automotive systems course (module 04) - fuel systems in compression ignition (ci) internal...

27 de outubro de 2016 | 1

Sistemas A

uto

mó

veis

Fuel systems – CI engines

Mário Alves ([email protected])

mailto:[email protected]


Sistemas A

uto

mó

veis

Outline

• Objective of fuel systems

• Classification of fuel systems

• Evolution – powertrains, technology, fuel pressure, regulations

• Objectives and requirements of Diesel fuel injection systems

• Evolution of Diesel fuel injection systems

• Diesel fuel injection system – architecture/components

• In-line pump systems

• Distributor-type pump injection systems

• Unit-Injector injection systems

• Unit-Pump injection systems

• Common-rail systems

• Fuel Injectors

• Exhaust system


Sistemas A

uto

mó

veis

Objective of fuel injection systems

• To deliver fuel into the cylinders

• at proper timings (optimizing power, preventing pre-ignition)

• in accurate amounts (for optimal A/F ratio, function of load, RPM,

engine temperature,…)

• in the right form (fuel atomization, for full combustion and lower

emissions)


Sistemas A

uto

mó

veis

Classification of fuel systems (CI and SI)

Operating principle

ICE type single or multiple injectors

direct/indirect injection

technology

Mechanical SI (single point) indirect Carburetor

Diesel (multi-point) direct or indirect

Injection Pump (in-line or rotary), few hundred bars

Electronic SI SPI indirect in the throttle body, few bars

MPI indirect Fuel rail, few bars

direct Fuel rail, tens of bars

Diesel (multi-point) direct Fuel-rail or pump/unit-injection, hundreds to thousands of bars


Sistemas A

uto

mó

veis

Evolution – market share (Europe and USA)

http://www.turnermason.com/index.php/oh-lord-wont-you-buy-me-

a-mercedes-benz-or-audi-vw-or-bmw-as-long-as-its-diesel/

http://www.turnermason.com/index.php/oh-lord-wont-you-buy-me-a-mercedes-benz-or-audi-vw-or-bmw-as-long-as-its-diesel/







































Sistemas A

uto

mó

veis

Evolution – light vehicles powertrain (current)

http://www.autocar.co.uk/car-news/industry/uk-under-pressure-european-air-quality-ruling


















Sistemas A

uto

mó

veis

Evolution – light vehicles powertrain (forecast)

http://www.economist.com/news/special-report/21576219-carmakers-are-

hedging-their-bets-powering-cars-great-powertrain-race

http://www.economist.com/news/special-report/21576219-carmakers-are-hedging-their-bets-powering-cars-great-powertrain-race

























Sistemas A

uto

mó

veis

Evolution – European emission standards (Diesel)

http://www.clm.co.uk/diesel-emissions-crackdown/








Sistemas A

uto

mó

veis

Evolution – European emission standards

https://www.ngk.de/en/technology-in-detail/lambda-sensors/basic-

exhaust-principles/euro-standards/

https://www.ngk.de/en/technology-in-detail/lambda-sensors/basic-exhaust-principles/euro-standards/















Sistemas A

uto

mó

veis

Evolution – emission reduction vs. technologies

http://www.accessmagazine.org/articles/fall-2001/clean-diesel-overcoming-noxious-fumes/














Sistemas A

uto

mó

veis


http://www.transportpolicy.net/index.php?title=EU:_Light-duty:_Emissions






Sistemas A

uto

mó

veis


https://www.researchgate.net/publication/260643808_Particulate_emissions_from_diesel_en

gines_Correlation_between_engine_technology_and_emissions/figures

https://www.researchgate.net/publication/260643808_Particulate_emissions_from_diesel_engines_Correlation_between_engine_technology_and_emissions/figures




Sistemas A

uto

mó

veis

Evolution – fuel pressure vs. models

• 1927: 100 bar • 1st series-production inline injection pump; MAN truck

• 1975: 300 bar • 1st VE distributor injection pump (VW Golf D)

• 1989: 900 bar • Axial-piston pump (Audi 100 TDI)

• 1995:

• 1st Diesel common-rail system for trucks (by Denso)

• 1997: 1,350 bar • 1st common rail system for light-duty (Bosch/fiat, Alfa-Romeo 156 2.4 JTD)

• 1998: 1,500 – 1,750 bar • VP 44 radial-piston pump (Opel Vectra, Audi A6 2.5 TDI, 1996; BMW 320d)

• 1998: 2,050 bar • 1st unit injector system (VW Passat TDI, 1998)

• 2003: > 2,000 bar • Bosch common rail with piezo injector (first deployed in the Audi A6 3.0 TDI, 2003/4)

• 2013/14: 2,500 bar • Denso releases 1st common-rail system with 2500 bar (2013)

• Bosch releases CRS3-25 common-rail system with 2500 bar (2014)

http://www.globaldenso.com/en/newsreleases/130626-01.html

http://www.car-engineer.com/injection-pressure-evolution-diesel-engine/



















Sistemas A

uto

mó

veis

Evolution – supercharging/injection pressures

https://www.researchgate.net/publication/260643808_Particulate_emissions_from_diesel_e

ngines_Correlation_between_engine_technology_and_emissions/figures





Sistemas A

uto

mó

veis

Evolution – production of different Diesel technologies

http://pt.slideshare.net/Henriquecarvalhob/tendncias-dos-sistemas-diesel

• Light vehicles (by Bosch)










Sistemas A

uto

mó

veis

Evolution – production of different Diesel technologies


• Commercial and heavy-duty vehicles (by Bosch)










Sistemas A

uto

mó

veis

Classification of CI fuel systems

• Class. according to when/how high fuel-pressure is produced

• High pressure generated when injection occurs (dependent on RPM)

• In-line pump systems (PE by Bosch)

• Distributor-pump systems (VE by Bosch)

• axial-piston

• radial piston

• Unit-Injector Systems (UIS by Bosch)

• Unit-Pump Systems (UPS by Bosch)

• High pressure always available

(independent of RPM)

• Accumulator-type = Common-Rail

Systems (CRS by Bosch)

http://www.appropedia.org/Engine_components




Sistemas A

uto

mó

veis


Distributor

pump

Common-

rail

Unit-

Injector

Unit-

pump

http://clwydinjectionservices.boschauto.co.uk/bosch-diesel/

http://www.trucktrend.com/how-to/expert-advice/0904dp-diesel-injection-pumps/


















Sistemas A

uto

mó

veis


• CI fuel systems can be classified according to where the fuel

is injected

• Indirect injection (right)

• Direct injection (left)

http://www.turnermason.com/index.php/oh-lord-wont-you-buy-me-a-mercedes-benz-

or-audi-vw-or-bmw-as-long-as-its-diesel/








































Sistemas A

uto

mó

veis


https://www.quora.com/What-is-the-difference-between-direct-and-

indirect-fuel-injection

Direct Injection

Indirect Injection

https://www.quora.com/What-is-the-difference-between-direct-and-indirect-fuel-injection





















Sistemas A

uto

mó

veis

Requirements of CI injection systems

• Generic objectives of a fuel injection system

• Reduce emissions and fuel consumption

• Maximize engine power/performance

• Requirements

• atomize & pulverize fuel very finely (better combustion)

• high pressure differential (btw fuel and combustion chamber)

• pressure inside cylinder 100 bar

• high fuel pressure (> 300 bar)

• optimal-spray injectors

• optimize injection timings and quantity (mass)

• ECU-control (real-time, closed-loop)

• fast-response injectors (piezo-electric)

• minimize pollutant emissions (according to regulations)

• EGR, catalyst, SCR, particulate filters


Sistemas A

uto

mó

veis

Diesel fuel injection system – architecture/components

• Major component groups

• Low (fuel) pressure system

• deliver fuel from the tank to the fuel injection system

• fuel tank, fuel supply pump, fuel filter.

• High (fuel) pressure system

• create high pressure, measure, control and deliver the fuel to the

combustion chamber

• high pressure pump, fuel injector; common-rail systems also include

a high-pressure fuel accumulator (aka fuel rail)

• Control system

• sensors, ECU, actuators

• in purely mechanical systems, control is performed by the high

pressure pump

http://www.dummies.com/how-to/content/how-do-diesel-engines-work.html














Sistemas A

uto

mó

veis

Diesel fuel injection system – architecture/components

• Overall architecture and main components

http://www.denso.com.sg/products/pump/diesel-fuel-injection

Injection-pump type Common-rail type





















Sistemas A

uto

mó

veis

Diesel fuel injection system – low pressure circuit

• Main objective • store fuel and feed the high-pressure circuit

• Main components • Fuel tank

• store and cool the fuel

• Feed pump (aka fuel supply, low-pressure, transfer, lift or primary pump)

• not used in some fuel systems (high-pressure pump does the job)

• drag fuel from the tank and push it to the high-pressure pump

• usually includes a pre-filter

• Fuel filter

• filters impurities and purges water out of the fuel circuit

• prevents engine damage & improves its performance

• Fuel heater

• avoid the forming of paraffin wax, in case of low temperatures (which can stop the fuel flow)

• can be embedded into the fuel filter

• Charcoal (carbon) canister

• transforms evaporated fuel into liquid fuel

• Pipes

• fuel feed/return

https://www.dieselnet.com/tech/diesel_fi_common-rail_control.php






Sistemas A

uto

mó

veis


• Fuel tank main objectives

• store the fuel

• receive the fuel return (backflow) from the high-pressure components

• host other components, e.g. feed pump and fuel level gauge

• Must feature

• optimal volume, shape and location

• robustness to prevent spillage and leakage, even in case of an accident,

e.g. rollover; must also be fire-proof

• fuel overheating and overpressure detection and mitigation, via

ventilation and safety valves

• fuel level gauge

• electrical harness for feed pump (if located inside the tank)


Sistemas A

uto

mó

veis


• Tank + canister example (Mercedes SLK320)

http://www.benzworld.org/forums/r170-slk-class/1434072-fuel-tank-filling-problem-slk320-pump.html




















Sistemas A

uto

mó

veis


http://www.tb-training.co.uk/CIsys.htm

http://www.autorepairnewark.info/how-can-mechanical-and-electric-fuel-pumps-work.html

• Feed pump (mechanically-driven)

• driven by camshaft, outside the tank






















Sistemas A

uto

mó

veis


• Feed pump (electrically-driven)

• ECU-controlled, inside the tank

• produces a few bars


http://www.agcoauto.com/content/news/p2_articleid/195







Sistemas A

uto

mó

veis


• Fuel filters remove

• m particles

• water (manual

or automatic

draining)

• Water sensor

• signals full

water chamber

http://de.bosch-automotive.com/en/parts_and_accessories/service_parts_1/filters_1/diesel_filters_1/diesel_filters_1





Sistemas A

uto

mó

veis


• Fuel heater

• avoids wax forming

for low temperatures

• upstream the filter

• inside/outside filter casing

http://www.justanswer.com/dodge/253gc-sometimes-truck-does-not-start-right-away-just-cranks.html






















Sistemas A

uto

mó

veis

Diesel fuel injection system – in-line pump systems

• One pump element for each engine cylinder

• elements arranged in a row

• activated by a camshaft in the in-line pump

• driven by the combustion engine

• via control wheels or chains

• Each pump element is connected via a high-pressure

line to an injection nozzle installed in the cylinder

head by means of a nozzle holder

• nowadays, the amount of fuel

injected and the start of delivery

are controlled by ECU.

• In-line fuel-injection pumps achieve

injection pressures of up to 1,300 bar

http://what-when-how.com/automobile/in-line-injection-pumps-automobile/

http://products.bosch-mobility-solutions.com/en/de/_technik/component/PT_CV_DS_Other-Injection-Systems_PT_CV_Diesel_2112.html


























Sistemas A

uto

mó

veis


• Amount of injected fuel depends on

• factory settings, manual adjustments, RPM, coolant temperature,

barometric pressure, accelerator position, start & stop solenoids

http://www.sl113.org/forums/index.php?topic=790.0




Sistemas A

uto

mó

veis



http://www.free-ed.net/sweethaven/MechTech/Automotive01/AutomotiveSystems03_Files.asp?iNum=42








Sistemas A

uto

mó

veis

Diesel fuel injection system – distributor-pump systems

• Distributor pumps classification

• axial piston or radial piston

• purely mechanically-controlled or ECU-controlled

http://de.bosch-

automotive.com/en/parts_and_accessories/motor_and_sytems/diesel/conventional_injection/conventional_injection_diesel_motorsys_parts

http://de.bosch-automotive.com/en/parts_and_accessories/motor_and_sytems/diesel/conventional_injection/conventional_injection_diesel_motorsys_parts







Sistemas A

uto

mó

veis


• Axial-piston pump basics

• pistons attached to a cylindrical block which move in the same

direction as the block's centerline (axially)

• reliable operation and simple design

http://www.globalspec.com/learnmore/flow_transfer_control/pumps/piston_plunger_pumps

http://vwdiesel.net/forum/index.php/topic,30340.0.html






Sistemas A

uto

mó

veis


• Radial-piston pump basics

• pistons arranged like wheel spokes around a cylindrical block.

• drive shaft rotates this cylindrical block which pushes or slings

the pistons, causing compression and expansion

• eccentricity between the piston housing and cylinder block

centerlines determines the piston stroke

• low noise level and high efficiency

http://www.globalspec.com/npapics/93/159940_050120134659_ExhibitPic.jpg

http://i1104.photobucket.com/albums/h331/specsalot/DelphiDFP6injectoronVW12lTDI-H.jpg http://www.globalspec.com/learnmore/flow_transfer_

control/pumps/piston_plunger_pumps

http://www.globalspec.com/npapics/93/159940_050120134659_ExhibitPic.jpg

http://i1104.photobucket.com/albums/h331/specsalot/DelphiDFP6injectoronVW12lTDI-H.jpg








Sistemas A

uto

mó

veis


• Mechanically-controlled (governed) axial-piston

distributor fuel-injection pump (VE by Bosch)

• typically up to 1100 bar; up to 1200 bar (SOTA VE-EDC)

http://www.dieselmotors.info/fuel-systems/diesel-engine-bosch-ve-fuel-pump.html
















Sistemas A

uto

mó

veis


• VE pump

















Sistemas A

uto

mó

veis



• VE pump






Sistemas A

uto

mó

veis


• Feed pump (aka vane pump)

• draws fuel through the filter from

the tank and supplies it to the

distributor plunger

• as the rotor spins, centrifugal force

holds the vanes against the walls of

the pressure chamber

• off-center (eccentric layout) of the

rotor and pressure chamber

"squeezes" fuel trapped between the

vanes and forces it out the delivery

port

• delivery pressure 3-7 bar,

depending on RPM

http://www.zexel.hk/news_more.asp?NewsID=97




Sistemas A

uto

mó

veis


• High-pressure compression and distribution

• injection pump driveshaft turns vane pump, distributor plunger,

and cam plate (as a unit)

• springs hold the cam plate and distributor plunger against

stationary rollers the plunger moves back and forth as it turns

http://chris.chemidl.in/vw-diesel-info/diesel-basics/injection-pump-distribution-injection-metering/


















Sistemas A

uto

mó

veis



• whenever an intake port on the plunger is in line with the filling

port in the pump body, fuel from the vane pump fills the high

pressure chamber.



















Sistemas A

uto

mó

veis



• as the plunger continues to turn, the outlet port lines up with the

injection ports in the pump body

• the cam plate pushes the plunger to “squeeze” the fuel in the high

pressure chamber



















Sistemas A

uto

mó

veis



• the delivery valve opens under pressure and high pressure fuel is

supplied to the injector

• The ports in the pump are arranged so that the injectors receive

fuel in the cylinder firing sequence



















Sistemas A

uto

mó

veis



• Complete sequence

• A – suction

• B – delivery


http://what-when-how.com/automobile/bosch-ve-type-distributor-pump-automobile/


Sistemas A

uto

mó

veis


• Governing the fuel injection quantity

• amount of fuel injected is controlled by a governor

• injection cut-off point depends on RPM & engine load

• controlled by the metering sleeve on the distributor plunger

• metering sleeve covers and uncovers a relief port in the

plunger – uncovering the relief port stops injection





Sistemas A

uto

mó

veis


• Governing the fuel injection quantity – engine start

• when engine is not running, starting spring presses the starting

lever to the left so that the metering sleeve moves to the right.

• distributor plunger must move further to expose the relief port

• injection lasts longer so that more fuel is supplied during starting



















Sistemas A

uto

mó

veis


• Governing the fuel injection quantity – idle speed

• flyweights partially expanded governor sleeve moves right

• starting lever pushes control lever metering sleeve moves left

• distributor plunger now moves less to expose the relief port.

• injection lasts shorter so that less fuel is supplied at idle



















Sistemas A

uto

mó

veis


• Governing the fuel injection quantity – acceleration

• control lever is pulled to the left by the accelerator lever

• metering sleeve is moved to the right (fuel is injected before relief

port is uncovered)

• RPM increases until governor movement “neutralizes” effect of

pedal linkage



















Sistemas A

uto

mó

veis


• Governing the fuel injection quantity – max RPM

• accelerator lever at “full load” maximum RPM

• flyweights stretch governor spring control lever moves right

• metering sleeve moves left (uncovers relief port at the beginning

of the distribution plunger stroke)

• LESS fuel injected and top speed is limited.



















Sistemas A

uto

mó

veis


• Governing the fuel injection quantity – 4 states


STARTING IDLE ACCELERATION MAX RPM




Sistemas A

uto

mó

veis


• Governing the fuel injection timing (advance)

• as RPM increases, stroke timing becomes shorter and injection

timing becomes longer

• burning must begin sooner to ensure that peak combustion

pressures still occur at the most efficient point after TDC

• injection timing is advanced by hydraulic piston in injection pump





Sistemas A

uto

mó

veis


• Governing the fuel injection timing (advance)

• > RPM fuel pressure from the vane pump

• vane pump pressure pushes the injection advance piston to the left

against the spring so that the roller housing turns slightly

• distributor plunger beings injection sooner





Sistemas A

uto

mó

veis


• Governing the fuel injection timing/quantity





Sistemas A

uto

mó

veis


• Bosch VP44 radial-piston injection pump

• introduced in 1998 to meet emissions standards (before common rail fuel

systems were available, in the 2000s) and to reduce fuel consumption

• direct-injection system for small to medium-size engines

• 2 ECUs control fuel injection quantity/timing

• injection pressures up to 1600 bar

http://zisokilt.jimdo.com/2012/06/29/bosch-vp44-diagram/

http://www.trucktrend.com/how-to/expert-advice/1303dp-injection-system-basics/




















Sistemas A

uto

mó

veis



• Engine Control Unit – ECU (aka ECM)

• receives and processes data from sensors

• commands FPCM (via CAN) for target fueling and timing

• Fuel Pump Control Module – FPCM

• embedded in the injection pump

• contains fueling, timing and diagnostic data.

• responds to ECM commands according to fueling data and timing in

its memory and actuates fueling+timing solenoids

http://dodgeram.org/tech/dsl/ISB/Vp44.htm

http://www.justanswer.com/heavy-equipment/4q11a-5-9-code-254-fuel-shut.html




















Sistemas A

uto

mó

veis



• section of the circuit diagram & sensors

http://www.justanswer.com/heavy-equipment/7fyc6-2003-freightliner-mt55-rolling-chassis-cummins-5-9.html






















Sistemas A

uto

mó

veis



• fuel injection flow and fuel injection timing (advance) control

http://www.aficionadosalamecanica.net/gestion_electronica_diesel2.htm




Sistemas A

uto

mó

veis

Diesel fuel injection system – unit-injector systems

• Unit Injector (UIS) and Unit Pump (UPS) systems

• each cylinder is served by a separate injection pumping element

or injection pump in close proximity to the cylinder

• Unit Pump (UP) systems

• enable short high pressure fuel lines (pump close to injector)

• Unit injector (UI) systems combine the pumping element

and the injector into one assembly

• eliminates high pressure lines

• < line dynamics problems (e.g. delay)

• > injection pressures (up to 2500 bar)


https://www.dieselnet.com/tech/diesel_fi_ui.php
















Sistemas A

uto

mó

veis


• Unit Injector Systems (UIS)

1. pressure generation unit

2. camshaft

3. rocker arm (roller type)

4. electromagnetic valve

5. injection nozzle

http://www.chiptuning.co.za/howdieselworks.php

http://www.northerndiesel.co.za/INJECTORS.htm






Sistemas A

uto

mó

veis


• UIS camshaft and basic control diagram

• engine camshaft has 3 cams (lobes) per cylinder

• ECU controls fuel injection quantity/timing

http://www.dongamarine.com/subtececu.html

http://www.gwdale.co.uk/UnitInjector.html

Admission & Exhaust cams

Unit injector cam






Sistemas A

uto

mó

veis


• Unit injector components

1. Electromagnetic (solenoid) valve

2. Pump tappet

3. Pump piston (plunger)

4. High pressure chamber (barrel)

5. Nozzle assembly

• spring

• nozzle check

• nozzle tip

http://engine-assembly-disassembly.blogspot.pt/2014/11/systems-operation-

c-15-c-16-and-c-18_85.html

http://engine-assembly-disassembly.blogspot.pt/2014/11/systems-operation-c-15-c-16-and-c-18_85.html























Sistemas A

uto

mó

veis


• Fuel injection cycle

1. Filling

• admission of fuel into the (high-pressure) fuel chamber

2. Pre-injection

• preparation for the injection phase

3. Injection

• high-pressure fuel injection into the combustion chamber

4. End of injection


c-15-c-16-and-c-18_85.html
























Sistemas A

uto

mó

veis


• Filling phase

1. rocker arm releases tappet (tappet spring

pushes it upwards)

2. plunger is pulled up by the tappet and the

tappet spring

3. upward movement of the plunger causes the

pressure in the plunger cavity to drop below

fuel supply pressure

4. Fuel flows from the fuel supply passage (via

open poppet valve) into the plunger cavity,

until as the plunger travels upward

5. when plunger reaches top of stroke, plunger

cavity is full of fuel and fuel flow stops

• this is the beginning of pre-injection


c-15-c-16-and-c-18_85.html

Mechanical movement

Moving parts

Fuel movement
























Sistemas A

uto

mó

veis


• Pre-injection phase

1. pre-injection starts with

• injector tappet/plunger at the top of the

fuel injection stroke

• plunger cavity full of fuel

• poppet valve opened

• nozzle closed

2. rocker arm starts pushing tappet/plunger

downwards

3. fuel leaves the plunger cavity, flowing through

the open poppet valve to the fuel supply

passage in the cylinder head

• pre-injection continues until solenoid is

energized, closing the poppet valve and

triggering injection (next)


c-15-c-16-and-c-18_85.html

Fuel supply pressure

Injection pressure

Moving parts

Mechanical movement

Fuel movement
























Sistemas A

uto

mó

veis


• Injection phase

(rocker arm keeps pushing tappet/plunger down)

1. ECU sends a current to the electromagnetic

valve solenoid, attracting the armature

2. poppet valve closes, blocking flow path for the

fuel that was leaving the high pressure chamber

(fuel return line to the tank)

3. plunger continues its downward movement,

compressing fuel in the high-pressure chamber

4. when fuel pressure reaches threshold, high

pressure fuel force overcomes spring force

5. high-pressure fuel flows out of the injector

nozzle (start of injection)

• injection continues while plunger moves

downwards and energized solenoid holds the

poppet valve closed


c-15-c-16-and-c-18_85.html


Injection pressure

Moving parts

Mechanical movement

Fuel movement
























Sistemas A

uto

mó

veis


• End of injection phase

1. ECU stops current flow to the solenoid,

releasing the armature

2. poppet valve opens, unblocking flow path for

the fuel to leave the high pressure chamber

3. this results in a rapid drop in injection pressure

4. when injection pressure drops below a certain

threshold, the force of the nozzle spring

overcomes the force of the fuel pressure

5. injection nozzle closes and fuel injection stops


c-15-c-16-and-c-18_85.html


Moving parts
























Sistemas A

uto

mó

veis


• UIS diagram (detailed) 1. Accelerator position (APP) sensor

2. Battery

3. Crankshaft position (CKP) sensor

4. Engine control module (ECM) 5. Engine control relay

6. Engine coolant temperature (ECT) sensor

7. Exhaust gas recirculation (EGR) solenoid

8. Fuel cooler

9. Fuel filter

10. Unit injector

11. Fuel lift pump 12. Fuel lift pump relay

13. Fuel pressure regulator

14. Fuel tank

15. Fuel temperature sensor

16. Glow plug relay

17. Glow plug

18. Glow plug warning lamp

19. Ignition switch

20. Intake air temperature (IAT) sensor

21. Malfunction indicator lamp (MIL)

22. Manifold absolute pressure (MAP) sensor

23. Mass air flow (MAF) sensor

24. Turbocharger wastegate regulating valve

25. Vehicle speed sensor (VSS)





Sistemas A

uto

mó

veis

Diesel fuel injection system – unit-pump injection systems

• One pump per cylinder (unit-pump), directly driven by engine camshaft

• Unit-pump connected to injector via short high-pressure line.

• For medium to heavy-duty diesel engines (up to 80 kW per cylinder)

• Fuel-injection pressures of up to 2,200 bar

• Injection quantity/timing

• Purely Mechanically-controlled

• ECU-controlled

http://www.hydrotransonline.com/Products/images/Diesel_UPS.jpg

http://www.indiamart.com/stanadyne-amalgamations/products.html








Sistemas A

uto

mó

veis


• System schematics (ECU-controlled system)

http://link.springer.com/article/10.1007%2F978-3-8348-9715-2_11/lookinside/000.png

http://link.springer.com/article/10.1007/978-3-8348-9715-2_11/lookinside/000.png











Sistemas A

uto

mó

veis


• Unit-pump and fuel

injector detail

http://link.springer.com/article/10.1007%2F978-3-8348-9715-2_11/lookinside/000.png












Sistemas A

uto

mó

veis

Diesel fuel injection system – common-rail systems

• High-pressure fuel accumulator feeds all

injectors

• usually known as common-rail

• High pressure fuel pump feeds fuel rail

• pressure is independent of RPM

• ECU controls fuel pressure and injection

quantity/timing

• First series-production systems

• Denso, 1995, heavy-duty trucks

• Hino Rising Ranger

• Bosch/Fiat, 1997, passenger cars

• Alfa Romeo 156 2.4 JTD

• Mercedes-Benz C 220 CDI

http://www.partinfo.co.uk/articles/106

https://www.dieselnet.com/tech/diesel_fi_common-rail.php








Sistemas A

uto

mó

veis


• Main components (high-pressure circuit)

1. Damping case, fuel return

2. High pressure accumulator

3. Fuel Pressure sensor

4. High pressure line

(accumulator to injector)

5. Fuel return line

6. Injector

7. High-pressure pump

8. Pressure regulator (pump)

9. High pressure line (to rail)

10. Pressure regulator (rail)

http://workshop-manuals.com/vauxhall/astra-

h/j__engine_and_engine_aggregates/fuel_injection_systems/electronic_diesel_control_edc_16_c39/

component_locator/illustration_of_common_rail/

http://workshop-manuals.com/vauxhall/astra-h/j__engine_and_engine_aggregates/fuel_injection_systems/electronic_diesel_control_edc_16_c39/component_locator/illustration_of_common_rail/








Sistemas A

uto

mó

veis


• System diagram

1. Feed pump

(not in all systems)

2. Filter

3. Overflow valve

4. Fuel return manifold

5. High Pressure pump

6. Pressure control valve

(not in all systems)

7. Rail pressure sensor

8. Fuel rail

9. Injectors

10. ECU

11. Fuel temperature sensor

12. Other sensors





Sistemas A

uto

mó

veis


• Example of control diagram

http://pt.slideshare.net/KamalVora1/dr-vora-ppt-chapter-6-crs














Sistemas A

uto

mó

veis


• Main manufacturers

• Denso

• HP2, HP3, HP4

• Bosch

• CRS1/CP1, CRS2/CP2, CRS3/CP3, CRS4/CP4

• Delphi

• Multec/DFP6

• Other

• Caterpillar

• Siemens

http://inyecciondieselnaval.blogspot.pt/2012/01/bosch-y-los-

sistemas-common-rail.html

http://inyecciondieselnaval.blogspot.pt/2012/01/bosch-y-los-sistemas-common-rail.html













Sistemas A

uto

mó

veis


• Bosch CRS1/CP1

http://www.remmington.info/Common%20rai

l%20pumps.htm

http://www.remmington.info/Common rail pumps.htm




Sistemas A

uto

mó

veis


• Bosch CRS3/CP3 EDC16 – fuel circuits

http://www.slideshare.net/amgadradhihadi/common-rail-diesel-fuel-systems












Sistemas A

uto

mó

veis


• Bosch CRS3/CP3 EDC16 – components overview













Sistemas A

uto

mó

veis


• Bosch CRS3/CP3 EDC16 – electromechanical diagram















Sistemas A

uto

mó

veis


• Bosch CRS3/CP3 EDC16 – ECU input/output diagram















Sistemas A

uto

mó

veis


• Bosch CP3 – main components (V8)

• high-pressure pump, fuel rails, injectors and fuel lines

http://www.trucktrend.com/how-to/parts-accessories/1204dp-inside-the-

bosch-cp3-injection-pump/

http://www.trucktrend.com/how-to/parts-accessories/1204dp-inside-the-bosch-cp3-injection-pump/



















Sistemas A

uto

mó

veis


• Bosch CP3 – low-pressure circuit

A. Feed pump

B. Flow rate limiter throttle

C. overflow valve

D. Fuel metering unit (fuel pressure regulator)

E. zero delivery throttle

http://www.trucktrend.com/how-to/parts-

accessories/1204dp-inside-the-bosch-cp3-injection-

pump/




















Sistemas A

uto

mó

veis


• Bosch CP3 – high-pressure circuit

A. Suction valves

B. Plungers (B)

C. High-pressure valves

http://www.trucktrend.com/how-to/parts-

accessories/1204dp-inside-the-bosch-cp3-injection-pump/




















Sistemas A

uto

mó

veis


• Bosch CP3 – high-pressure pump overview

http://img.photobucket.com/albums/v374/grand_toots/2000%20Eddie%20Bauer%20Ford%20Explorer/HPFP.jpg

http://img.photobucket.com/albums/v374/grand_toots/2000 Eddie Bauer Ford Explorer/HPFP.jpg

http://img.photobucket.com/albums/v374/grand_toots/2000 Eddie Bauer Ford Explorer/HPFP.jpg


Sistemas A

uto

mó

veis


• Bosch CP3 – high-pressure pump front/side views













Sistemas A

uto

mó

veis


• Bosch CP3 – high-pressure pump component list

1. Flange

2. Shaft

3. Polygonal ring

4. Housing

5. Gear pump

6. Overflow valve

7. Low-pressure inlet

8. Fuel metering unit

9. Backflow connector

10. High-pressure connector

11. Plunger

12. Bucket

13. Suction valve

14. High-pressure valve (out to rail)





















Sistemas A

uto

mó

veis


• Unit-Pump common rail systems (by Delphi)

• Low-cost, small engines (India market)

http://www.automotiveworld.com/megatrends-articles/global-tier-one-found-something-common-rail-indias-largest-supplier/

http://www.delphi.com/manufacturers/other/powertrain/dsl_upcr


























Sistemas A

uto

mó

veis

Fuel injectors

• Fuel injectors are important to

• improve engine performance/power

• reduce fuel consumption

• mitigate exhaust gas emissions

• Injector malfunctioning leads to:

• high exhaust emissions

(particularly unburnt hydrocarbons)

• increased fuel consumption

• erratic idling

• poor cold starting

• engine knocking

• engine hesitation

• reduced engine horsepower

http://www.autozone.com/repairinfo/repairguide/repairGuideContent.jsp?pageId=0900c1528026672a

http://padstow.carmechanic.net.au/diesel-injector-cleaning/2802










Sistemas A

uto

mó

veis

Fuel injectors

• Injectors can be classified according to:

• Type of ICE and fuel

• SI or CI

• Function (what are aimed at)

• single-point (indirect) injection, multi-point indirect

injection, direct injection, cold-start injection

• Working principle

• (purelly) mechanical, electromagnetic, piezoelectric

• Nozzle type

• Single/multiple hole nozzle, pintle nozzle, pintaux nozzle


Sistemas A

uto

mó

veis

Fuel injectors

• Nozzle types

http://www.splashmaritime.com.au/Marops/data/text/Med3tex/Engpropmed2_files/image054.jpg

http://europe.autonews.com/apps/pbcsi.dll/storyimage/CA/20061113/ANE/61109031/AR/0/AR-61109031.jpg&MaxW=622&cci_ts=20061109144328








Sistemas A

uto

mó

veis

• Injector working principle

Fuel injectors

http://vegburner.co.uk/dieselengine.html

http://image.dieselpowermag.com/f/tech/general/9382293%20w799%20h499%20cr1%20ar0/0703dp_14_z+bosch_diesel_injection_system+latest_piezo_injectors.jpg

Mechanical

Electromagnetic

Piezoelectric

http://image.dieselpowermag.com/f/tech/general/9382293 w799 h499 cr1 ar0/0703dp_14_z+bosch_diesel_injection_system+latest_piezo_injectors.jpg





Sistemas A

uto

mó

veis

Fuel injectors

• Injection has greatly evolved

• more fuel pressure

• multiple jets

• Leads to

• better fuel atomization

• less engine noise

• less exhaust emissions

http://www.techlineinfo.com/fiat-multijet-ii-the-next-generation-

green-diesel-engine-technology/

http://www.techlineinfo.com/fiat-multijet-ii-the-next-generation-green-diesel-engine-technology/





















Sistemas A

uto

mó

veis

Exhaust system

• …

• …


Sistemas A

uto

mó

veis

Glossary (English/Portuguese)

• …


Sistemas A

uto

mó

veis

Recommended references

• https://www.dieselnet.com/

• http://www.appropedia.org/Engine_components

• http://www.trucktrend.com/how-to/expert-advice/0904dp-diesel-injection-pumps/

• http://auto.howstuffworks.com/diesel.htm

• http://www.tb-training.co.uk/CIsys.htm

• http://www.slideshare.net/amgadradhihadi/common-rail-diesel-fuel-systems

• http://pt.slideshare.net/KamalVora1/dr-vora-ppt-chapter-6-crs

• http://www.walshcarlines.com/pdf/Impact%20of%20Diesel%20Fuel%20Injection%20SIAT%202005.pdf

• https://www.researchgate.net/publication/260643808_Particulate_emissions_from_dies

el_engines_Correlation_between_engine_technology_and_emissions



















http://auto.howstuffworks.com/diesel.htm

http://auto.howstuffworks.com/diesel.htm



























http://www.walshcarlines.com/pdf/Impact of Diesel Fuel Injection SIAT 2005.pdf



https://www.researchgate.net/publication/260643808_Particulate_emissions_from_diesel_engines_Correlation_between_engine_technology_and_emissions



automotive systems course (module 04) - fuel systems in compression ignition (ci) internal...

Engineering