Download - Electronic Diesel Fuel System ( Common Rail)
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COMMON RAIL FUEL INJECTIONCOMMON RAIL FUEL INJECTION
SYSTEMSYSTEM
;JL";L\U V[g0 VMJZ CM,L\UVMO VM8MDMAF., s 0Lh,
f],[XG G\AZ : 15
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Demand On Modern Diesel EngineDemand On Modern Diesel En
gineDevelopmentDevelo
pment
• Low fuel consumptionLow fuel consumption
• Low pollutant emissionsLow pollutant emissions
•
Quiet running enginesQuiet running engines
• Improved engine performanceImproved engine performance
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Common rail !el in"e#tion s$stem and itsCommon rail !el in
"e#tion s$stem and its
!n#tion!n#tion
• Provide the diesel engine with fuelProvide the diesel engine with fuel
• Generate the high pressure needed for fuelGenerate the high pressure needed for fuel
injection and distribute the fuel to theinjection and distribute the fuel to the
individual cylindersindividual cylinders
• Inject precisely correct amount of fuel atInject precisely correct amount of fuel at
exactly the right moment in time.exactly the right moment in time.• In contrast to other injection system CommonIn contrast to other injection system Common
rail fuel injection system is an accumulatorrail fuel injection system is an accumulator
injection system.injection system.
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%o& does a CR s$stem !n#tion'%o& does a CR s
$stem !n#tion'
S u b f u n ! " # n s # f $ C % F & s ' s ! ( )
L o w p r e s s u r e c i r c u i t i g h p r e s s u r e c i r c u i t ! C " w i t h s e n s o r s
C O M M O N R A I L F U E L I N J E C T I O N S Y S T E M
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Low –pressure circuit comprises of:Low –pressure circuit comprises of:
Fuel tank ,Pre-supply pump, Fuel filter, And theFuel tank ,Pre-supply pump, Fuel filter, And therespective connection linesrespective connection lines
#he Common $ail %ub functions#he Common $ail %ub functions
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Low &pressure circuitLow &pressure circuit#he low &pressure circuit is responsible for#he low &pressure circuit is responsible for
transporting the fuel to the high &pressure circuittransporting the fuel to the high &pressure circuit
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%ig( )press!re #ir#!it #omprises*%ig( )press!re #ir#!it #omprises*
%ig( ) press!re p!mp &it( press!re ) #ontrol valve%ig( ) press!re p!mp &it( press!re ) #ontrol valveT(e (ig( ) press!re a##!m!lator +Rail ,&it( t(e rail )T(e (ig( ) press!re a##!m!lator +Rail ,&it( t(e rail )press!re sensor press!re sensor
In"e#tors- andIn"e#tors- and
T(e respe#tive (ig( ) press!re #onne#tion lines.T(e respe#tive (ig( ) press!re #onne#tion lines.
#he Common $ail %ub functions#he Common $ail %ub functions
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#he high & pressure circuit#he high & pressure circuit
It is t(e responsi/ilit$ o t(e (ig(It is t(e responsi/ilit$ o t(e (ig(
press!re #ir#!it to generate a #onstantpress!re #ir#!it to generate a #onstant!nvar$ing (ig( press!re in t(e (ig(!nvar$ing (ig( press!re in t(e (ig(
press!re a##!m!lator +t(e rail, and topress!re a##!m!lator +t(e rail, and to
in"e#t t(e !el t(ro!g( t(e in"e#tors intoin"e#t t(e !el t(ro!g( t(e in"e#tors intot(e engine0s #om/!stion #(am/ers.t(e engine0s #om/!stion #(am/ers.
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!C" and sensors!C" and sensors
#he common rail !C" evaluates the signals from the#he common rail !C" evaluates the signals from thefollowing sensors.following sensors.
Cran'shaft & speed sensor( Camshaft sensor(Cran'shaft & speed sensor( Camshaft sensor(
)ccelerator*pedal travel sensor )ccelerator*pedal travel sensor
#he Common $ail %ub functions#he Common $ail %ub functions
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#he common rail !C" evaluates the signals from the#he common rail !C" evaluates the signals from thefollowing sensors+following sensors+
,oost & pressure sensor( )ir temperature sensor(,oost & pressure sensor( )ir temperature sensor(
)ir & mass meter( and $ail pressure sensor. )ir & mass meter( and $ail pressure sensor.
#he Common $ail %ub functions#he Common $ail %ub functions
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#he Common $ail %ub functions#he Common $ail %ub functions
!C" and sensors!C" and sensors#he sensor are responsible for measuring important#he sensor are responsible for measuring important
physical -uantities. #he !C" calculates injected fuelphysical -uantities. #he !C" calculates injected fuel
-uantity( start of injection( duration of injection( and-uantity( start of injection( duration of injection( and
rate of discharge curve( as well supervises the correctrate of discharge curve( as well supervises the correct
functioning of the injection system as a whole.functioning of the injection system as a whole.
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P$! %"PPL P"/PP$! %"PPL P"/P
#ransports fuel from the fuel tan' to the high pressure#ransports fuel from the fuel tan' to the high pressurepump.pump.
)n electric fuel pump is used for this purpose in the )n electric fuel pump is used for this purpose in theC$0I%.C$0I%.
1hen the electric fuel pump is switched off( the supply1hen the electric fuel pump is switched off( the supplyof fuel is interrupted and the engine stops.of fuel is interrupted and the engine stops.
COMMON RAIL FUEL INJECTION SYSTEMCOMMON RAIL FUEL INJECTION SYSTEM
DESIGN DESIGN
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P$! %"PPL P"/PP$! %"PPL P"/P
#he electric fuel pump comprises of+#he electric fuel pump comprises of+
2.!lectric /otor 2.!lectric /otor
3.$oller*Cell Pump3.$oller*Cell Pump
4.5on $eturn 6alve4.5on $eturn 6alve
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#he roller cell is#he roller cell isdriven by an electricdriven by an electric
motor.motor.
Its rotor is mountedIts rotor is mountedeccentrically andeccentrically andprovided with slotsprovided with slotsin which movablein which movablerollers are free torollers are free totravel.travel.
P$! %"PPL P"/PP$! %"PPL P"/P
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#he rollers are forced#he rollers are forced
against the base plateagainst the base plateby rotation and by fuelby rotation and by fuelpressure .pressure .
#he fuel is#he fuel is
transported to thetransported to theoutlet openings on theoutlet openings on thepump7s pressure side.pump7s pressure side.
P$! %"PPL P"/PP$! %"PPL P"/P
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1ear t$pe !el p!mp1ear t$pe !el p!mp
*h( +-( g($*h( +-( g($
h((/ s +-(n b'h((/ s +-(n b'!h( (ngn( .!h( (ngn( .
D(/-(' u$n!!' sD(/-(' u$n!!' s+(!/' 1#1#!#n$/+(!/' 1#1#!#n$/
!# (ngn( s1((+ .!# (ngn( s1((+ . Shu! #2 s b' )($nsShu! #2 s b' )($ns
#f $n#f $n(/(!#)$gn(!..(/(!#)$gn(!..
P$! %"PPL P"/PP$! %"PPL P"/P
variantsvariants
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igh* pressure pumpigh* pressure pump
#he pump plunger moves downwards#he pump plunger moves downwards
#he inlet valve opens#he inlet valve opens
#he fuel is drawn in to the pumping element#he fuel is drawn in to the pumping elementchamber8suction stro'e9chamber8suction stro'e9
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)t ,:C( the inlet valve closes )t ,:C( the inlet valve closes
#he fuel in the chamber can be compressed by#he fuel in the chamber can be compressed bythe upward moving plunger.the upward moving plunger.
igh* pressure pumpigh* pressure pump
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)n electromagnet is )n electromagnet isused for pumpingused for pumpingelement switch*off.element switch*off.
igh* pressure pumpigh* pressure pump
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igh* pressure accumulator 8$ail9igh* pressure accumulator 8$ail9%tore fuel%tore fuel
Prevent pressure fluctuationsPrevent pressure fluctuations
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$ail is a forged*steel tube.$ail is a forged*steel tube.
I: is approx.. 2;mmI: is approx.. 2;mm
Length is between 3
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Pressure*control valve 8:$69Pressure*control valve 8:$69
$esponsible for$esponsible for
maintaining themaintaining thepressure in thepressure in therail at arail at aconstant level.constant level.
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$ail*pressure sensor 8$:%9$ail*pressure sensor 8$:%9
/easures the/easures the
pressure in the railpressure in the rail
inputs the informationinputs the information
to the !C"to the !C"RDS shouldRDS should
provideprovideextremelyextremely
preciseprecise
measuredmeasured
values. values.
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Injector Injector Injects exactly the correct amount of fuelInjects exactly the correct amount of fuel
in to the combustion chamber at preciselyin to the combustion chamber at precisely
the right moment in timethe right moment in time
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#he injector is e-uipped with+#he injector is e-uipped with+
3>3 electromagnetic servo valve3>3 electromagnetic servo valve
5o??le5o??le
6alve control chamber 6alve control chamber
$eturn line$eturn line
Injector Injector
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#he essential forces for correct functioning are+#he essential forces for correct functioning are+
5o??le*spring force5o??le*spring force
6alve spring force6alve spring force
!lectromagnet force!lectromagnet force
0orce due to the pressure in the valve*control0orce due to the pressure in the valve*controlchamberchamber
0orce due to the pressure in the no??le needle0orce due to the pressure in the no??le needle
Injector Injector
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!C" with sensors!C" with sensorsCommon $ail is an !:C controlled injectionCommon $ail is an !:C controlled injection
systemsystem
#he !C" controls @ monitors the complete#he !C" controls @ monitors the completeinjection processinjection process
#he sensors delivers all the measured values#he sensors delivers all the measured values
which are re-uired in the processwhich are re-uired in the process
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%ummary
Components of C$0I% are+Components of C$0I% are+
Pre-supply pumpPre-supply pump
High-pressureHigh-pressurepumppump
High-pressureHigh-pressure
accumulator(rail)accumulator(rail) Pressure-controlPressure-control
valve valveRail-pressure sensor Rail-pressure sensor
InjectorsInjectors
!" #ith sensors!" #ith sensors
!$%%$& R'I " I&*!+I$&!$%%$& R'I " I& *!+I$&
S,S+%S,S+%
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!"##"$ %A&L F'(L &$)(!*&"$ ++*(#!"##"$ %A&L F'(L &$)(!*&"$ ++*(#
+'##A% +'##A%
1.The basic functional !ou"s of the co##on !ail a!e $ lo%1.The basic functional !ou"s of the co##on !ail a!e $ lo% & "!essu!e ci!cuit ' hih & "!essu!e ci!cuit ECU an( & "!essu!e ci!cuit ' hih & "!essu!e ci!cuit ECU an(
senso!s.senso!s.
).In the lo% & "!essu!e ci!cuit' the fuel is cleane( b* a filte!).In the lo% & "!essu!e ci!cuit' the fuel is cleane( b* a filte!
an( then t!ans"o!te( to the hih & "!essu!e ci!cuitan( then t!ans"o!te( to the hih & "!essu!e ci!cuit
CA//A5 $)IL 0"!L I5B!C#IA5 %%#!/CA//A5 $)IL 0"!L I5B!C#IA5 %%#!/
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%"//)$%"//)$4.In the high & pressure circuit ( the maximum4.In the high & pressure circuit ( the maximumpressure of 2(4; bar is generated in the high &pressure of 2(4; bar is generated in the high &pressure accumulator 8$ail9.pressure accumulator 8$ail9.
#he pressure is maintained at a constant#he pressure is maintained at a constantlevel ( and the fuel is ta'en from the rail everylevel ( and the fuel is ta'en from the rail everytime an injection ta'es place.time an injection ta'es place.
D.#he !C" controls and monitors the completeD.#he !C" controls and monitors the completeinjection system. "sing the signals from theinjection system. "sing the signals from thesensors( the !C" calculates all the values forsensors( the !C" calculates all the values forthe injection process and triggers thethe injection process and triggers thecomponents in high*pressure circuit 8pressure &components in high*pressure circuit 8pressure &control valve( injectors9.control valve( injectors9.