DIESEL INJECTION SYSTEMS

Chapter 5- Part II
Introduction to Diesel injection system

 The fuel injection system is one of the most important components in

CI engines

 The effectiveness of fuel injection system is greatly affects the

engine performance with respect to

 Power output

 Fuel economy

 Smooth engine operation

 Clean burn
Functional Requirements of Fuel Supply System
Functional Requirements of Fuel Supply System
Types of Fuel Supply System in CI Engine
Classification of Supply System
Air Injection System
Solid Injection System

 In this context, Solid Injection Systems can be classified into four

main categories

1. Mechanical Injection System (conventional injection system)

2. Common rail systems
3. Unit injection systems
4. Unit pump systems
Mechanical Injection Systems
Direct Injection/indirect injection

 Until VW brought in Turbo Direct Injections (TDIs), all diesels had a

separate injection pump to provide pressurized diesel to each injector,
these were either in-line pumps or distributor pumps
 Injection pumps are expensive and complex with very fine tolerances and
are only serviceable by people who know what they're doing

 However, they are extremely durable and should outlast the engine if the
fuel is kept clean and water-free)

 Most large truck/machinery diesels and some early passenger diesels

were direct injection

 Direct injection means just that diesel fuel is atomized by the injector and
sprayed directly into the combustion space offered by the ascending piston
Mechanical Injection Systems
Direct Injection/indirect injection

 Direct injection diesels are generally noisier than IDI (In Direct Injection)
diesels

 Indirect injection was adopted by engine developers as a way of offering

petrol engine-like characteristics to buyers of diesel engine passenger cars
and light commercials... e.g. less noise, smoother running and a more
compact engine

 Direct injection is generally more fuel efficient than indirect injection as the
fuel isn't forced to "swirl" in the pre-combustion chamber, a process that
saps some of its potency

 Direct injection became applicable in passenger car diesel only after

computerization of the fuel system. This combined with modifications to the
pump(s) and injectors solved all of the problems of earlier direct injection
engines
With In-line injection pump
With Distributor injection pump
Mechanical Injection Systems-Direct Injection

Direct injection
Small losses
Higher efficiency
Lower fuel consumption
Engine speeds, up to about 4000 rpm
Mechanical Injection Systems-Indirect
Injection/Swirl chamber

Indirect-injection and swirl-chamber

Combustion is quick
Operate at high speeds, up to about
6000 rpm.
Greater losses
Lower efficiency
High fuel consumption

Swirl-chamber engine Pre combustion indirect-injection engines

Larger volume than the indirect- Roughly 25%, is separated into a pre-chamber
injection engine Fuel into the pre-chamber
Roughly 50% in the swirl-chamber Not sufficient air in the pre-chamber
Same process as in the indirect- Mixture is pressed out into the combustion
injection diesel chamber
Swirl-chamber engines-passenger- Heated electrically
car diesels
Common Rail Injection

 Common rail injection involves a high pressure fuel pump delivering

extremely high pressure fuel to a pipe (the common rail) that delivers fuel
to the injectors, Unlike other systems, the fuel is under a constantly high
pressure.

 Each injector is computer controlled, Electronic Diesel Control (EDC) in order

to deliver the exact amount of fuel to the cylinder at the exact time it's
needed.

 This ensures that the nozzle needle is opened or closed by the actuator, be
it solenoid valve or Piezo.

 Injectors with Piezo actuators are somewhat narrower and operate at a

particularly low noise level.
Common Rail Injection

Common rail systems have a modular design. Each system consists of a

high-pressure pump, injectors, a rail, and an electronic control unit.
Common Rail System (CRS)
Common Rail Diesel Fuel Systems
Common Rail Sub-Function

Leak off line

Common Rail Sub-Function
Common Rail Sub-Function
Common Rail Sub-Function
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel System Components
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Overview of a computer-controlled high-pressure common rail V-8 diesel engine
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail Diesel Fuel Injector Operation
Common Rail System Advantages and Benefits
Dimension of Modern Injection Technology
Unit Injector System

 The unit injector system is an electronically controlled system developed by

Bosch for diesel direct injection.

 It is suitable for cars and light commercial vehicles with up to 5 l engine

capacity and 312 hp engine power, the first installation in series production
cars was 1998.

 The pump and nozzle are therefore combined in a compact assembly which
is installed directly in the cylinder head.

 The unit injector system enables high injection pressures up to 2,200 bar.
 High performance for clean and powerful engines
 High engine power balanced against low consumption and low engine
emissions
 High degree of efficiency due to compact design
 Low noise level due to direct assembly in the engine block
Unit Injector System (UIS)
Unit Injector System (UIS)
Unit Injector System (UIS)
Injection profile rate of common rail and unit injector
Unit Pump System (UPS)
Unit Pump System (UPS)
Injection Pump
Comparision b/n EUI, CRS and pump line nozzle unit
 Three groups of fuel system were under consideration: (1) an electronically
controlled distributer pump, (2) an electronically controlled unit injector (EUI or
pump-nozzle unit) and (3) a common rail (CR) injection system.
Comparision b/n EUI, CRS and pump line nozzle
unit
 The efforts around each of the three technology lead to commercial fuel
systems for production vehicles, however the common rail system provided a
number of advantages and would eventually come to dominate as the primary
fuel system used in light-duty vehicles.

 DI engines are characterized by higher peak combustion pressures and, thus, by

higher noise than IDI engines.

 It was found that improved noise and low NOx emissions were best achieved by
introducing pilot injection(s).

 Pilot injection was most easily realized in the common rail system, which was capable
of stable deliveries of small pilot fuel quantities over the entire load/speed range of
the engine

 CRS has flexibility in controlling fuel injection quantity and injection timing enables
better spray penetration and mixing even at low engine speeds and loads.
Comparision b/n EUI, CRS and pump line nozzle
unit
 As high speed direct injection (HSDI) engines developed, more of the
energy to mix the air with fuel came from the fuel spray momentum as
opposed to the swirl mechanisms employed in older, IDI combustion systems.

 Only high pressure fuel injection systems were able to provide the mixing
energy and good spray preparation needed for low PM and HC emissions.

 To generate the energy required to inject the fuel in approximately 1

millisecond, the conventional distributor pump would have to provide nearly
1 kW of hydraulic power in four (in a 4-cylinder engine) 1 ms bursts per
pump revolution, thus placing considerable strain on the drive shaft