Numerical-experimental optimization of the Common-Feeding injection system concept for application to light-duty commercial vehicles

2021 ◽  
pp. 1-19
Author(s):  
Zhiru Jin ◽  
Oscar Vento ◽  
Tantan Zhang ◽  
Alessandro Ferrari ◽  
Antonio Mittica ◽  
...  
Keyword(s):  
Fuel Injection ◽  
Experimental Tests ◽  
Injection Rate ◽  
Production Costs ◽  
Injection System ◽  
Diagnostic Model ◽  
Hydraulic Test ◽  
High Pressure Pump ◽  
Light Duty ◽  
Cr System

Abstract The innovative Common Feeding (CF) fuel injection system has been designed for a light duty commercial vehicle diesel engine in order to reduce production costs and to allow easy installation on the engine, compared to a Common Rail (CR) system. In the CF apparatus, an additional delivery chamber is mechanically fixed at the high-pressure pump outlet, and the rail is removed from the hydraulic circuit. Experimental tests have been carried out on a hydraulic test rig in order to compare the general performance of the prototypal CF system with those of a CR system equipped with different rail volumes. In the cases of the double injections, the fluctuations of the injected mass pertaining to the second injections have been investigated during dwell time sweeps, and design solutions have been provided to minimize such oscillations. Moreover, an injection system numerical diagnostic model has been validated, and the reduced accumulation volumes linked phenomena have been analyzed. In general, the performance of the injection systems with different hydraulic capacitances or shapes of the accumulator are similar. One difference is that the injection rate features slightly different slopes during the rising phases; furthermore, cycle-to-cycle dispersions in the injected mass increase to some extent when the hydraulic capacitance is dramatically decreased. Finally, the frequencies of the free pressure waves, due to the water hammer occurring at the end of a hydraulic injection, are different when the shape of the accumulation volume changes, whereas these frequencies are independent of the accumulation volume sizes.

Further Development and Experimental Analysis of a New Common Rail FIS Without Accumulator

2009 ◽  
Author(s):  
Andrea Emilio Catania ◽  
Alessandro Ferrari
Keyword(s):  
High Performance ◽  
Fuel Injection ◽  
Common Rail ◽  
Production Costs ◽  
Disturbance Attenuation ◽  
Injection System ◽  
System Response ◽  
Internal Diameter ◽  
Main Function ◽  
Cr System

An innovative hydraulic layout for Common Rail (CR) fuel injection systems (FIS) without accumulator was further developed and assessed. The rail was removed and replaced by a high-pressure pipe junction to have faster dynamic system response during engine transients, smaller pressure induced stresses and reduced production costs. Compared to a commercial rail, whose internal volume ranges from 20 to 40 cm3, the junction provided a hydraulic capacitance of about 2 cm3 with the main function of connecting the pump delivery to the electroinjector feeding pipes. The modified injection system was realized and subjected to experimentation under engine-like working conditions on a high performance Moehwald-Bosch test bench. The injection performance of the new system with different hydraulic layouts was shown to be generally similar to those of a commercial CR system. Besides, for multiple injections, the new layout dynamics were substantially improved by a reduced dependence of the overall injected fuel amount on dwell-time (DT) during sequential injection events. This was achieved by selecting injector supplying pipes with an internal diameter and length out of the present production range. The results supported the findings that the rail capacitance was not a key parameter in pressure wave disturbance attenuation.

Injector Coking Effects on Engine Performance and Emissions

2009 ◽  
Author(s):  
Antonio Arpaia ◽  
Andrea E. Catania ◽  
Stefano d’Ambrosio ◽  
Alessandro Ferrari ◽  
Sabino P. Luisi ◽  
...  
Keyword(s):  
Ageing Time ◽  
Engine Performance ◽  
Experimental Tests ◽  
Injection Rate ◽  
Design Parameters ◽  
Diagnostic Model ◽  
Engine Test ◽  
Test Bed ◽  
Hydraulic Test ◽  
Operating Variables

The physical origin of injector coking in diesel engines was clarified and the most critical design parameters and operating variables for the occurrence of the phenomenon were identified. Injector fouling was shown to be affected by many factors, such as injector temperature, nozzle configuration, hole diameter and conicity, fuel composition. In particular, minute quantities of Zn, which can be added to the fuel, were verified to sensibly catalyze the growth of the undesired deposits. Optical and Scanning Electron Microscope (SEM) analyses were conducted both outside and inside different injectors and four locations were identified as main sites for the deposits. Furthermore, different typologies of coking, such as dry and wet coking, were identified and discussed. Energy Dispersive X-ray (EDX) spectroscopy images of the deposits on the spray hole walls revealed a significant presence of Zn when the fuel was doped with such an element. An extensive campaign of experimental tests was carried out at the engine test bed with different nozzle setups in order to evaluate performance deteriorations, in terms of power output, fuel consumption and emissions, after distinct ageing processes. The effects of both Zn concentration in the fuel and ageing time on the losses of engine performance were separately essessed. A previously developed combustion multi-zone diagnostic model was applied to prove the consistency between experimental in-cylinder pressure time hystories and engine-out emissions. Finally injection rate time histories were measured at the hydraulic test rig under different working conditions for both new and aged injectors. The experimental changes in the EVI profiles subsequent to fouling were analyzed and related to the corresponding variations in emissions and engine power, which resulted at the engine test bench.

An Experimental Investigation of Biodiesel Injection Characteristics Using a Light-Duty Diesel Injector

2007 ◽  
Author(s):  
Scott A. Miers ◽  
Alan L. Kastengren ◽  
Essam M. El-Hannouny ◽  
Douglas E. Longman
Keyword(s):  
Fuel Injection ◽  
Injection Rate ◽  
Injection System ◽  
Injector Nozzle ◽  
Light Duty ◽  
Surface Finishes ◽  
Start Of Injection ◽  
Diesel Injection ◽  
Nozzle Geometries ◽  
Biodiesel Fuels

The objective of this research was to experimentally evaluate the effects of two biodiesel fuels with different viscosities on fuel injection characteristics using a light-duty, common-rail, diesel injection system. A pure biodiesel (B100) and a 50/50 blend of pure biodiesel and refined, bleached, and deodorized vegetable oil (B50V50) were compared with a laboratory diesel fuel equivalent (D100). The fuel viscosity ranged from 2.6 cSt (D100) to 10.9 cSt (B50V50). Three injection pressures and two injector nozzle geometries and surface finishes were also investigated. Measurements of the injected fuel quantity showed that as fuel viscosity increased, the injected volume decreased and the variability in the injected volume tended to increase. This effect was more significant in an injector nozzle with converging, highly hydro-ground holes than one with straight, lightly hydroground holes. The rate-of-injection (ROI) data were quite similar for D100 and B100 when using the straight, lightly hydro-ground nozzle. There is a marked reduction in peak injection rate for the B100, compared to D100, when the highly hydro-ground nozzle was utilized. With both nozzles, the B50V50 blend produced narrower ROI curves with peak injection rates equal to or exceeding those of D100 fuel. For all three fuels, the start-of-injection delay increased as fuel viscosity increased. The end-of-injection time was very similar for D100 and B100 but was advanced for the B50V50 blend.

scholarly journals Diagnostics of common rail components based on pressure curves in the fuel rail

2018 ◽  
Vol 173 (2) ◽  
pp. 3-8
Author(s):  
Mirosław KARCZEWSKI ◽  
Krzysztof KOLIŃSKI
Keyword(s):  
High Pressure ◽  
Fuel Injection ◽  
Dynamic Pressure ◽  
Common Rail ◽  
Injection System ◽  
Fuel Injector ◽  
Labview Software ◽  
Cr System ◽  
Data Acquisition Module ◽  
Pressure Changes

Majority of modern diesel engines is fitted with common-rail (CR) fuel systems. In these systems, the injectors are supplied with fuel under high pressure from the fuel rail (accumulator). Dynamic changes of pressure in the fuel rail are caused by the phenomena occurring during the fuel injection into the cylinders and the fuel supply to the fuel rail through the high-pressure fuel pump. Any change in this process results in a change in the course of pressure in the fuel rail, which, upon mathematical processing of the fuel pressure signal, allows identification of the malfunction of the pump and the injectors. The paper presents a methodology of diagnosing of CR fuel injection system components based on the analysis of dynamic pressure changes in the fuel rail. In the performed investigations, the authors utilized LabView software and a µDAC data acquisition module recording the fuel pressure in the rail, the fuel injector control current and the signal from the camshaft position sensor. For the analysis of the obtained results, ‘FFT’ and ‘STFT’ were developed in order to detect inoperative injectors based on the curves of pressure in the fuel rail. The performed validation tests have confirmed the possibility of identification of malfunctions in the CR system based on the pressure curves in the fuel rail. The ‘FFT’ method provides more information related to the system itself and accurately shows the structure of the signal, while the ’STFT’ method presents the signal in such a way as to clearly identify the occurrence of the fuel injection. The advantage of the above methods is the accessibility to diagnostic parameters and their non-invasive nature.

scholarly journals Experimental Methodology and Facility for the J69-Engine Performance and Emissions Evaluation Using Jet A1 and Biodiesel Blends

Energies ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 4530 ◽  
Author(s):  
Gabriel Talero ◽  
Camilo Bayona-Roa ◽  
Giovanny Muñoz ◽  
Miguel Galindo ◽  
Vladimir Silva ◽  
...  
Keyword(s):  
Fossil Fuels ◽  
Fuel Injection ◽  
Engine Performance ◽  
Injection Pressure ◽  
Experimental Tests ◽  
Experimental Methodology ◽  
Injection System ◽  
Small Scale ◽  
Gas Temperature ◽  
Maximum Increase

Aeronautic transport is a leading energy consumer that strongly contributes to greenhouse gas emissions due to a significant dependency on fossil fuels. Biodiesel, a substitution of conventional fuels, is considered as an alternative fuel for aircrafts and power generation turbine engines. Unfortunately, experimentation has been mostly limited to small scale turbines, and technical challenges remain open regarding operational safety. The current study presents the facility, the instrumentation, and the measured results of experimental tests in a 640 kW full-scale J69-T-25A turbojet engine, operating with blends of Jet A1 and oil palm biodiesel with volume contents from 0% to 10% at different load regimes. Findings are related to the fuel injection system, the engine thrust, and the emissions. The thrust force and the exhaust gas temperature do not expose a significant variation in all the operation regimes with the utilization of up to 10% volume content of biodiesel. A maximum increase of 36% in fuel consumption and 11% in injection pressure are observed at idle operation between B0 and B10. A reduction of the CO and HC emissions is also registered with a maximum variation at the cruise regime (80% Revolutions Per Minute—RPM).

Simulation and Experimental Analysis of Diesel Fuel-Injection Systems With a Double-Stage Injector

1999 ◽  
Vol 121 (2) ◽  
pp. 186-196 ◽  
Author(s):  
A. E. Catania ◽  
C. Dongiovanni ◽  
A. Mittica ◽  
C. Negri ◽  
E. Spessa
Keyword(s):  
Fuel Injection ◽  
Injection Rate ◽  
Operating Conditions ◽  
Flow Coefficient ◽  
Injection System ◽  
System Component ◽  
Local Pressure ◽  
Pump Speed ◽  
Minor Losses ◽  
Set Up

A double-spring, sacless-nozzle injector was fitted to the distributor-pump fuel-injection system of an automotive diesel engine in order to study its effect on the system performance for two different configurations of the pump delivery valve assembly with a constant-pressure valve and with a reflux-hole valve, respectively. Injection-rate shapes and local pressure time histories were both numerically and experimentally investigated. The NAIS simulation program was used for theoretical analysis based on a novel implicit numerical algorithm with a second-order accuracy and a high degree of efficiency. The injector model was set up and stored in a library containing a variety of system component models, which gave a modular structure to the computational code. The program was also capable of simulating possible cavitation propagation phenomena and of taking the fluid property dependence on pressure and temperature, as well as flow shear and minor losses into account. The experimental investigation was performed on a test bench under real operating conditions. Pressures were measured in the pumping chamber at two different pipe locations and in the injector nozzle upstream of the needle-seat opening passage. This last measurement was carried out in order to determine the nozzle-hole discharge flow coefficient under nonstationary flow conditions, which was achieved for the first time in a sacless-nozzle two-stage injector over a wide pump-speed range. The numerical and experimental results were compared and discussed.

scholarly journals Analysis of changes in the angular velocity of the crankshaft of the marine engine for diagnosing the wear and location the failure of the fuel injection system

2021 ◽  
Vol 25 (1) ◽  
pp. 72-76
Author(s):  
Sebastian Drewing ◽  
Norbert Abramczyk ◽  
Daria Żuk
Keyword(s):  
Fuel Injection ◽  
Combustion Process ◽  
Angular Acceleration ◽  
Injection Pressure ◽  
Angular Speed ◽  
Injection System ◽  
Failure Behavior ◽  
High Pressure Pump ◽  
Marine Engine ◽  
Fourier Transform Spectra

Abstract The combustion process can be simply described as periodic explosions in a cylinder with its frequency dependent on the number of cylinders and the rotational speed of the shaft. In practice, uniformity of combustion parameters in every cylinder is almost impossible. Due to this fact, instantaneous angular acceleration does not remain the same at the ends of the crankshaft. These observations formed the basis for the investigation of the instantaneous angular speed of the crankshaft ends. To investigate the influence of the failure behavior of the fuel systems during a shaft's rotational movement, a series of experiments were planned. For the simulations, a medium-speed marine engine driving electro generator was selected. The failure simulation was based on the installation of clogged spray holes, draining of part of fuel dose from high-pressure pump and decreasing of injection pressure by a lower tension of the injector spring. The results of measurement were processed and analyzed through a comparison of the fast Fourier transform spectra. As a general conclusion, a difference between general harmonics order of magnitudes was detected.

scholarly journals EFFECT OF ETHANOL ON PERFORMANCE AND DURABILITY OF A DIESEL COMMON RAIL HIGH PRESSURE FUEL PUMP

Transport ◽  
2015 ◽  
Vol 31 (3) ◽  
pp. 305-311 ◽  
Author(s):  
Tomas Mickevičius ◽  
Stasys Slavinskas ◽  
Raimondas Kreivaitis
Keyword(s):  
High Pressure ◽  
Diesel Fuel ◽  
Fuel Injection ◽  
Common Rail ◽  
Injection System ◽  
Fuel Injection System ◽  
Fuel Blend ◽  
High Pressure Pump ◽  
Fuel Pump ◽  
Fuel Delivery

This paper presents a comparative experimental study for determining the effect of ethanol on functionality of a high pressure pump of the common rail fuel injection system. For experimental durability tests were prepared two identical fuel injection systems, which were mounted on a test bed for a fuel injection pump. One of the fuel injection systems was feed with diesel fuel; other fuel injection system was fuelled with ethanol–diesel fuel blend. A blend with 12% v/v ethanol and 88% v/v diesel fuel and low sulphur diesel fuel as a reference fuel were used in this study. To determine the effect of ethanol on the durability of the high pressure pump total fuel delivery performance and surface roughness of pump element were measured prior and after the test. Results show that the use of the ethanol–diesel blend tested produced a negative effect on the durability of the high pressure fuel pump. The wear of plungers and barrels when using ethanol–diesel fuel blend caused a decrease in fuel delivery up to 30% after 100 h of operation.

Research on Simulation for the Electronic Unit Pump Fuel Injection System of HXn5 Diesel Locomotive

2013 ◽  
Vol 645 ◽  
pp. 445-449 ◽  
Author(s):  
Ming Hai Li ◽  
Zhe Zhou ◽  
Xian Zhe Jia
Keyword(s):  
Fuel Injection ◽  
Electronic Control Unit ◽  
Control Unit ◽  
Injection Rate ◽  
Injection System ◽  
Fuel Injection System ◽  
Hydraulic Characteristics ◽  
Diesel Locomotive ◽  
Electronic Unit Pump ◽  
Fuel Injection Rate

Parameters are obtained by mapping the entity structural electronic control unit pump injection system of HXn5 diesel locomotive introduced from USA. A simulation model was built up with GT-Fuel, which can well reflect the electromagnetic and hydraulic characteristics of the fuel injection system, as well as the fuel injection rate and fuel quantity. Compares with locally high-power diesel, the calculation curves show its superiority, which will establish a foundation for optimization and improvement of local fuel injection system.

Sign in / Sign up

Export Citation Format

Share Document