Common Rail Fuel Injection Technology in Diesel Engines

Guangyao Ouyang is a Professor at the Naval University of Engineering, China. He has close to three decades of experience in the design and optimization of power machinery.
 
Shijie An is an Associate Professor at the Naval University of Engineering, China.
 
Zhenming Liu is a scholar at the Naval University of Engineering, China.
 
Yuxue Li is an Associate Professor at the Naval University of Engineering, China.

A wide-ranging and practical handbook that offers comprehensive treatment of high-pressure common rail technology for students and professionals
 
In this volume, Dr. Ouyang and his colleagues answer the need for a comprehensive examination of high-pressure common rail systems for electronic fuel injection technology, a crucial element in the optimization of diesel engine efficiency and emissions. The text begins with an overview of common rail systems today, including a look back at their progress since the 1970s and an examination of recent advances in the field. It then provides a thorough grounding in the design and assembly of common rail systems with an emphasis on key aspects of their design and assembly as well as notable technological innovations. This includes discussion of advancements in dual pressure common rail systems and the increasingly influential role of Electronic Control Unit (ECU) technology in fuel injector systems. The authors conclude with a look towards the development of a new type of common rail system. Throughout the volume, concepts are illustrated using extensive research, experimental studies and simulations. Topics covered include:
* Comprehensive detailing of common rail system elements, elementary enough for newcomers and thorough enough to act as a useful reference for professionals
* Basic and simulation models of common rail systems, including extensive instruction on performing simulations and analyzing key performance parameters
* Examination of the design and testing of next-generation twin common rail systems, including applications for marine diesel engines
* Discussion of current trends in industry research as well as areas requiring further study
 
Common Rail Fuel Injection Technology is the ideal handbook for students and professionals working in advanced automotive engineering, particularly researchers and engineers focused on the design of internal combustion engines and advanced fuel injection technology. Wide-ranging research and ample examples of practical applications will make this a valuable resource both in education and private industry.

Preface xiii
 
Introduction xv
 
1 Introduction 1
 
1.1 The Development of an Electronic Control Fuel Injection System 2
 
1.1.1 Position Type Electronic Control Fuel Injection System 3
 
1.1.2 Time Type Electronic Control Fuel Injection System 4
 
1.1.3 Pressure-Time Controlled (Common Rail) Type Electronic Control Fuel Injection System 4
 
1.1.3.1 Medium-Pressure Common Rail System 5
 
1.1.3.2 High-Pressure Common Rail System 6
 
1.2 High-Pressure Common Rail System: Present Situation and Development 7
 
1.2.1 For a Common Rail System 7
 
1.2.1.1 Germany BOSCH Company of the High-Pressure Common Rail System 8
 
1.2.1.2 The Delphi DCR System of the Company 10
 
1.2.1.3 Denso High-Pressure Common Rail Injection System of the Company 10
 
1.2.2 High-Power Marine Diesel Common Rail System 11
 
1.2.2.1 System Structure 11
 
1.2.2.2 High-Pressure Oil Pump 12
 
1.2.2.3 Accumulator 13
 
1.2.2.4 Electronically Controlled Injector 13
 
2 Common Rail System Simulation and Overall Design Technology 15
 
2.1 Common Rail System Basic Model 15
 
2.1.1 The Common Rail System Required to Simulate a Typical Module HYDSIM 16
 
2.1.1.1 Container Class 16
 
2.1.1.2 Valves 17
 
2.1.1.3 Runner Class Module 19
 
2.1.1.4 Annular Gap Class Module Physical Model Shown in Figure 2.6 20
 
2.1.2 The Relevant Parameters During the Simulation Calculations 21
 
2.1.2.1 Fuel Physical Parameters 21
 
2.1.2.2 Fuel Flow Resistance 21
 
2.1.2.3 Partial Loss of Fuel Flow 22
 
2.1.2.4 Rigid Elastic Volume Expansion and Elastic Compression 22
 
2.2 Common Rail System Simulation Model 23
 
2.2.1 High-Pressure Pump Simulation Model 23
 
2.2.2 Injector Flow Restrictor Simulation Model 24
 
2.2.3 Simulation Model Electronic Fuel Injector 25
 
2.2.4 Overall Model Common Rail System 25
 
2.3 Influence Analysis of the High-Pressure Common Rail System Parameters 26
 
2.3.1 Influence Analysis of the High-Pressure Fuel Pump Structure Parameters 26
 
2.3.1.1 Frequency of the Fuel Supply Pump 27
 
2.3.1.2 Quantity of the Fuel Supply by the High-Pressure Supply Pump 27
 
2.3.1.3 Diameter of the Oil Outlet Valve Hole of the High-Pressure Pump 29
 
2.3.1.4 Influence of the Pre-tightening Force of the Oil Outlet Valve 31
 
2.3.2 Analysis of the Influence of the High-Pressure Rail Volume 33
 
2.3.3 Influence of the Injector Structure Parameters 34
 
2.3.3.1 Control Orifice Diameter 34
 
2.3.3.2 Influence of the Control Chamber Volume 36
 
2.3.3.3 Influence of the Control Piston Assembly on the Fuel Injector Response Characteristics 36
 
2.3.3.4 Influence of the Needle Valve Chamber Volume 38
 
2.3.3.5 Influence of the Pressure Chamber Volume 38
 
2.3.3.6 Influence of the Nozzle Orifice Diameter on the Response Characteristics of the Injector 39
 
2.3.4 Influence of the Flow Limiter 40
 
2.3.4.1 Influence of the Plunger Diameter 40
 
2.3.4.2 Influence of the Flow Limiter Orifice Diameter 41
 
2.3.5 Common Rail System Design Principle 42
 
3 Electronically Controlled Injector Design Technologies 43
 
3.1 Electric Control Fuel Injector Control Solenoid Valve Design Technology 43
 
3.1.1 Solenoid Valve 33 Mathematical Analysis Model 43
 
3.1.1.1 Circuit Subsystem 43
 
3.1.1.2 Magnetic Circuit Subsystem 46
 
3.1.1.3 Mechanical Circuit Subsystem 47
 
3.1.1.4 Hydraulic Subsystem 48
 
3.1.1.5 Thermodynamic Subsystem 48

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