UNIVERSITI TENAGA NASIONAL

COLLEGE OF ENGINEERING
MECHANICAL DEPARTMENT

INTERNAL COMBUSTION ENGINE

MEHB493

ASSIGNMENT 3

NAME : AZHAR BIN AZIZAN

ID : ME093576

SECTION : 01

: FIRAS BASIM ISMAIL, DR.

LECTURER
Fuel Injection

Fuel injection is a system where the process of mixing fuel and air in an internal combustion
engine. These system is a norm in standard compression-ignition (CI) engines, but the system has
been adopted to the spark-ignition engine (SI) system in most modern automobile engines [1].
These systems will have different setting depends on the type of the fuels [2]. There is different
type of fuel injection system, depends on the type of engines, either SI engines and CI engines.
There are three main type of fuel injection; direct, semi-direct and indirect [3].

Types of Fuel Injection in CI engines.

In CI engines, it is a must and standard practice to use fuel injection system. The main function of
the fuel injection in diesel engine is regarding the injection timing control, atomization, bulk
mixing, air utilization, and injection quality control [3]. This will affect efficiency of the fuel
during the injection timing control.

Before the type of the fuel injection been discussed, the general overview of the system
should be studied. The fuel tank for diesel is different from gasoline, as it has a larger filler neck
and no evaporative emission control devices or carbon canister [3]. The transfer pump is used to
drawn the diesel from the tank, which then deliver to the injection pump. There are filter and water-
fuel separator in between the line system. The injection pump is used to increase the pressure of
the diesel to 138 MPa before distribute it among the injectors, which has a same length throughout
the system to ensure proper injection timing [4].

1. Indirect Injection (IDI)

Fuel injector inject the diesel into a pre-chamber, which is connected to the cylinder by a
narrow opening. The initial combustion at this location, causing the slow rate of
combustion, which reduces the noise [3]. In this type, the glow plug is needed to pre-heat
the diesel and help initialize the combustion. IDI actually is an old technology compared
to the DI [5]. Because of that, the system is inexpensive and has greater reliability, due to
the lack of electronics components and emission control [4].
2. Direct Injection (DI)

Diesel is injected directly to the combustion chamber, directly at the top of the piston,
which had a bowl or cup-shaped crown [5]. Direct injection occurs at high pressure cause
the complete atomization to occur. Because of that, the system does not need the help of
pre-chamber for the diffusion of the fuels. The advantages of using the DI system can be
listed as follows [1], [3]:

a) Higher thermal efficiency

b) Lower NOx and particulate emissions
c) Lower noise, vibration and harness (NVH)
d) Greater performance potential
e) Greater high-altitude performance (compared to natural aspirated IDI system)

3. High-pressure common rail system (HPCR)

This system is newly developed, consists of low pressure circuit, high pressure circuit, and
ECU. Low pressure circuit consists of fuel tank, pre-supply pump, fuel filter ant the
respective connection lines. The fuel then been transferred to the high-pressure circuit with
pressure control valve, high pressure accumulator (rail) with the rail pressure sensor,
injector, and the respective high-pressure connection lines [3]. The injection timing will be
determined by the ECU and the decision is based on the engine operating condition and
emission control. HPCR can provides up to 5 injection events per single compression
stroke of the engine [6]. Besides that, the pressure is developed by the high-pressure pump,
which mechanically operated by the engine.

4. Electronic Return-less Fuel System

This system only consists a fuel pump with voltage regulator, a fuel supply line, fuel rail.
There is no fuel pressure regulator to regulate the pressure of the fuel, but the fuel pump
itself regulate the pressure of the fuel [7]. There is also a bypass valve for the fuel on the
supply line so that the fuel can go back to the tank if there to many fuel be drawn. This
system is more cheap and compact because there is no fuel pressure regulator.
Types of fuel injection in SI engine

In SI engine, there are two ways to mix air and fuel before entering the combustion chamber, which
is carburettor and fuel injector [1]. The carburettor system is the old technology still used in the
old automobiles engine. In the most modern automobile engine, the fuel injector because it has a
lot of advantages over the carburettor [8]. For the fuel injection system, there are three different
fuel injections; indirect, semi-direct, and direct injection.

1. Indirect Injection

This system has several names that always been called, which is manifold injection, single
point injection (SPI), or throttle body injection (TBI). The injector usually upstream from
the throttle and the pressure are low, which is around 2 to 6 bar. The fuel enters the
combustion chamber in aqueous state with high pressure compared to the carburettor
system [3]. This allow the fuel to evaporates in the cylinder and causing cooling effect
towards the mixture and speed up the atomization of the fuels. This cooling effect increase
the volumetric efficiency, hence improving the power of the engine. The system however
still has problems with the distribution of the fuel and air mixture as carburettor but without
venturi restriction. Besides that, the system has higher injection pressure compared to the
carburation [3].

2. Semi-direct injection
The system is called as port fuel injection (PFI), indirect multipoint injection (IMPI) or
simply multi-joint injection (MPI). In this system, the fuel injected right at the manifold
runner before the valve because the fuel injector located in each induction manifold just in
front the inlet [3]. The injection pressure is around 2 to 6 bar. The system does not need to
be synchronized with engine induction cycle because the fuel injected to each induction
pipe simultaneously where it is mixed and store before the intake valve open. Due to that
purpose, the system needs no timing and requires low discharge pressure. The injector does
not expose direct with combustion, which reduces the maintenance cost [3]. Besides that,
there are no difficulties on the fuel distribution because mixture moved a short distance
before entering cylinder. Induction manifold deals only with induced air, so the branch
pipes can be enlarged for better ram effect.
 3. Direct injection

The system called also as direct multi-point injection (DMPI) or gasoline direct injection
(GDI). As the name stated, the injection happens straight at the combustion chamber during
intake or compression process [3]. Because of that, the nozzle should be able to resist high
temperature and high-pressure condition [2]. The injection pressure must be high to
compensate the shorter permitted time for injection. More valve overlaps to utilized the
fresh air for scavenging. The position of the injector is very important because one position
cannot satisfy all the operating condition [5]. The intake manifold will only transport air
induced because the line of fuel and air is separated. Mixing of air and fuel actually happen
in the combustion chamber.

Advantages and Disadvantages of Fuel Injection

In CI engines, there are no other choices for the injection system rather than fuel injection.
Compared to the SI engines, which previously using carburettor to mix the fuel and air, CI engines
are using the fuel injection from the beginning. Because of that, there are no need to figure out the
advantages and disadvantages of the fuel injection in CI engines, as there is nothing to compared.
It is different with SI engines case, where previously use carburettor and then using the fuel
injection in modern automobiles engines.

CI engines

The diesel fuel injection is a revolutionary system introduced later in 20 th century. The P-L-N
system that characterised the system at 1920 but has all disappeared due to its impracticality when
compared to the fuel injection. During that period, the fuel injection has a superior advantages
compared to the P-L-N system [9]. The advantages are as follow:

1. Completely flexible injection timing

2. Higher fuel injection pressure
3. Adjustable fuel pressure depends on the engine operating condition
4. Tailoring the injection rate over the course of the single injection events and multiple
injection events.
The disadvantage of the system is merely the cost. The whole system must be able to handle high
pressure condition. Besides that, the complexity of the system also one of its disadvantage.

SI engines

The modern automobiles engines have adopted the fuel injection rather than improving the
carburettor system due to a certain issue. There are advantages and disadvantages of using fuel
injection system in SI engines [3], [8]. The advantages and disadvantages in the Spark-Ignition
(SI) engines are as listed below:

Advantages:

1. Fuel atomization generally improved and reducing fuel consumption.

2. Better acceleration response [for multipoint-injection(MPI)].
3. Precise in metering fuel in ports.
4. Precise fuel distribution between cylinders (MPI).
5. Adaptable and suitable for supercharging (MPI and SPI).
6. Fuel surge during fast cornering or heavy braking eliminated.
7. Fuel transportation in manifold required (MPI) so no wall wetting.
8. Improved breathing capacity due to absence of venturi no restriction in air flow, which
leads to high volumetric efficiency, torque and power.
9. Hot spots for preheating cold air eliminated, thus denser air enter
10. Manifolds branch pipes not concerned with mixture preparation (for MPI)

Disadvantages:

1. Production and maintenance cost are high.

2. need more attention and car, more servicing to avoid problems.
3. Requires special servicing equipment to diagnose faults and failures.
4. Special knowledge of mechanical and electrical during diagnosis.
5. Contain more mechanical and electrical components that increase chances of failures.
6. Increase usage of the mechanical and hydraulic power and noises due to pumping and
metering the fuels.
7. Very careful filtration needed due to fine tolerances.
Reason on using fuel injection

CI Engine

The performance of the system in diesel engine solely based on the injection of the fuel. Because
the fuel in diesel engine is self-ignited, the fuel injected must also in high pressure state. The way
of how the fuel been injected will determine the differences in engine performance, emissions, and
noise characteristic [4]. The main purposes is to deliver the fuel into the combustion chamber. In
order the engine to effectively make use of the fuel is by [4]:

1. Proper injection timing must be controlled as engine operating condition varied.

2. The correct amount of must be delivered to meet power requirement, injection metering
must be controlled

SI Engine

There are two main factors why a lot of manufacturer of the modern automobiles change to fuel
injection system, rather than stick with using carburation system.

1. Fuel economy and emission.

Fuel injection is more precise on control, results in more efficient use of fuel, reduced
fuel consumption and fewer emission [8]. The system called ECU actually calculating the
amount of oxygen leaving the system and the engine operating condition, to give the best
timing and amount of air-fuel ratio that needed to burn to produce fewer emission and
acquire best performances.
2. Power and performance
Because the fuel injection and the electronic control unit is more accurate, fuel can be
tuned to match driver demand [8].
Electronic Fuel Injection (EFI) System

The electronic consists of three subsystems, which is fuel delivery system, air induction system
and the electronic system. The fuel delivery system consists of fuel tank, fuel pump, fuel filter,
fuel delivery pipe, fuel injector, fuel pressure regulator and fuel return pipe. The air induction
system consists of air cleaner, air flow meter, throttle valve, air intake chamber, intake manifold
runner and intake valve. The electronic control system consists of various engine sensor, electronic
control unit (ECU), fuel injector assemblies and related wiring [3].

The fuel delivery system will take care the fuel supplied to the system. The fuel across this line
before fused with air and injected to the combustion chamber. The function of air induction system
is to provide a sufficient amount of clean air to fused with the fuels [10]. The electronic control
system will specify the ratio of air-fuel mixture, the injection timing and others. The electronic
control units (ECU) acts as the brains of the system by arranging all the timing to reach the
optimum combustion [11].

Below is the procedure on the fuel injection system working [3], [10]:

1. Air enters the engine through the air induction system and the volume flowrate is measured
by using air flow meter.
2. The ECU pulses the injector by switching the injector ground circuit on and off. The
location of the injector is at the intake manifold behind the intake valve. The injectors are
electrical solenoid controlled by ECU.
3. When the injector is turned on, it opens, spraying the atomized fuels at the back sides of
intake valve.
4. The fuels mix with the air and vaporizes due to the low pressure in the intake manifold.
ECU signalled the injector to inject the right amount of air.
5. The ECU decision making is based on the RPM of the engine and intake air volume.
Because of that, the injection will vary with the conditions of the engines. The ECU is
capable to monitor the coolant temperature, engine speed, throttle angle, and exhaust
oxygen content and makes injection corrections.
Engine Management System (EMS)

Nowadays, most of the modern automobiles equipped with the Electronic Control Unit (ECU),
which able to control almost everything regarding ignition, fuel delivery and emission control.
This will make the engine to achieve its full performance, good fuel economy and reducing the
production of air pollution [12]. There is always a price for this convenience setup, which is the
complexity of the system.

Many powertrain control module (PCM) todays have 16-bit and 32-bit processor for the
system, depending on the complexity of the cars system [13]. This allows the system to compute
the injection timing, ignition and timing control which happen in millisecond when the engine
started. The ECU also capable to control spark ignition control, idle speed control device, an
exhaust gas recirculation (EGR) vacuum switching valve [3]. Below listed some details for each
process:

1. Ignition Spark Management [Electronic Spark Advance (ESA)]

Spark advance angle is regulated by monitoring engine operation condition, calculating the
optimum spark timing, and firing spark plug at the appropriate time.
2. Idle Speed Control (ISC)
Engine idle speed is regulated by means of several different types of ECU controlled
devices. The ECU will monitor the engine operating condition to determine the idle speed
strategy to use.
3. Exhaust Gas Recirculation (EGR)
The system regulates the periods under which EGR can be introduced to the engine. This
can be done by the usage of EGR vacuum switching valve.
References

[1] W. W. Pulkrabek, "Air and Fuel Induction," in Engineering Fundamentals of the Internal
Combustion Engine, Harlow, PEARSON, 2014, pp. 197-250.

[2] J. Bruzek, "What Are The Different Types of Fuel Injection?," cars.com, 1 September 2016.
[Online]. Available: https://www.cars.com/articles/what-are-the-different-types-of-fuel-
injection-1420690418419/. [Accessed 6 August 2017].

[3] D. F. B. Ismail, "Fuel Injection System," Internal Combustion Engine, pp. 1-43.

[4] H. J. Magdi K. Khair, "Diesel Fuel Injection," DieselNet.co, 12 November 2013. [Online].
Available: https://www.dieselnet.com/tech/diesel_fi.php. [Accessed 6 August 2017].

[5] D. Hub, "Indirect vs Direct Injection," DIESELHUB, 12 January 2010. [Online]. Available:
http://www.dieselhub.com/tech/idi-vs-di.html. [Accessed 6 August 2017].

[6] A. International, "HIGH PRESSURE COMMON RAIL FUEL INJECTION (HPCR)," AXI,
2016. [Online]. Available: http://www.axi-international.com/resource-center/diesel-
101/high-pressure-common-rail-fuel-injection-hpcr/. [Accessed 6 August 2017].

[7] Enginebasics.com, "A look at the difference beteween Returnless and Return Type Fuel Set-
ups," Enginebasics.com, 2010. [Online]. Available:
https://www.enginebasics.com/Engine%20Basics%20Root%20Folder/Returnless%20Fuel
%20System.html. [Accessed 6 August 2017].

[8] B. Berew, "CARBURETOR VS FUEL INJECTION A SHORT HISTORY AND PROS &
CONS," KNOW HOW, 30 June 2016. [Online]. Available:
http://knowhow.napaonline.com/carburetor-vs-fuel-injection-short-history-pros-cons/.
[Accessed 6 August 2017].

[9] H. Jskelinen, "Fuel Injection for Clean Diesel Engines," DieselNet Technology Guide,
july 2017. [Online]. Available: https://www.dieselnet.com/tech/engine_fi.php. [Accessed 7
August 2017].
[10 D. Tracy, "How Electronic Fuel Injection Works," JALOPNIK, 6 November 2013. [Online].
] Available: http://jalopnik.com/how-electronic-fuel-injection-works-499902815. [Accessed 6
August 2017].

[11 Power4flight, "The Benefits of Electronic Fuel Injection (EFI)," Power4flight, [Online].
] Available: http://power4flight.com/benefits-of-efi/. [Accessed 6 August 2017].

[12 B&B, "Introduction to Engine Management Systems," Electronics Manufacturing Company,

] 23 May 2012. [Online]. Available:
http://www.autotap.com/techlibrary/Intro_to_Engine_Management.asp. [Accessed 6 August
2017].

[13 Crankit, "Engine Management System (EMS)," CrankIT, 30 January 2017. [Online].
] Available: https://crankit.in/engine-management-system-ems/. [Accessed 6 August 2017].