This content is not included in your SAE MOBILUS subscription, or you are not logged in.
An Evaluation of Common Rail, Hydraulically Intensified Diesel Fuel Injection System Concepts and Rate Shapes
Annotation ability available
Sector:
Language:
English
Abstract
Hydraulically intensified medium pressure common rail (MPCR) electronic fuel injection systems are an attractive concept for heavy-duty diesel engine applications. They offer excellent packaging flexibility and thorough engine management system integration.
Two different concepts were evaluated in this study. They are different in how the pressure generation and injection events are related. One used a direct principle, where the high-pressure generation and injection events occur simultaneously producing a near square injection rate profile. Another concept was based on an indirect principle, where potential energy (pressure) is first stored inside a hydraulic accumulator, and then released during injection, as a subsequent event. A falling rate shape is typically produced in this case. A unit pump, where the hydraulic intensifier is separated from the injector by a high-pressure line, and a unit injector design are considered for both concepts.
Details of the injection process, including hydraulic and mechanical characteristics, were analyzed and compared. A one dimensional fuel injection simulation program was used. A summary of the mathematical model and program structure is provided and the advantages and disadvantages are outlined.
Due to the different rate shapes, the two Fuel Injection System (FIS) concepts result in different calculated combustion and emission characteristics. A CFD model for three-dimensional analysis of chemically reactive flow with sprays, KIVA, was used to assess the combustion and emission characteristics of the different systems used in the study.
The effect of a short injection duration on combustion and emissions was also explored. The calculated results showed an increase in the duration of heat release and soot emissions in this case. This may be attributed to the local fuel rich zones created.
Each FIS concept was composed of identical major components including a hydraulic control valve, hydraulic intensifier, check valves, and nozzle. Starting from a 'generic' design, a fair comparison was possible.
This paper discusses the approaches, methods, and results of the evaluation study. The final objective of the project is to design and build a prototype FIS and demonstrate its capability in a single cylinder research engine.
Recommended Content
Authors
- K. Gebert - BKM, Inc.
- R. L. Barkhimer - BKM, Inc.
- N. J. Beck - BKM, Inc.
- D. D. Wickman - Engine Research Center, University of Wisconsin-Madison
- K. V. Tanin - Engine Research Center, University of Wisconsin-Madison
- S. Das - Engine Research Center, University of Wisconsin-Madison
- Rolf D. Reitz - Engine Research Center, University of Wisconsin-Madison
Topic
Citation
Gebert, K., Barkhimer, R., Beck, N., Wickman, D. et al., "An Evaluation of Common Rail, Hydraulically Intensified Diesel Fuel Injection System Concepts and Rate Shapes," SAE Technical Paper 981930, 1998, https://doi.org/10.4271/981930.Also In
References
- Hooker, R. J., “Orion, A Gas Generator Turbocompound Engine”, Volume 65, 1957, SAE Transactions.
- Beck, N. J. and Uyehara, O. A., “Factors That Affect BSFC and Emissions For Diesel Engines: Part II Experimental Confirmation of Concepts Presented in Part I”, SAE Paper No. 870344
- Abata, D. L., Stroia, B. J., Beck, N. J., and Roach, A. R., “Diesel Engine Flame Photographs With High Pressure Injection”, SAE Paper No. 880298
- Beck, N. J, Uyehara, O. A. and Johnson, W. P. “Effects of Fuel Injection on Diesel Combustion”, SAE paper 880299
- Gebert, K., Beck, N. J., Barkhimer, R. L., and Wong, H. C., “Strategies To Improve Combustion and Emission Characteristics of Dual-Fuel Pilot Ignited Natural Gas Engines”, SAE Paper No. 971712
- Gibson, D., H. “A Flexible Fuel Injection Simulation”, SAE paper 861567
- Ichihashi, I., Takaishi, T., Tosa, Y. and Nagae, Y. “Studies of Fundamental Characteristics - Comparison of Unit Injector and Pump-Line-Nozzle Injection Systems”, SAE paper 920629
- Knefel, T., Sobieszanski, M. “A Comparison of Unit Injector and Pump Line Nozzle Systems”, SAE paper 970350
- Soteriu, C., Smith, M. “From Concept to End Product - Computer Simulation in the Development of the EUI-200”, SAE paper 960866
- Erlach, H., Chmela, F., Cartellieri, W. and Herzog, P. “Pressure Modulated Injection and Its Effect on Combustion and Emissions of a HD Diesel Engine”, SAE paper 952059
- Gibson, D., H., Shinogle, R. D. and Moncelle, M. E. “Meeting the Customer's Need - Defining the Next Generation Electronically Controlled Unit Injector Concept for Heavy Duty Diesel Engines”, SAE paper 961285
- Coldren, D. R. and Moncelle, M. E. “Advanced Technology Fuel System for Heavy Duty Diesel Engines”, SAE paper 973182.
- Gibson, D. H., Hefler, G. W. “Hydraulically Actuated Fuel Injector With Direct Control Needle Valve”, US Patent 5,669,355 Sep. 23, 1997.
- Miller, C. R., Waldman, D., J., Shafer, S. F. “Direct Operated Check HEUI Injector”, US Patent, 5,651,345, Jul.29, 1997.
- Chen, S., K., Mather, D., Reitz, R. “Current and Advanced Design Concepts for High Power Density Mid-Range Truck Diesel Engines”, SAE paper 972689
- Mather, D. K. and Reitz, R., D. “Modeling the Influence of Fuel Injection Parameters on Diesel Engine Emissions”, SAE paper 980789
- Beck, N, J., Barkhimer, R. L., Calkins, M., A., Johnson, W., P., Weseloh, W. E. “Direct Digital Control of Electronic Unit Injectors”, SAE 840273
- Rohl, L. and Prescher, K. “Theoretische und Experimentalle Untersuchung der Stromung in Dichtspalt eines Einspritzpumpenelements, MTZ, Vol. 43, No., 10, 1982.
- Cernej, A., Gebert, K., Filipovic, I., Dobovišek, Z., “Leakage Flow at Injector Using Methanol-DF2 Emulsion as Fuel”, 7th International Symposium on Alcohol Fuels, Editions Technip, p. 634, Paris, 1986
- Sturman, E., O., Pena, J., A., Peterson, P. W. “A CNG Specific Fuel Injector Using Latching Solenoid Technology”, SAE paper 951914
- Gebert, K., Savery, C. W. “Fluid Mechanics of Electronically Controlled High Pressure Fuel Injection”, Contract 10-262-9465, Final report, Portland State University, Portland, Oregon, 1987
- Gebert, K., Beck, N., J., Barkhimer, R., L., Wong, H., C. “Development of Pilot Fuel Injection System for CNG Engine”, SAE paper 961100
- Yanagihara, H., Sato, Y., Mizuta, J. “A Study of DI Diesel Combustion Under Uniform Higher-Dispersed Mixture Formation”, JSAE Review 18 (1997), 247-254
- Amsden, A. A., Butler, T. D., O'Rourke, P. J., and Ramshaw. J. D., “KIVA: A comprehensive Model for 2D and 3D Engine Simulations,” SAE Paper 850554, 1984.
- Amsden, A. A., O'Rourke, P. J. and Butler, T. D., “KIVA-II: A Computer Program for Chemically Reactive Flows with Sprays,” Los Alamos National Laboratory Report No. LA-11560-MS, 1989.
- Han, Z., and Reitz, R. D., “Turbulence Modeling of Internal e Combustion Engines Using RNG k-ε Models,” Combustion Science and Technology, 106, pp. 4-6, 267, 1995.
- Reitz, R. D., “Modeling Atomization Processes in High--Pressure Vaporizing Sprays,” Atomization and Spray Technology, 3, 309, 1987.
- Gonzalez, M. A., Lian, Z. W., and Reitz, R. D., “Modeling Diesel Engine Spray Vaporization and Combustion,” SAE Paper 920579, 1992.
- Liu, A. B., Mather, D., and Reitz, R. D., “Modeling the Effects of Drop Drag and Breakup on Fuel Sprays,” SAE Paper 930072, 1993.
- Halstead, M., Kirsh, L., and Quinn, C., “The Autoignition of Hydrocarbon Fuels at High Temperatures and Pressures - Fitting of a Mathematical Model,” Comb. Flame, 30, pp. 45-60, 1977.
- Theobald, M. A., and Cheng, W. K., “A Numerical Study of Diesel Ignition,” ASME Paper 87-FE-2, 1987.
- Kong, S. C., and Reitz, R. D., “Multidimensional Modeling of Diesel Ignition and Combustion using a Multistep Kinetics Model,” Paper 93-ICE-22, ASME Trans., Journal of Engineering for Gas Turbines, and Power, 115, No. 4, pp. 781-789, 1993.
- Abraham, J., Bracco, F. V., and Reitz, R. D., “Comparisons of Computed and Measured Premixed Charge Engine Combustion,” Combust. Flame, 60, pp. 309-322, 1985.
- Bowman, C. T., “Kinetics of Pollutant Formation and Destruction in Combustion,” Prog. Energy Comb. Sci., 1, pp. 33-45, 1975.
- Hiroyasu, H., and Kadota, T., “Models for Combustion and Formation of Nitric Oxide and Soot in DI Diesel Engines,” SAE Paper 760129, 1976.
- Nagle, J., and Strickland-Constable, R. F., “Oxidation of Carbon between 1000-2000 C,” Proc. of the Fifth Carbon Conf., 1, pp. 154, 1962.
- Han, Z., Uludogan, A., Hampson, G. J., and Reitz, R. D. “Mechanisms of soot and NOx Emission Reduction Using Multiple -Injection in a diesel Engine, SAE Paper 960633, 1996.