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Common Rail

Direct Injection
CRDI

What is CRDI ?
CRDI stands for Common Rail Direct Injection.
Direct injection of the fuel into the cylinders of an engine
via a single, common line, called the common rail which
is connected to all the fuel injectors.
Instead of providing separate piston pumps for fuel
supply, the common rail alone supplies high pressure fuel
to each cylinder.

The
Technology

Whereas ordinary diesel direct fuel-injection systems have to build up


pressure anew for each and every injection cycle, CRDI engines
maintain constant pressure regardless of the injection sequence.
This pressure then remains permanently available throughout the fuel
line.
The electronic control unit (ECU) modifies injection pressure precisely
as needed, based on data obtained from sensors on the cam and
crankshafts. ie compression and injection occur independently of each
other.
This technique allows fuel to be injected as needed, saving fuel and
lowering emissions.

PRINCIPLE OF CRDi IN DIESEL


ENGINES
is named as GDI( Gasoline Direct Injection)
Introduced to remove the drawbacks of carbureted and
MPFI systems

Main advantage is that even petrol engines can be run under the
very lean mixture ratio of 50:1.

Figure showing that by introduction of GDI in petrol


engines A lean mixture of A\F ratio of 50:1 can be burnt
successfully

Layout of a typical CRDI


system

Differences between
DI and CRD
Constant pressure regardless of the injection sequence.
Fuel is supplied directly to a common rail from where it
is injected directly onto the cylinder head

High Pressure of about (1600 bar) , Improved


pulverization

Electronic engine management system continually adjusts


the peak fuel pressure according to engine speed and
throttle position

Compression and injection occur independently of each


other

Circuit Diagram

Electronic Control Unit

ECU monitors Engine variables such as


Temperature
intake pressure
RPM
air mass intake
demand for power (from accelerator)
provides real time control
modifies injection pressure precisely as needed ,
based on data obtained from cam and crankshaft.

Electronic Fuel
Injector
Electromagnet moves the
plunger - opening
solenoid valve
Injector pulse width
controlled by ECU

rapid

CHARACTERISTICS
Spiral shaped Intake port for optimum swirl of air
entering cylinder spiral port induces optimum swirl
in the intake air leading to more efficient mixing and
combustion of fuel inside cylinder

Integrated port at cylinder head for exhaust gas


recycling building up input air temperature, reducing
vibrations and cooler exhaust

Precise Air Flow Metering


Air-flow meter located in front of the turbocharger's
compressor permitting an exact analysis of the air-mass
that is being taken in.

Air mass alters depending on temperature or atmospheric


pressure.

The microcomputer that controls engine timing receives


precise data.

It is thus able to regulate exhaust-gas recycling according to


engine load and speed in the interest of lowering nitrous
oxide and particle emissions.

Multiple Pilot And Post Injection


Leading to smoother compression and expansion-reducing noise levels

More efficient combustion and burning up of fuel leading


to quieter engine cycles

Reduces unburnt HC , NOx and CO and particles in


exhaust

CRDI - Future
Trends
Ultra-high pressure common-rail injection (1800 bar)

generating ideal swirl in the combustion chamber allowing the


air/fuel mixture to form a perfect vertical vortex - uniform
combustion and greatly reduced NOx emissions

CRDi and Particle Filter - To reduce particle emissions from


exhaust

CRDi and closed-loop control injection - Using ion sensor to

provide real-time combustion data for each cylinder such as


temperature and pressure.

PARTICLE
FILTER

Porous silicon
carbide unit
Decreases Particle
emissions
Trapped particles
burnt up into CO2 and
water

ADVANTAGES OF
CRDI

Reduced noise and vibration


Reduced smoke , particulates and exhaust
Increased fuel economy
Higher power output even at lower rpm

DISADVANTAGES

Increased Cost due to high pressure pump and


electronic control unit

Technology cannot be employed in present engines

Hyundai Accent
CRDi

Pioneering new generation


CRDi engines in India
3 Cylinder 1.5 litre and 4 cylinder 2 litre
engines
81 bhp and 187 NM max torque at 2700 rpm ,
max 4000 rpm
5 speed gear box , 0 100 in 13 sec , max speed
170 km/hr
26.2 kmpl in highway , 12 kmpl town riding

CONCLUS
ION
by 20%
Cuts fuel consumption

Doubles torque at low engine speeds


Increases power by 25%.
It also brings a significant reduction in the noise and
vibrations of conventional diesel engines.
In emission, greenhouse gases (CO2) is reduced by 20%. At a
constant level of NOx, carbon monoxide (CO) emissions are
reduced by 40%, unburnt hydrocarbons (HC) by 50%, and
particle emissions by 60%.
CRDI principle not only lowers fuel consumption and
emissions possible; it also offers improved comfort and is
quieter than modern pre-combustion engines. Common-rail
engines are thus clearly superior to ordinary motors using

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