This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Common Rail without Accumulator: Development, Theoretical-Experimental Analysis and Performance Enhancement at DI-HCCI Level of a New Generation FIS
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 16, 2007 by SAE International in United States
Annotation ability available
An innovative hydraulic layout for Common Rail (C.R.) fuel injection systems was proposed and realized. The rail was replaced by a high-pressure pipe junction to have faster dynamic system response during engine transients, smaller pressure induced stresses and sensibly reduced production costs. Compared to a commercial rail, whose inside volume ranges from 20 to 40 cm3, such a junction provided a hydraulic capacitance of about 2 cm3 and had the main function of connecting the pump delivery to the electroinjector feeding pipes. In the design of the novel FIS layout, the choice of high-pressure pipe dimensions was critical for system performance optimization. Injector supplying pipes with length and inner diameter out of the actual production range were selected and applied, for stabilizing the system pressure level during an injection event and reduce pressure wave oscillations.
The new injection system was realized and subjected to experimentation under engine-like working conditions on a high performance Moehwald-Bosch MEP2000-CA4000 test bench. The injection performance of the new system was shown to be similar to those of a commercial C.R., for a single injection. Besides, for multiple injections, the innovative layout dynamics was substantially improved by a reduced dependence of the overall injected fuel amount on dwell-time (DT) in sequential injection events. Hydraulic layout solutions preventing the occurrence of resonance flow phenomena among injectors were used to minimize fluid dynamic interference among injectors. The results confirmed that the rail capacitance was not a key parameter in pressure wave disturbance attenuation, whereas injector inlet-pipe sizes did have a considerable effect on these.
In addition, a modification of latest solenoid-generation commercial Multijet electroinjector was realized so as to sensibly reduce the limits of DT for fusion-free sequential injection shots, thus enhancing such component at HCCI combustion application level. The design of the injector based on an integrated experimental-theoretical analysis of system dynamics, was carried out using a previously developed C.R. numerical model. Experimental results on injector characteristics were discussed.
CitationCatania, A., Ferrari, A., Mittica, A., and Spessa, E., "Common Rail without Accumulator: Development, Theoretical-Experimental Analysis and Performance Enhancement at DI-HCCI Level of a New Generation FIS," SAE Technical Paper 2007-01-1258, 2007, https://doi.org/10.4271/2007-01-1258.
- Catania A.E. Ferrari A. Mittica A. 2006 “High Pressure Rotary Pump Performance in Multijet C.R. Systems” ASME ESDA Paper 2006-95590
- Bosch Internal Technical Report
- Catania A.E. Ferrari A. Manno M. 2005 “Parametric Analysis of Layout Effects on Common Rail Multiple-Injections” ASME ICED Fall Technical Conference, Paper No. ICEF2005-1288
- U.S. Department of Energy 2001 “Homogeneous Charge Compression Ignition (HCCI) Technology - A report to the U.S. Congress”
- Foster D.E. Najt P.M. 1983 “Compression-Ignited Homogeneous Charge Combustion” SAE Paper No. 830264
- Stanglmaier R.H. Roberts C.E. 1999 “Homogeneous Charge Compression Ignition (HCCI): Benefits, Compromises, and Future Engine Applications” SAE Paper No. 1999-01-3682
- Gray A.W. Ryan T.W. 1997 “Homogeneous Charge Compression Ignition (HCCI) of Diesel Fuel” SAE Paper No. 971676
- Ando H. Kuwahara K. 2001 “A keynote on future Combustion Engines” SAE Paper No. 2001-01-0248
- Su W. Wang H. Liu B. 2005 “Injection Mode Modulation for HCCI Diesel Combustion” SAE Paper No. 2005-01-0117
- Helmantel A. Denbratt I. 2004 “HCCI Operation of a Passenger Car Common Rail DI Diesel Engine with Early Injection of Conventional Diesel Fuel” SAE Paper No. 2004-01-0935
- Buchwald R. Brauer M. Blechstein A. Sommer A. Kahrstedt J. 2004 “Adaption of Injection System Parameters to Homogeneous Diesel Combustion” SAE Paper No. 2004-01-0936
- Su W. Zhang X. Lin T. Pei Y. Zhao H. 2004 “Study of Pulse Spray, Heat Release, Emissions and Efficiencies in a Compound Diesel HCCI Combustion Engine” Fall Technical Conference of the ASME ICED, Paper No. ICEF2004-927
- Catania A.E. Ferrari A. Manno M. 2005 “Development and Application of a Complete Common Rail Injection System Mathematical Model for Hydrodynamic Analysis and Diagnostics” Spring Technical Conference of the ASME ICED, Paper No. ICES 2005-1018. Submitted for publication in ASME Transactions, Journal of Engineering for Gas Turbines and Power
- Catania A.E. Ferrari Spessa E. 2006 “Numerical-Experimental Study and Solutions to Reduce the Dwell Time Threshold for Fusion-Free Consecutive Injections in a Multijet Solenoid-Type C.R. System” Spring Technical Conference of the ASME ICED, Paper No. ICES 2006-1369. Submitted for publication in ASME Transactions, Journal of Engineering for Gas Turbines and Power
- Catania A. E. Ferrari A. Manno M. Pellettieri R. Spessa E. 2004 “Development, Setup and Instrumentation of a High-Performance Diesel Injection System Test Bench: Preliminary Experimental Results on the Dynamics of a C.R. System” Proceedings, LIX ATI Congress, 2 821 834
- Bosch W. 1966 “The Fuel rate Indicator: a New Measuring Instrument for Display of Individual Injection Characteristics” SAE Paper No. 660749
- Baratta M. Catania A. E. Ferrari A. “Hydraulic Circuit Design Keys to Eliminate the dependence of the Injected Fuel on Dwell Time in Multijet Common Rail Systems” Spring Technical Conference of the ASME ICED, Paper No. ICES 2006-1426
- Catania A. E. Ferrari A. Manno M. Spessa E. 2005 “Experimental Investigation of Dynamics Effects on Multiple-Injection Common Rail System Performance” Spring Technical Conference of the ASME ICED, Paper No. ICES 2005-1108. Submitted for publication in ASME Transactions, Journal of Engineering for Gas Turbines and Power
- Catania A.E. Ferrari A. Manno M. Spessa E. 2006 “A Comprehensive Thermodynamic Approach to Acoustic Cavitation Simulation in High-Pressure Injection Systems by a Conservative Homogeneous Barotropic-Flow Model” ASME Transactions, Journal of Engineering for Gas Turbines and Power. 128 434 445