SEMINAR – 2008

Common Rail Direct Injection

Engine

Presented By:
JUNET BABU
S7 MECHANICAL
 What is CRDI ?
• CRDI stands for Common Rail Direct
Injection meaning, 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 SUCESSFULLY
LAYOUT OF A TYPICAL CRDI ENGINE
 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 and demand for power (from
accelerator) and provides real time control
and modifies injection pressure precisely
as needed , based on data obtained from
cam and crankshaft.
Electronic Fuel Injector
• electromagnet moves
the plunger - opening
rapid solenoid valve
• Injector pulse width
controlled by ECU
 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
 CONCLUSION
• cuts fuel consumption by 20%
• 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
either direct or indirect fuel-injection systems.
THE END