Common rail fuel injection technology in diesel engines /
Guangyao Ouyang ; in collaboration with Shijie An, Zhenming Liu, Yuxue Li.
- 1 online resource.
Includes index. Guangyao Ouyang is a Professor at the Naval University of Engineering, China. He has close to three decades of experience in the design and optimization of power machinery.
Shijie An is an Associate Professor at the Naval University of Engineering, China.
Zhenming Liu is a scholar at the Naval University of Engineering, China.
Yuxue Li is an Associate Professor at the Naval University of Engineering, China.
Preface xiii
Introduction xv
1 Introduction 1
1.1 The Development of an Electronic Control Fuel Injection System 2
1.1.1 Position Type Electronic Control Fuel Injection System 3
1.1.2 Time Type Electronic Control Fuel Injection System 4
1.1.3 Pressure–Time Controlled (Common Rail) Type Electronic Control Fuel Injection System 4
1.1.3.1 Medium-Pressure Common Rail System 5
1.1.3.2 High-Pressure Common Rail System 6
1.2 High-Pressure Common Rail System: Present Situation and Development 7
1.2.1 For a Common Rail System 7
1.2.1.1 Germany BOSCH Company of the High-Pressure Common Rail System 8
1.2.1.2 The Delphi DCR System of the Company 10
1.2.1.3 Denso High-Pressure Common Rail Injection System of the Company 10
1.2.2 High-Power Marine Diesel Common Rail System 11
1.2.2.1 System Structure 11
1.2.2.2 High-Pressure Oil Pump 12
1.2.2.3 Accumulator 13
1.2.2.4 Electronically Controlled Injector 13
2 Common Rail System Simulation and Overall Design Technology 15
2.1 Common Rail System Basic Model 15
2.1.1 The Common Rail System Required to Simulate a Typical Module HYDSIM 16
2.1.1.1 Container Class 16
2.1.1.2 Valves 17
2.1.1.3 Runner Class Module 19
2.1.1.4 Annular Gap Class Module Physical Model Shown in Figure 2.6 20
2.1.2 The Relevant Parameters During the Simulation Calculations 21
2.1.2.1 Fuel Physical Parameters 21
2.1.2.2 Fuel Flow Resistance 21
2.1.2.3 Partial Loss of Fuel Flow 22
2.1.2.4 Rigid Elastic Volume Expansion and Elastic Compression 22
2.2 Common Rail System Simulation Model 23
2.2.1 High-Pressure Pump Simulation Model 23
2.2.2 Injector Flow Restrictor Simulation Model 24
2.2.3 Simulation Model Electronic Fuel Injector 25
2.2.4 Overall Model Common Rail System 25
2.3 Influence Analysis of the High-Pressure Common Rail System Parameters 26
2.3.1 Influence Analysis of the High-Pressure Fuel Pump Structure Parameters 26
2.3.1.1 Frequency of the Fuel Supply Pump 27
2.3.1.2 Quantity of the Fuel Supply by the High-Pressure Supply Pump 27
2.3.1.3 Diameter of the Oil Outlet Valve Hole of the High-Pressure Pump 29
2.3.1.4 Influence of the Pre-tightening Force of the Oil Outlet Valve 31
2.3.2 Analysis of the Influence of the High-Pressure Rail Volume 33
2.3.3 Influence of the Injector Structure Parameters 34
2.3.3.1 Control Orifice Diameter 34
2.3.3.2 Influence of the Control Chamber Volume 36
2.3.3.3 Influence of the Control Piston Assembly on the Fuel Injector Response Characteristics 36
2.3.3.4 Influence of the Needle Valve Chamber Volume 38
2.3.3.5 Influence of the Pressure Chamber Volume 38
2.3.3.6 Influence of the Nozzle Orifice Diameter on the Response Characteristics of the Injector 39
2.3.4 Influence of the Flow Limiter 40
2.3.4.1 Influence of the Plunger Diameter 40
2.3.4.2 Influence of the Flow Limiter Orifice Diameter 41
5.5.4.1.2 Increasing the Advance Angle Compensation Method 269
5.5.4.2 The Realization of the Control Pulse Generation Module of the Injector 271
6 Research on Matching Technology 273
6.1 Component Matching Technology of the Common Rail System 273
6.1.1 Matching Design of the High-Pressure Fuel Pump 273
6.1.2 Matching Design of the Rail Chamber 274
6.1.3 Matching Design of the Injector 274
6.1.3.1 Modeling and Verification of Diesel Engine Spray and the Combustion Simulation Model 276
6.1.3.2 Optimal Parameters and Objective Functions 278
6.1.3.3 Simulation Experiment Design (DOE) 278
6.1.3.4 Establishment of an Approximate Model for the Response Surface 280
6.2 Parameter Optimization and Result Analysis of the Injection System 281
6.2.1 DoE Optimization 281
6.2.2 Global Optimization Based on the Approximate Model 282
6.2.3 Optimization Results Analysis 283
6.3 Optimization Calibration Technology of the Jet Control MAP 285
6.3.1 Summary 285
6.3.2 Optimal Calibration Method 285
6.3.3 Optimization of Target Analysis 286
6.4 Off-line Steady-State Optimization Calibration of the Common Rail Diesel Engine 286
6.4.1 Mathematical Model for Optimization of the Electric Control Parameters 287
6.4.2 Experimental Design 287
6.4.3 Establishment of the Performance Prediction Response Model 288
6.4.4 Optimal Calibration 289
6.4.5 Test Result 291
7 Development of the Dual Pressure Common Rail System 293
7.1 Structure Design and Simulation Modeling of the Dual Pressure Common Rail System 295
7.1.1 Design of the Dual Pressure Common Rail System Supercharger 295
7.1.2 Modeling of the Dual Pressure Common Rail System 299
7.2 Simulation Study of the Dual Pressure Common Rail System 299
7.2.1 Study of the Dynamic Characteristics of the System 299
7.2.1.1 Simulation of the Dynamic Characteristics of the System 300
7.2.1.2 Sensitivity Analysis of the Structural Parameters of the Supercharger 303
7.2.1.3 Study on Pressure Oscillation Elimination of the Supercharger Chamber in the Dual Pressure Common Rail System 308
7.2.1.3.1 Scheme I 309
7.2.1.3.2 Scheme II 311
7.2.2 Prototype Trial Production 312
7.3 Control Strategy and Implementation of the Dual Pressure Common Rail System 313
7.3.1 Control Strategy of the Dual Pressure Common Rail System 314
7.3.2 Hardware and Software Design of the Controller Based on the Single Chip Microcomputer 315
7.3.2.1 The Basic Composition of the Control System 315
7.3.2.2 Performance of Control Chip and Its Circuit Design 316
7.3.2.2.1 The Circuit Design of the Minimum System of the Single Chip Microcomputer 316
7.3.2.2.2 Design of the Serial Communication Circuit 316
7.3.2.2.3 Pulse Signal Conditioning Circuit 318
7.3.2.3 Programming of Control System 319
7.3.3 Drive Circuit Design 319
7.3.3.1 Design Requirements of the Driving Circuit 319
7.3.3.2 Design of the Power Drive Circuit 321
7.3.3.2.1 Power Drive Circuit of the GMM Actuator 321
7.3.3.2.2 Power Drive Circuit of the Solenoid Valve 323
7.4 Experimental Study on the Dual Pressure Common Rail System 325
7.4.1 Test of Pressurization Pressure and Injection Law 325
7.4.1.1 Test Platform for Pressurization Pressure and Fuel Injection 325
7.4.1.2 Simulation and Test 328
7.4.1.3 Effect of the Turbocharging Ratio on Pressure and Fuel Injection Law 329
7.4.1.4 Effect of the Control Time Series on Pressurization Pressure and Fuel Injection Law 334
7.4.1.5 Test of System High-Pressure Oil Consumption 334
7.4.2 Test on Spray Characteristics of the Dual Pressure Common Rail System 336
7.4.2.1 Spray Photography Test Platform 336
7.4.2.2 Effect of the Fuel Injection Law on Fuel Injection Quantity 338
7.4.2.3 Effect of the Injection Rate Shape on Spray Penetration and the Spray Cone Angle 338
7.4.3 Experimental Research Conclusions 340
Index 343
DESCRIPTION A wide-ranging and practical handbook that offers comprehensive treatment of high-pressure common rail technology for students and professionals
In this volume, Dr. Ouyang and his colleagues answer the need for a comprehensive examination of high-pressure common rail systems for electronic fuel injection technology, a crucial element in the optimization of diesel engine efficiency and emissions. The text begins with an overview of common rail systems today, including a look back at their progress since the 1970s and an examination of recent advances in the field. It then provides a thorough grounding in the design and assembly of common rail systems with an emphasis on key aspects of their design and assembly as well as notable technological innovations. This includes discussion of advancements in dual pressure common rail systems and the increasingly influential role of Electronic Control Unit (ECU) technology in fuel injector systems. The authors conclude with a look towards the development of a new type of common rail system. Throughout the volume, concepts are illustrated using extensive research, experimental studies and simulations. Topics covered include:
Comprehensive detailing of common rail system elements, elementary enough for newcomers and thorough enough to act as a useful reference for professionals Basic and simulation models of common rail systems, including extensive instruction on performing simulations and analyzing key performance parameters Examination of the design and testing of next-generation twin common rail systems, including applications for marine diesel engines Discussion of current trends in industry research as well as areas requiring further study Common Rail Fuel Injection Technology is the ideal handbook for students and professionals working in advanced automotive engineering, particularly researchers and engineers focused on the design of internal combustion engines and advanced fuel injection technology. Wide-ranging research and ample examples of practical applications will make this a valuable resource both in education and private industry.