development of a common rail injection system
TRANSCRIPT
DEVELOPMENT OF A COMMON RAIL
INJECTION SYSTEM
Janne Enlund, Dave Jay, Niclas Liljenfeldt & Hannu Tienhaara
WÄRTSILÄ CORPORATION
Development of a common rail injection system / J.Enlund 1 © Wärtsilä 20th of October 2014
Content
• Introduction
• Common rail 2 system
• Simulations using GT-SUITE-Injector model
-Pump model
-Integrated high-pressure system model
-Integrated high- and low-pressure system model
• Conclusions
Development of a common rail injection system / J.Enlund 2 © Wärtsilä 20th of October 2014
Main business areas
Ship PowerPersonnel: 6300
Power PlantsPersonnel: 1100
Development of a common rail injection system / J.Enlund 3 © Wärtsilä 20th of October 2014
ServicesPersonnel:
11 000
R&D
Development of a common rail injection system / J.Enlund 4 © Wärtsilä 20th of October 2014
4-stroke diesel engines: Wärtsilä 32
• Several different configurations
• Different emission targets
Flexible injection system is
needed!
Marine engines Marine engines Power Plant engines Power Plant engine
Cylinder bore 320 mm 320 mm 320 mm 320 mm
Piston stroke 400 mm 400 mm 400 mm 400 mm
Engine speed 720 - 750 rpm 720 - 750 rpm 720 - 750 rpm 720 – 750 rpm
Piston speed 9.6 - 10 m/s 9.6 - 10 m/s 9.6 - 10 m/s 9.6 – 10 m/s
Mean effective pressure 24.9 bar 28.8 bar 22.9 - 23.3 bar 24.9 bar
Output per cylinder 480/500 kW 550/580 kW 450/460 kW 480/500 kW
Available cylinder
configurations
6L, 7L, 8L, 9L, 12V, 16V,
18V6L, 8L, 9L, 12V, 16V
6L, 7L, 8L, 9L, 12V, 16V,
18V, 20VW20V32
CR2 injection system
Development of a common rail injection system / J.Enlund 5 © Wärtsilä 20th of October 2014
CAD Image of system originally shown in live
presentation at GT conference removed for
confidentiality in published presentation
Development of a common rail injection system / J.Enlund 6 © Wärtsilä 20th of October 2014
• Maximum operation pressure 1800 bar
• Capable of pilot-, main- and post injections
• Designed for LFO- and HFO operation
CR2 injection system
CR2 INJECTOROne circuit injector
improved performance / accuracy
improved robustness / reliability
increased system pressure
reduction of costs
Images of injector CAD and hydraulic
schematic originally shown in live
presentation at GT conference
removed for confidentiality in
published presentation
Simulations using GT-SUITE: Injector model
Development of a common rail injection system / J.Enlund 7 © Wärtsilä 20th of October 2014
Accumulator
Flow fuse
Control part
Nozzle
CAD Image of injector originally
shown in live presentation at GT
conference removed for confidentiality
in published presentation
Simulations using GT-SUITE: Injector model validation in test rig 1/2
Development of a common rail injection system / J.Enlund 8 © Wärtsilä 20th of October 2014
SOI EOI
Validation was carried out in the test
rig, which consists of three injectors.
Good match between the simulation
and the measurement in terms of
pressure!
Simulations using GT-SUITE: Injector model validation in test rig 2/2
It was possible to improve the needle
lift correlation by dividing the
mechanical needle structure in to the
several mass-spring elements.
Development of a common rail injection system / J.Enlund 9 © Wärtsilä 20th of October 2014
Simulations using GT-SUITE: High-pressure pump model
Development of a common rail injection system / J.Enlund 10 © Wärtsilä 20th of October 2014
Model of one element Full pump model
MDV
Plunger
element
Rotation
part
CAD Image of pump
originally shown in live
presentation at GT
conference removed for
confidentiality in published
presentation
Simulations using GT-SUITE: Integrated high-pressure system model
Development of a common rail injection system / J.Enlund 11 © Wärtsilä 20th of October 2014
High-pressure injection system Model of the system
Injectors
Pump
Safety
valve
CAD Image of pump, rail and
injectors originally shown in live
presentation at GT conference
removed for confidentiality in
published presentation
Simulations using GT-SUITE: Validation of the high-pressure system model
Development of a common rail injection system / J.Enlund 12 © Wärtsilä 20th of October 2014
Validation/ checks:
• Pressure pulsation
• Safety valve functionality
Simulations using GT-SUITE: Integrated high- & low-pressure system model
Development of a common rail injection system / J.Enlund 13 © Wärtsilä 20th of October 2014
Leakage lines from the injectors
Low-pressure pipe system
Injectors
PDSV
Pump
Simulations using GT-SUITE: Interaction with the low-pressure system
Development of a common rail injection system / J.Enlund 14 © Wärtsilä 20th of October 2014
Leakage
line
Engine exit
point
• Pulsation in engine exit point is < 16
bar in all cases!
Injectors
PDSV Pump
• Good correlation between the simulation and
the measurement
• Enables fast and efficient system development with less
design errors
• Possibility to optimize the high-pressure system and also the
interaction with the low-pressure system
GT-SUITE is an excellent tool for component and system
development!
Conclusions
Development of a common rail injection system / J.Enlund 15 © Wärtsilä 20th of October 2014
THANK YOU!
Janne Enlund
R&D, System simulation
+358 443504765