Fuel Systems for IC Engines

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"This is an impressive coverage of the latest technology of component design for both diesel and petrol FI engines in compliance with the latest emission legislations. The book provides an insight into the technology, and readers will benefit from discussions on the overall future trend of fuel systems."--Materials World, March 2014

• Cover imageTitle pageCopyrightKeynote AddressChapter 1: Energy prognosis until 2030; reserves; transport fuelsPOLITICAL INFLUENCEPOPULATIONWORLDWIDE GDP (+ 2.7 %) IS GROWING FASTER THAN ENERGY CONSUMPTIONENERGY CONSUMPTION IS GROWING BY 1.2 % P.AKEY FACTOR ENERGY EFFICIENCYELECTRICITY GENERATION REMAINS THE BIGGEST PRIMARY ENERGY CONSUMEROIL IS DOMINATING THE TRANSPORT SECTOR FAR INTO THE FUTURELIGHT VEHICLE CONSUMPTION IS STAGNATING IN SOME REGIONS, HEAVY DUTY PART IS GROWINGLIGHT DUTY VEHICLES IN THE EU ARE NEARLY STAGNATING FROM 2015ENERGY EFFICIENCY IN THE USA 2030 STILL BEHIND OTHER REGIONSLIGHT DUTY CONSUMPTION IN THE USA PEAKS IN 2015CAN THE ADDITIONAL DEMAND FOR OIL BE SUPPLIED FROM THE PRESENT SOURCES?OIL WILL BE THERE WHEN WE DON'T NEED IT FOR TRANSPORT ANY LONGERALL PRICE PREDICTIONS ARE WRONGSystems ArchitectureChapter 2: CO2 savings due to electronically controlled fuel pumps in fuel delivery modulesABSTRACT1 INTRODUCTION2 REFERENCE VEHICLE EMISSION CYCLE FOR CO2 EMISSIONS3 STATE OF THE ART4 DELPHI NEW GENERATION OF FUEL MODULE5 CONCLUSIONSChapter 3: Influences of AdBlue® spray targeting and mixing devices on the UWS distribution upstream of the SCR catalystINTRODUCTION1 MOTIVATION2 DOSER CHARACTERIZATION AND CFD MODELINGACKNOWLEDGEMENTChapter 4: Significance of droplet size when injecting aqueous urea into a Selective Catalytic Reduction after-treatment system in a light-duty Diesel exhaustABSTRACTNOTATION1 INTRODUCTION2 MEASURED DROPLET SIZES3 MODEL DESCRIPTION4 RESULTS AND DISCUSSION5 CONCLUSIONSACKNOWLEDGEMENTSAppendixGasoline di SystemsChapter 5: Outwardly opening solenoid injector for homogenous Gasoline engines with direct injectionABSTRACT1 INTRODUCTION2 PARTICULATE REDUCTION BY OPTIMIZED OPERATION3 PARTICULATE REDUCTION BY OPTIMIZED INJECTION STRATEGY4 PARTICULATE REDUCTION BY OPTIMIZED MIXTURE Formation5 SUMMARY AND OUTLOOKChapter 6: Advanced fuel metering gasoline – requirements and Bosch system solutionsABSTRACT1 INTRODUCTION2 MARKET SPECIFIC CHALLENGES3 TRENDS4 PORT FUEL INJECTION (PFI)5 DIRECT INJECTION (DI)6 SUMMARYMedium/Heavy-Duty DieselChapter 7: Latest fuel injection systems on medium speed engines used for IMO tier 3 requirements in 2016ABSTRACT1 INTRODUCTION2 CURRENT IMO TIER 2 SYSTEM – W20CR3 W20 INJECTION SYSTEMS COMBINED WITH EGR4 TWIN ELEMENT JERK PUMP PLUS TWIN NOZZLE5 SECOND GENERATION HFO COMMON RAIL - CR26 THE DUAL FUEL INJECTION – IMO TIER 3 COMPLIANT NOW ON GAS OPERATION7 EURO EU67/98 3B COMPLIANT - FUTURE WÄRTSILÄ LOCOMOTIVE ENGINE8 SUMMARYChapter 8: Ultra high pressure and enhanced multiple injection – potentials for the diesel engine and challenge for the fuel injection systemABSTRACT1 REQUIREMENTS FOR THE FUTURE DIESEL ENGINES2 TRENDS FOR FIE COMPONENT IMPROVEMENTS3 ULTRA HIGH INJECTION PRESSURE FOR HEAVY DUTY APPLICATIONS4 IMPORTANCE OF INJECTION ACCURACY5 HYDRAULIC MEASURES AND CONTROLS TO IMPROVE INJECTION ACCURACY6 SUMMARYChapter 9: Pressure is nothing without control: Evolution of control valve designABSTRACT1 INTRODUCTION2 DESIGN AND DEVELOPMENT OF AN HD ACTUATOR3 RESULTS4 FUTURE REQUIREMENTS5 CONCLUSIONS6 Acknowledgements8 Legal StatementAppendicesChapter 10: Medium and heavy duty diesel fuel injection system requirements to meet future emissions legislationINTRODUCTIONEMISSIONS LEGISLATIONMARKETAFTERTREATMENT ROUTES TO ACHIEVE EMISSIONS LEGISLATIONEFFECT OF INJECTION PRESSURE ON PARTICULATE EMISSIONSTHERMAL MANAGEMENT STRATEGIESMULTIPLE INJECTIONSCLOSE COUPLED POST INJECTIONTRANSIENT CONTROL OF INJECTIONFUEL SYSTEM EFFICIENCYFUEL QUALITYCONTROL SYSTEMSSUMMARYChapter 11: Diesel common rail fuel systems technology for high efficiency ultra low emissions medium duty engines1 BACKGROUND OF THE DFP4.2 HIGH PRESSURE PUMP2 MD CYCLE ANALYSIS: TYPICAL LIGHT DUTY APPLICATION VS. MEDIUM DUTY APPLICATION3 DFP4.2: TWIN PLUNGER PUMP DESIGN CONCEPT BACKGROUND4 DFP4.2 DEVELOPMENT5 DFI 2.5 INJECTOR6 DCM3.7 ELECTRONIC CONTROL UNIT7 KEY CONTROL STRATEGIES8 CONCLUSIONSLight-Duty DieselChapter 12: Diesel injector internal deposits in High Pressure Common Rail diesel enginesABSTRACT1 INTRODUCTION2 EXPERIMENTAL3 RESULTS4 DISCUSSION5 CONCLUSIONSACKNOWLEDGEMENTSChapter 13: Investigations of injection strategies for stable cold idling of an HPCR diesel engine with a compression ratio of 15.5:1ABSTRACT2 INTRODUCTION3 TEST PROCEDURE4 RESULTS AND DISCUSSION5 CONCLUSIONSACKNOWLEDGEMENTSChapter 14: Multiple small vs single large pilot injections for Diesel enginesABSTRACT1 INTRODUCTION2 METHODOLOGY3 RESULTS AND DISCUSSION4 SUMMARY5 ACKNOWLEDGEMENTSGasoline di Spray GenerationChapter 15: Fuel spray structure, flame propagation and charge motion at fuel impingement locations within a DISI engineABSTRACT1 INTRODUCTION2 EXPERIMENTAL CONFIGURATION AND DATA ANALYSIS3 RESULTS AND DISCUSSION4 CONCLUSIONS5 ACKNOWLEDGEMENTSChapter 16: Effects of highly-heated fuel and/or high injection pressures on the spray formation of gasoline direct injection injectorsABSTRACTGLOSSARY1 INTRODUCTION2 PHYSICAL FUNDAMENTALS3 PROCEDURE / MEASUREMENT TECHNOLOGY4 RESULTS5 SUMMARY / FURTHER PROCEDUREChapter 17: Fuel economy and emission potential of spray-guided combustion in gasoline enginesABSTRACT1 HISTORICAL REVIEW AND INTRODUCTION2 KEY ELEMENTS FOR CO2 REDUCTION AT DAIMLER3 FUEL INJECTION SYSTEM REQUIREMENTS FOR THE SPRAY-GUIDED COMBUSTION4 COMBINATION OF LEAN-BURN COMBUSTION PROCESS WITH TURBOCHARGING5 ASSESSMENT OF DOWNSIZING AND LEAN-BURN COMBUSTION IN THE MODERN TECHNOLOGY TOOLSET6 SUMMARYDiesel SprayChapter 18: Reynolds number effects on atomization and cyclic spray fluctuations under gasoline direct injection conditionsABSTRACT1 INTRODUCTION2 EXPERIMENTAL SETUP3 RESULTS AND DISCUSSION4 CONCLUSIONACKNOWLEDGEMENTChapter 19: Effect of viscosity, temperature and nozzle length-to-diameter ratio on internal flow and cavitation in a multi-hole injectorABSTRACTINTRODUCTIONEXPERIMENTAL SET UP AND INSTRUMENTATIONSRESULTS AND DISCUSSIONCONCLUSIONSACKNOWLEDGEMENTChapter 20: Spray stability from VCO and a new Diesel nozzle design conceptABSTRACTINTRODUCTIONEXPERIMENTAL SET-UPRESULTS AND DISCUSSIONCONCLUSIONSACKNOWLEDGMENTChapter 21: Virtual erosion prediction, design optimization and combustion system integration of high pressure fuel injector systems1 INTRODUCTION2 VIRTUAL INJECTIOR SYSTEM DESIGN DEVELOPMENT3 INJECTOR PERFROMANCE AND CALIBRATION ANALSYS4 SUMMARYDevelopment and MethodologyChapter 22: Innovative measurement technologies for fuel injection systemsABSTRACT1 INTRODUCTION2 DEMANDS ON THE INJECTION MEASUREMENT TECHNOLOGY FROM MODERN FUEL INJECTION SYSTEMS3 LATEST DESIGNS OF INJECTION MEASUREMENT TECHNOLOGIES4 APPLICATIONS FOR COMMON RAIL INJECTORS5 CONCLUSIONSChapter 23: Instrument for the test of the injectors based on the measuring of spray momentumABSTRACTINTRODUCTIONTHEORETICAL BACKGROUNDSPRAY MOMENTUM TEST BENCH DESCRIPTIONRESULTSLOCAL MEASUREMENTSGDI INJECTOR APPLICATIONCONCLUSIONChapter 24: Determining common rail system tolerances using Monte Carlo Method and Design-of-ExperimentsABSTRACT1 INTRODUCTION2 RAIL PRESSURE CONTROL3 TOLERANCE CALCULATION SCHEME4 RESULTS5 CONCLUSIONAuthor Index