Fuel Injection System

By:
Jaydeep Chauhan, 150280711005
Gourav Gupta, 150280711010
Sagar Vagadiya, 150280711016
Index
Introduction
Requirements of a Diesel Injection System
Classification of Injection System
Diesel Injection Systems
Nozzles of Different Types
Spray Pattern
Electronic Fuel Infection System
Cooling System
Role of Thermostats & Radiator
INTRODUCTION:
The fuel-injection system is the most vital component in
the working of CI engine.
The engine performance, power o/p , economy etc is
greatly dependent on the effectiveness of the fuel-injection
system.
Basically the purpose of carburetion & fuel-injection is the
same i.e. preparation of the combustible charge. But in
case of carburetion fuel is atomized by processes relying on
the air speed greater than fuel speed at the fuel nozzle ,
whereas in fuel-injection the fuel speed at the point of
delivery is greater than the air speed to atomize the fuel.
Requirements of Diesel Injection System

The functional requirements of an injection system are

listed below:
Introduction of the fuel into the combustion chamber
should take place within a precisely defined period of
the cycle.
The metering of amount of fuel injected per cycle
should done very accurately.
The quantities of fuel metered should vary to meet the
changing load & speed requirements.
The injection rate should be such that it results in the
desired heat-release pattern.
The injected fuel must be broken into very fine droplets.
Requirements of Diesel Injection
System
Proper spray pattern to ensure rapid mixing of
fuel & air.
Beginning & end of injection should be sharp.
Timing the injection of the fuel correctly in
cycle so that maximum power is obtained,
ensuring economy & clean burning.
Uniform distribution of fuel droplets
throughout the combustion chamber.
Functional Elements
1. PUMPING ELEMENT: To move the fuel from the fuel
tank to cylinder & piping etc.
2. METERING ELEMENTS: To measure & supply the
fuel at the rate demanded by load & speed.
3. METERING CONTROL: To adjust the rate of
metering elements for changes in load & speed of the
engine.
4. DISTRIBUTING ELEMENTS: To divide the metered
fuel equally among the cylinder.
5. TIMING CONTROLS: To adjust the start & the stop of
injection.
6. MIXING ELEMENT: To atomizes & distribute the
fuel within the combustion chamber.
Classification Of Injection Systems
Diesel injection systems can be divided into two
basic types. They are :

Air injection system

Solid injection system

Air Injection System
In this method fuel is forced into the cylinder by means
of compressed air to a very high pressure. The rate of
fuel admission can be controlled by varying the pressure
of air .
The fuel is metered & pumped to the fuel valve by a
camshaft driven fuel pump. The fuel valve is opened by
means of a mechanical linkage operated by the camshaft
which controls the timing of injection . The fuel valve is
also connected to a high pressure air line fed by a multi
stage compressor which supplies air at a pressure of
about 60 to 70 bar.
Advantages Disadvantages
It provides better It requires a high pressure
multi stage compression.
atomization & A separate mechanical
distribution of fuel. linkage is required to time
Heavy & viscous the operation of fuel valve.
fuels, which are The fuel valve sealing
requires considerable skill.
cheaper can also be Due to the compression &
injected. the linkage the bulk of the
engine increases . This also
results in reduced B.P due to
power loss in operating the
compression & linkage.
In case of sticking of the fuel
valve , the system becomes
quite dangerous due to the
presence of high pressure air.
Solid Injection System
In this method fuel is injected directly into the
combustion chamber without primary
atomization is termed as solid injection. it is also
termed as mechanical injection.
Solid injection system can be classified into four
types:
1. Individual pump & injector.
2. Unit injector system.
3. Common rail system.
4. Distributor system.
Individual Pump & Injector
In this system , each
cylinder is provided
with one pump & one
injector.
Also in this system a
separate metering &
compression pump is
provided for each
cylinder.
The pump may be
placed close to cylinder
as shown in fig(a)
Individual Pump & Injector
May be arranged in a cluster as
shown in fig(b).

In high pressure pump ,

plunger is actuated by a cam &
produces the fuel pressure
necessary to open the injector
valve at the correct time .

The amount of fuel injected

depends on the effective stroke
of the plunger.
Unit Injector System
The unit injector system
is one in which the pump
& injector are combined
in one housing.
Each cylinder is provided
with one of these unit
injectors.
Fuel is brought up to the
injector by a low pressure
pump at proper time, a
rocker arm actuates the
plunger & thus injects the
fuel into the cylinder.
Common Rail Direct Injection
In common rail system a
high pressure fuel pump
delivers fuel to an
accumulator, whose
pressure is kept constant
with the help of a
pressure regulating valve.
A common rail or a pipe
starts from the
accumulator & leads to
the different distributing
elements for each
cylinder.
Video on crdi
CRDi
For each cylinder there is a separate metering &
timing element which is connected to an automatic
injector injecting fuel into the cylinder.

In the common rail system the supply pressure of the

fuel is independent of speed & hence is not affected
by the fuel pump.

The amount of fuel entering the cylinder is regulated

by varying the length of the push rod stroke.
Distributor System
In this system the pump which
pressurizes the fuel also
meters & times it .

The fuel pump after metering

the required amount of fuel
supplies it to rotating
distributor at the correct time
for supply to each cylinder.
Distributor System
The number of injection strokes per cycle for the
pump is equal to the number of cylinders.

Since there is only one metering element , a

uniform distribution is automatically ensured .

Not only that , the cost of the fuel injection

system also reduces to a valve less than two
third of that for individual pump system.
Jerk Pump Injector
Nozzle
Nozzle is a part of an injector through which the
fuel is sprayed into the combustion chamber.
Various types of nozzles used in CI engine are:
Single hole nozzle
Multi-hole nozzle
Pintle nozzle
Pintaux nozzle
Single Hole Nozzle
Single hole nozzle are used in open
combustion chamber. At the center of
the nozzle body there is a single hole
which is closed by the nozzle valve.
The size of the hole is usually larger
than 0.2mm.
The hole may be drilled centrally or at
an angle to the centre line of the
nozzle.
Main disadvantages of the Single hole
nozzle are:
i. Single hole nozzle has tendency to
dribble.
ii. The spray angle is very narrow.
This does not facilitate good mixing
unless higher air velocities are
provided.
Multi-Hole Nozzle
In order to mix the fuel properly
even with the slow air movement
available with many open
combustion chamber ,a Multi-hole
nozzle.
The number of holes varies from 4
& 18 and the size from 1.5mm to
0.35mm.
Advantages;
i. Gives good atomization.
ii. Distribute fuel property even
with lower air motion available
in open combustion chamber.
. Disadvantages;
i. Dribbling b/w injection.
ii. Very high injection.
iii. Close tolerance in manufacture
& hence costly.
Pintle Nozzle
In order to avoid the weak injection &
dribbling the spindle is provided with a
projection called pintle , which
protrudes through the mouth of the
nozzle body. It either cylindrical or
conical in shape.
The size & shape of the pintle can be
varied according to the requirement.
Advantages:

i. It is self cleaning type.

ii. It prevent the carbon deposition on
the nozzle hole.
iii. It result in good atomization.
iv. It avoid weak injection & dribbling.
. Disadvantages:
i. Distribution & penetration poor.
Hence not suitable for open
combustion chamber.
Pintaux Nozzle
It is a type of pintle nozzle which
has an auxiliary hole drilled in
the nozzle body
If the fuel is injected in a
direction upstream the direction
of air, the delay period is reduced
due to increased heat transfer
b/w air & fuel. This results in
good cold starting performance.
Disadvantages:
i. The tendency of the auxiliary
hole to choke.
ii. The injection characteristics
are even poorer then multi hole
nozzle.
Spray Patterns
Reasons for patterns
Design Algorithm to Facilitate Fluid
Dynamics
The basic concept of the design model is as follows.
The fuel injected into a combustion chamber is divided
into many zones.
Events in each zone, such as droplet break-up,
evaporation, airfuel mixing, ignition, heat release, heat
transfer and formation of exhaust emission are traced
and calculated in order to obtain zonal temperature and
compositions.
The mass, internal energy and mole quantity of NOx of
every zone are calculated to obtain cylinder-averaged
temperature, airfuel ratio and NOx concentration.
Fluid Dynamics Factors: Geometric
Features
Spray development
After fuel is injected into the cylinder, spray break-up
takes place in few crankshaft angles followed by wall
impingement.
In these stages, the movement of the fuel jet follows
different laws.
Before break-up, the jet follows the energy
conservation law and the initial velocity of jet is as
follows:
 Diesel fuel injection nozzles

Sac type VCO-type

The holes in a modern injection system are very small, typically 50 250 m, and
they are manufactured using a complicated EDM (Electro Discharge Machining)
process.
A. DIRECT OR NON-RETURN SYSTEM

This system is useful for large installations

where plenty of water is available. The water
from a storage tank is directly supplied through
an inlet valve to the engine cooling water jacket.
The hot water is not cooled for reuse but simply
discharged.
 Mass flow rate through Nozzle

d
m f C D An 2 f p m f C D An 2 f p
360 N
Spray Structure
Distribution of Droplets in A Spray
Distribution of Droplets in A Spray
Penetration of Fuel Spray
The spray penetration length and spray penetration rate
from a fuel injector are the parameters used to judge fuel
spray performance.
The merits of high or low penetration largely depend on
engine design and geometry.
Shorter spray penetration may be of an advantage where
it reduces fuel impingement, but in larger engines may
inhibit maximum air utilization.
Spray Velocity Distribution in A Two Hole Nozzle
Effect of Swirl
Electronic Fuel Injection System(EFL)
Modern gasoline injection system use engine sensors, a
computer and solenoid operated fuel injectors to meter
& inject the right amount of fuel into the engine
cylinder. These system is called as electronic fuel
injection system(EFL) use electrical & electronic
devices to monitor & control engine operation.
An electronic control unit (ECU) or computer receives
electrical signals in the form of current or voltage from
various sensors. It then uses the stored data to operate
the injectors , ignition system & other engine related
devices. As a result, less unburned fuel leaves the
engine as emissions & the vehicle gives better mileage.
 Under full load, the ECU will sense a wide open throttle,
high intake manifold pressure,& high inlet air flow. The
ECU will then increase the injector pulse width to enrich
the mixture which will enable the engine to produce higher
power.
Under low load & idling conditions, the ECU will shorten
the pulse width by which the injectors are kept in the
closed position over a longer period of time. Because of
this, air-fuel mixture will become leaner & will result in
better fuel economy.
EFI system has a cold start injector too. This is an extra
injector that sprays fuel into the center of the engine intake
manifold when the engine is cold. It server the same
purpose as the carburetor choke. The cold start injector
ensures easy engine start up in very cold weather.
Typical Sensors Used In EFI System
Exhaust gas (or) oxygen sensor
Engine temperature sensor
Air flow sensor
Air inlet temperature sensor
Throttle position sensor
Manifold pressure sensor
Camshaft position sensor
Knock sensor
Merits Demerits
Formation of ice on the throttle High maintenance cost.
plate is eliminated.
Better atomization & Difficulty in servicing.
vapourization will make the Possibility of malfunction of
engine less knock. some sensors.
Manifold wetting is eliminated
due to the fuel being injected into
or close to cylinder & need not
flow through the manifold.
Atomization of fuel is
independent of cracking speed &
therefore starting will be easier.
Distribution of fuel being
independent of vapourization less
volatile fuel can be used.
Position of the injection unit is
not so critical & thereby the
height of the engine can be less.
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