource Finished Plungers, Slippers, Nozzle Valves, Solenoid Valves

• Assembly & Test Can Be Done In-House

CNC DemonstrationCNC DemonstrationHAAS SL-20 W/Live Tools OrderedHAAS SL-20 W/Live Tools Ordered

Prototype Cost & Lead TimesPrototype Cost & Lead Times

• Prototype Cost & Lead Times Reduced by 50%

• Changes Can Be Made Rapidly

• Assembly Simplified-Field Serviceable

• Easily Adaptable to Many Engines

• Production Planned 2009