By

KEDAR D. GOKHALE
ME 02 M 094
(Tata Technologies Ltd)
 I.C. Engines; Still a
dominant prime mover
for automobiles !
However
Challenges exist !

Exhaust Emissions
reduction (Air Pollution)
Better NVH & Driveability
Fuel Economy improvement
(CO2 - Global warming)
Safety aspects
Competitive Costs
(..Contd)

Direct Injection Diesel

Engine
with Flexible FIE viz.
Common Rail System
can offer:
ü Reduced Combustion Noise
ü Diffused NOx – PM Trade-off
ü High specific power output
Hence
“Common Rail”
has become a buzzword in
Automotive Industry.
1) Start Diesel Injection...
- at the right Moment (Injection Timing)
- in the right Quantity (and Rate !)
- in the right Form (Atomization & Penetration)
- Consistently
- Cycle by Cycle
- Cylinder to Cylinder
- Over a Period of Time
2) End the Injection sharply.
n Mechanical Systems
n - Pump – Line – Injector
n In line Type
n Rotary Distributor Type
n Unit Pump Type
n Unit Injectors
n Electronic Systems
n - Pump – Line - Injector
n Electronic Inline Type
n Electronic Rotary Type
n Electronic Unit Pump
n Electronic Unit Injector
n Common Rail System
n Solenoid Operated
n Unbalanced Servo Valve
n Balanced Servo valve
n Piezo Operated
n Servo valve type
n Direct acting type
Common Rail System is a modular, e’
controlled diesel injection system offering
closed loop flexible control of Injection

A “Rail” which is common

for all cylinders, stores the
fuel at high pressure and
delivers it to each cylinder
at almost constant pressure.
Hence the name
“Common Rail”
01 = H.P.Pump
02 = Element Shutoff valve
03 = Rail Pressure Sensor
04 = Pressure-limiter Valve
05 = H.P. Accumulator (Rail)
06 = Injector
07 = Phase sensor
08 = HFAMS
09 = Fuel Filter
10 = Boost Pressure Sensor
11 = Feed Pump
12 = Bi-Metal valve
13 = Coolant temperature Sensor
14 = Turbocharger
15 = Return line valve
16 = Speed Sensor
17 = Vacuum Valve
18 = EGR Pressure Transducer
19 = Vacuum Reservoir
20 = Fuel Tank
21 = In Tank Fuel Pump
22 = Battery
23 = Accelerator Pedal Position
Sensor
 High Pressure Pump (Bosch)

High Pressure Rail C.R. Injector

01: Fuel Return
02: Solenoid Connector
03: Solenoid Assembly
04: H.P. Fuel Inlet
05: low pressure zone
06: Ball Valve
07: Fuel Path to Nozzle
08: Fuel Path to Ball Valve
09: Needle Stem
10: Nozzle
11: Needle
v Heterogeneous Combustion
v Smoke limited Power Output
v Always Lean (Overall AFR 20 ~ 80)
v Criticality of In Cylinder Flows
v Quality Governed
Fuel Injection Parameters are Critical...
Common Rail advantages:
n Injection Pressure fairly independent of Engine Speed & Load.
n Multiple Injections (Pilot, Main, Post) for better emissions & NVH.
n Commonization of parts across Variants (Diesel & Gasoline)
n Flexible and accurate Timing Control
n Flexible Injection Rate Control
n Flexible Torque Curve Shape Control
n Additional control on
n EGR
n Turbocharger
n Particulate Trap
n Improved Cycle to Cycle Control
n Improved Cylinder to Cylinder control
n Additional Parameters Processing capabillity
 Evolution of DI Diesel Engine for
Passenger Cars

Example: Fiat 1.9 L TCIC Engine (Bosch)

Common Rail
Injection
Max. Injection Pressure: 1350 bar
No Injection Rate Shaping Electronic
Pilot Injn 1.5 mm /St @ 500 bar
3
Distributor Pump
Swirl Ratio : 2.5
C.R. : 18.5 Max. Injection Pressure: 900 bar
Two Spring Injector(Rate Shaping) Mechanical
BHP / Litre : 57.1
No Pilot Injection Distributor Pump
Torque Nm / Litre : 130
Swirl Ratio : 3.0
Max. Injection Pressure: 700 bar
C.R. : 20
No Injection Rate Shaping
BHP / Litre : 51.7
No Pilot Injection
Torque Nm / Litre : 100
Swirl Ratio : 3.5
C.R. : 18
BHP / Litre : 47.6
Torque Nm / Litre : 95
 Bore x Engine Max Power kW Max Torque
Sr Engine Description Application C.R. BHP per Litre
Stroke cc (hp) @ RPM Nm @ RPM

DuraTorq, 4 cyl CR DI,

1
16V DOHC, VGTCIC
Ford Mondeo 86 x 86 1998 19 83 (113) @ 4000 280 @ 1900 57
Merc, 4 cyl CRDI, 16V Mercedes
2
DOHC, TCIC C 200 CDI
88 x 88.3 2148 18 84 (114) @ 4200 250 @ 2300 53
Hyundai, 3 cyl, CRDI, Hyundai 187 @ 2000 ~
3
12V DOHC Accent
83 x 92 1493 18 60 (82) @ 4000
2700 55
Toyota, 1.4D-4D, 4 cyl Toyota Yaris 170 @ 2000 ~
4
CRDI, 8V SOHC Verso D-4D
73 x 81.5 1364 19 55 (75) @ 4000
2800 55

5 Hyundai 4 Cyl CRDI Terracan 97.1 x 98 2902 19 110 (150) @ 3800 333 @ 2000 51.7
Fiat, 4 cyl, CRDI, 16V
6
DOHC, Multijet
Fiat Punto 69.6 x 82 1251 N.A. 51 (70) @ 4000 180 @ 1750 56
Fiat, 4 cyl, CRDI, 8V
7
SOHC, Multijet
Fiat Punto 82 x 90.4 1910 18 74 (100) @ 4000 259 @ 1750 52.3

BHP / litre for Typical DI Diesel Engine with Mechanical FIE = 45~48
 Advantage over Present
Engine Present DI Emerging DI

a a a a
Feature Diesel Diesel Power Fuel
Nox P.M. NVH
Density economy

a a a a a
Combustion 2 Valves per 4 Valves per
System cylinder cylinder

a
Fuel Injection Mechanical
Common Rail
System (Rotary) Pump

a a a a
Oxidation Lean Nox
Aftertreatment
catalyst Catalyst

a a
Boosting Fixed geometry Variable
System Turbo Geometry turbo

a
Actuator Pneumatic Electric

C.I. &
Base Structure Aluminium
Aluminium