STUDY OF DIESEL ENGINE FUEL SYSTEM

Aim: -

To study the various devices, utilize in diesel engine fuel system.

Equipment Required: -

1. Diesel fuel feed system. (Tank)

2. Fuel feed pump / list pump

3. fuel injection pump

4. fuel injector / nozzle holder

5. Governors

Procedure: -

i. Diesel fuel feed System: -

 The diesel fuel feed system consists of a diesel tank, feed pump, filter, injection pump,
injector and connecting lines of the fuel feed system for a four-cylinder diesel engine. The diesel
fuel is first swiped by the deed pump, this is forced through a filter to infection pump. The filters
filter all the minute dust particles. When the pressure in the filter increases, a certain amount of
fuel is released. This released fuel returns to the tank. The injection pump there gets the fuel from
the feed pump. In injection pump there are plungers. By the operation of plunger, the fuel reaches
the injector. The fuel is sprayed through the injection into cylinder. A certain amount of fuel which
is not injected returns to the tank through diesel over flow pipe.

1. Fuel Injector :-

Scematic diagram of fuel system in CI engine

FUEL INJECTOR
 The purpose of the fuel injector is to inject a small volume of fuel in a fine spray and assists in
bringing each droplet into contact with a sufficient oxygen to give quick and complete combustion.

A fuel injector consists of a needle valve which is pressed on its seat in the nozzle by a plunger
or spindle. A compression spring controls the pressure upon the plunger by which the needle opens.
A nozzle is attached to the body of the injector by capnut. The fuel enters the nozzle through
drillings in the injector body. The fuel may pass from a gallery down the sides of the lower parts
of the needle valve, or it may through an annular groove in the nozzle seat. The body of the nozzle
holder provider access for the fuel and an outlet for the fuel that leaks into the area occupied by
the spring.

When the needle valve is raised from its seat by the pressure of the fuel acting on the conical
or stepped face of the valve, the injection of the fuel takes place. When the injection pressure falls
below the spring pressure, the valve closes. This action tends to set up an oscillation of the calve
during onto small particles. Fuel leakage past the needle valve stem enters the upper part of the
injector and is returned to the pump suction chamber or to the fuel tank. Fuel leakage provides
lubrication for the valve stem.

2. Nozzles:
Types of fuel injection nozzles:-

For adequate mixing of fuel particles with sufficient air fir complete combustion of the fuel it
is necessary that the correct shape of spray suitable to the combustion chamber as well as proper
penetration of the air change should be provided. There are in general four types of nozzles used
in injection.

i. Single hole
ii. Multi hole
iii. Pintle type
iv. Pintaux type
 (i). Single hole nozzle:-

A single hole nozzle has one hole at its centre the fuel is sprayed through this nozzle is one
way.

(ii). Multi hole nozzle:

These nozzles have many holes arranged around the nozzle in a circle. The number, size,
and the angle of the holes may vary according to the engine.

(iii). Pintle Nozzle:

The nozzle provides a soft form of spray operating at a low injection pressure of 80-100
atmosphere (or) 8 – 10 KNsq. Met. This self-clearing nozzle having a small cone extension at the
end of the needle produces a conical spray pattern. As it leaves the injector, the velocity of fuel
increases. The emission of the conical spray between the needle pin and the orifice wall due to the
pin on lower end of the needle needle being tapered in ward, the spray cone in this type is generally
kept at 60o angle.
 (iv). Pintaux type nozzle:-

With normal design of the pintle (or) single hole nozzle the fuel is sprayed tangentially in
to the spherical chamber of the engine. In this way the fuel is not sprayed into the hottest zone or
towards the centre of the chamber. and for cold starting the engine needs heater plugs. There fore
to overcome the heating difficulty of the engine the nozzles are designed of pintaux type. At stating
the nozzle valve is lifted slightly thus the pintle hole is not cleared and the fuel is only discharge
through the quriliary hole into the central hot zone there by obtaining better cold starting
performance.

Fuel Injection pump:-

Description and Construction of the Pump.

The in-line injector pump, a multi-pumping-element unit, has one element for each engine
cylinder. Each element contains a plunger, a barrel, and a delivery valve all placed in a single row
in a casing made in two parts. One part is a steel T-shaped body containing the fuel passages and
pumping elements. The second is an aluminium-alloy cam-box and governor housing, which
contains the camshaft and bearing, cam followers, control rod, governor assembly, and operating
linkage.

The camshaft creates the plunger movement for each pumping element occuring in the
firing order and at the correct point in the engine’s cycle of operation. The followers relay the cam-
lobe lift to the plungers, and the governor senses the changes in engine speed and, in conjunction
with the accelerator-lever position, automatically regulates the amount of fuel to be injected into
the combustion chamber.
Plunger-and-barrel Pumping Action.
Towards the end of the down ward movement of the plunger in the barrel both the inlet and spill
ports are uncovered, and the inlet port opens slightly before the spill port. Fuel at lift-pump pressure
is forced through both ports and it fills up the space above the plunger.

Cycle of operation. A. Filling. B. Cut-off point (beginning of injection). C. Spill over

As the plunger moves up, it first cuts off the spill port. During its movement it pushes
back a small quantity of fuel through the inlet port until the top edge of the plunger cuts off this
port from the space above the plunger, which is completely filled with fuel. The rising plunger
pressurises the trapped fuel and forces open the delivery valve situated above the plunger. The
plunger then transmits rising pressure through the existing fuel in the pipeline to the injector-nozzle
needle. Eventually this pressure build-up lifts the needle off its seat, and fuel is sprayed out into
the combustion chamber.

Further upward movement of the plunger forces fuel past the delivery valve until the
upper edge of the plunger helical groove is exposed to the barrel spill port. As fuel escapes down
the axial spill passage, across to the helical groove, and out through the spill port the fuel pressure
suddenly collapses. The spring-loaded delivery valve is then closed, due to which fuel delivery
and injection stop.
 PUMPING ELEMENT

OUTPUT CONTROL. A. STOP. B. HALF LOAD. C. FULL LOAD.

OUTPUT CONTROL.
 The plunger stroke is always constant as it is controlled by the cam-lobe, but the part of the
stroke, which actually pumps varies. During the upward travel of the plunger the point at which
the spill occurs is altered by partially rotating the plunger relative to the barrel. The device used
for this operation consists of an arm attached to the bottom of the plunger.

This engages a box-shaped control-arm mounted on a square-sectioned control-rod. The

control-rod is located to one side of the pumping elements and is positioned parallel to the
camshaft. It links up all the plunger control-arms due to which any to-and-fro movement of this
control-rod rotates each plunger an equal amount. The amount of fuel injected by each plunger is
thus determined before the spill port is uncovered.

When the plunger is partially rotated in the barrel, the position of the plunger helical spill
groove varies relative to the fixed barrel spill port, so that the effective pumping stroke of the
plunger either increases or decreases. If the helical groove aligns with the spill port earlier in the
plunger upstroke, the amount of fuel injected is reduced. For a late spill to increase the delivered
output, the effective plunger stroke is lengthened, which indicates the full-load position. For the
shut-off position i.e. no delivery, the plunger is rotated until the helical groove uncovers the spill
port in the barrel for the entire stroke so that the fuel cannot be trapped and compressed within the
barrel.

Delivery. valve Action.

The function of the delivery valve is to provide
(a) residual pipeline pressure, so that each successive pumping stroke immediately
actuates the injector,
(b) rapid fuel cut-off, to eliminate injector-nozzle dribble, and
(c) positive continuous air purging or bleeding.

DELIVERY-VALVE ACTION. A. CLOSED. B. INJECTION. C. END OF INJECTION

 Different components used in the Fuel pump injections systems

When the plunger rises on its injection stroke, the pressurized fuel lifts the delivery valve, so that
fuel is displaced towards the injector. Further upward movement of the plunger aligns the helical
groove and the spill port, so the injection stops. The delivery valve is then immediately closed by
the return-spring. This causes the remaining fuel in the pipeline to be subjected to a residual
pressure, which is about 2945 kPa. In the process of closing the delivery valve, the piston portion
of the valve initially cuts off the fuel pipeline above the valve from the barrel-pumping chamber
and then sweeps further down to rest on its seat. The delivery valve also assists in taking air out of
the system, because the fuel volume between the delivery valve and the nozzle does not add to the
pump clearance volume. The plunger action of the close-fitting piston increases the total volume
of the fuel trapped between the valve and the injector, and this causes a rapid pressure drop, which
unloads the injector line pressure to below the working pressure. Consequently the injector needle
is able to snap on to its seat, thus providing a clean cut-off without nozzle dribble. A cylindrical
shouldered piece of low-carbon steel with a hole through the centre and a transverse slot across
the enlarged shouldered end is called volume reducer, which fits inside the delivery-valve holder.
Its acts as a spring-guide and also reduces the effective volume and compressibility of the fuel
between the delivery valve and the injector. In the absence of the volume reducer, the effective
volume is increased and the sweeping action of the delivery-valve piston is insufficient to reduce
the line pressure. This almost certainly promotes injection dribble.

Governors:-

Governor controls fuel delivery at all engine speeds and varying load conditions. The
quantity of fuel fir idling and maximum speed is controlled and correct fuel delivery is ensured for
all condition in between there two extremes. There are three types of governors follows

i. Mechanical (or) Centrifugal governor

ii. Pneumatic governor
iii. Hydraulic governor
i. Mechanical (or) Centrifugal governor: -

it consists of spring opposed, centrifugally actuated fly writes which suitable linkages move
the central rod of the injection pump in the proper direction to increase or to decrease the fuel
supplies from the pump elements. It is mostly used in auto motive injection pump.

The basic operation and principle of the governor when the engine speed increases then fly
weights attached with cam shaft move out wards under the influence of centrifugal force to
overcome the tension of the governor spring the motion of the fly weight is trans mitted to the
control rod through the bell cranks the trans mition rod and the fulcrum lever. In this way when
the engine speed increases the control rods is moved in the direction of less fuel there by reducing
the delivery of the fuel and controlling the speed of the engine.
Pneumatic Governor:

As the vacuum in the inlet air supply varies in accordance with the speed and different load
conditions of the engine. The vacuum is utilized in the injection pump to control the fuel delivery
there by governing the pump. This type of governor consists of two separate units, the air inlet
manifold. venture and a vacuum operated diaphragm unit mounted on the end of the fuel injection.
These two units are connected by means of a vacuum pipe.

Result:

Thus the fuel injection system of a compressed ignition system has been reviewed.