CRDI or common rail direct injection system is a method of injection of fuel into

the engine cylinders of petrol and diesel engines.In the engines, a high pressure
common rails used to inject the fuel in individual valves.In the modern
generation engines this fuel injection system is used mostly because of
technological advancement.In this method a common and single line is used to
inject the fuel. This common line is connected to all the fuel injectors in the
system, this common line is known as common rail.

The difference between conventional injection method and CRDI is that in the
conventional method the system needs to build the pressure again and again for
every cycle of fuel injection process and CRDI is able to maintain the required
pressure constantly for every cycle of injection i.e. CRDI will provide the same
pressure in the common rail system.

The ECU (electronic control unit) control the pressure as per the requirement.
ECU uses sensors on the crankshaft and cam. The injection pressure is
controlled or regulated on the factors like engine speed and load.The whole
process makes the injection to be happened as per the requirement. It makes
the system efficient, economical eco-friendly. Nowadays piezoelectric injectors
are being used to get the higher pressure precisely.

HISTORY Of CRDI
Robert Huber is the name behind initial development of CRDI. He developed its
prototype in 60’s decade. Few more names come after him for the further
development of this technology.After Robert Huber, Dr. Marco Ganser worked on
it. In the 90’s decade this technology is used in the production vehicle in
japan.The first public passenger vehicle with this technology is used in 1997 in
model Alfa Romeo 156 2.4 JTD.This technology was used in the marines and
engine locomotives for a period of time.

Schematic Diagram Of CRDI Process

The line diagram of CRDI shows that the system is controlled by ECU. The
sensors in the system are used to feed the input in the ECU.ECU will provide the
signal to the injectors on the basis of engine factors like engine load, engine
speed, temperature etc.The various components of engine will be controlled by
sensors. The required quantity of fuel in required time will be calculated by it.

In the system the advance solenoid fuel injectors will be used instead of using
conventional injectors.In this system a common fuel distribution pipe is used to
distribute the fuel evenly for all cylinders. That is why the system is called
common rail system. This helps to maintain the pressure and the fuel can be
stored here. So the supply and storage is maintained constant to the solenoid
injectors by the common rail.In the modern engine with CRDI the injectors are
used with turbocharger to increase the efficiency. It helps to reduce emissions
and improves power output.

WORKING PROCESS OF CRDI

The working process of CRDI is very simple to understand as given below-
  In the process of CRDI a pump is used to pressurize the fuel.
  After the compression of fuel in the high pressure pump, the fuel is supplied to the
common fuel rail.
  Then the fuel will be distributed to the different injectors.
  Injectors will finally inject the fuel in the engine cylinders.
CRDI Engine Advantage Disadvantage
The Technology has some merits and demerits associated with it. These are
given below

Advantage Of CRDI System

The vehicle engines with CRDI technology offers following advantages-
  The engine with CRDI produces more power and torque then conventional direct
injection system
  It has the ability to increase the power and torque of engine by 25%.
  It increases the power and efficiency and reduces the emission.
 It decrease the noise and vibration and provides improved pick up.
It increase the fuel efficiency and decrease the fuel consumption i.e. mileage of
the engine would be increased.

Disadvantage Of Common Rail Direct Injection System

This technology also have some cons as other technologies.

     Its cost of vehicles with this technology is high.

     This technology cannot be implemented in all type of engines.
     The cost of maintenance is also high because its spare parts are
expensive.
Application Of CRDI
The CRDI technology is feasible with both petrol engine and diesel engine.As this
technology is very useful, so most of the car manufacturer are using this
technology now. And this technology has given a prominent benefits to the
automobile industry.This technology can also be used in engine locomotives and
marines.Carter:

1. CAMSHAFT SENSOR FUNCTION

The task of the camshaft sensor is to work with the crankshaft sensor to define the
exact position of the crankshaft drive. Through the combination of both sensor
signals, the engine control unit knows when the first cylinder is in the top dead point.
 
This information is needed for three purposes:

1. For the start of injection during sequential injection.

2. For the actuation signal of the solenoid valve for the pump-nozzle injection
system.
3. For cylinder-selective knocking control.

2.OIL PRESSURE SENSOR.

Standard oil pressure sensors work by displaying a warning signal when the oil
pressure falls outside of the set range. Two important components to the oil pressure
sensor include the spring-loaded switch and a diaphragm. The spring-loaded switch
is connected to the diaphragm that is exposed to the oil pressure.

The pressure switch is mounted onto the side of an engine block and wired to an oil
gallery. As the force of the oil pressure starts to build on the diaphragm, this force
overcomes the switch spring pressure, which then pulls apart the electrical contacts
to turn on the warning light. If the oil pressure falls below the set limit, the diaphragm
releases pressure off the springs to close the switch contacts that would normally
result in the display of a warning sign to the driver (Figure 1).

3.CRANKSHFT POSITION SENSOR

A crank sensor is an electronic device used in an internal combustion engine, both

petrol and diesel, to monitor the position or rotational speed of the crankshaft. This
information is used by engine management systems to control the fuel injection or
the ignition system timing and other engine parameters. Before electronic crank
sensors were available, the distributor would have to be manually adjusted to a timing
mark on petrol engines.
The crank sensor can be used in combination with a similar camshaft position sensor
to monitor the relationship between the pistons and valves in the engine, which is
particularly important in engines with variable valve timing. This method is also used
to "synchronise" a four stroke engine upon starting, allowing the management system
to know when to inject the fuel. It is also commonly used as the primary source for
the measurement of engine speed in revolutions per minute.
Common mounting locations include the main crank pulley, the flywheel,
the camshaft or on the crankshaft itself. This sensor is one of the two most important
sensors in modern-day engines, together with the camshaft position sensor. As the
fuel injection (diesel engines) or spark ignition (petrol engines) is usually timed from
the crank sensor position signal, failing sensor will cause an engine not to start, or
will cut out while running. Engine speed indicator takes speed indication also from
this sensor.
4. OIL LEVEL
All Gill oil level sensors utilise advanced capacitive measurement technology to
feedback oil level in real time. The sensors have no moving parts, so are ideal for
use in harsh operating conditions or where significant vibration is experienced.
Each Gill oil level sensor is factory calibrated in the specified oil type and is ready to
use out of the box. Each oil sensor can store up to twelve individual calibration files
in the sensor memory, so using the sensor with multiple oil types is simple - just call
up the required calibration file using our free software.
A fully-configurable 0-5V analogue output is provided, which is typically calibrated
0.25V empty, 4.75V full. The sensors can be calibrated to give the full-scale output
over just a portion of the sensor, if required.
5. variable timing eccentric shaft sensor

The eccentric shaft position sensor is used as a feedback for the Valvetronic
eccentric camshaft. The eccentric shaft is actuated by the Valvetronic motor and in
return controls variable intake valve lift. The eccentric shaft sensor is mounted to the
cylinder head beneath the valve cover. The top of the sensor protrudes up through
valve cover and is sealed by a rubber gasket. The eccentric shaft sensor tends to
wick engine oil up through electrical connector, creating an oil leak at top front of
valve cover. If you suspect your sensor is leaking, follow these steps to inspect and
replace it. This is a time consuming repair, so plan a day for it and have everything
you need on hand before you begin.

6. Oil Temperature Sensor (OTS) | Thermometrics

Description
Thermometrics Oil Temperature Sensor (OTS) monitors the temperature of the
engine oil in a vehicle and displays this measurement to the vehicle’s occupants. If a
vehicle operates at too high a temperature, the engine can be in danger of damage.
The OTS prevents this by allowing the operator to stop the vehicle and switch off the
engine if the temperature of the oil gets too high as a result of an over heated
engine.
Features:

 High accuracy and long term stability

 Fast response time
 Integral sealed connector
 Small size
 Field-proven design
 Pigtail versions also available
 Alternate RvT curves available
 Different geometries to meet package requirements
 Other resistance and beta values available

 7. CYKLINDER HEAT TEMPERATURE SENSOR

 The cylinder head temperature sensor is an electronic engine management
sensor found on many modern vehicles today. As its name implies, the
cylinder head temperature sensor measures the temperature of the engine
cylinder head. Temperature is one of the most important engine parameters
that the computer uses to calculate timing and fuel for maximum engine
performance and efficiency. The cylinder head is similar in purpose to the
coolant temperature sensor, however, it is more accurate due to the
construction and operation of the sensor. Due to the important role that the
coolant head temperature sensor plays in the engine
performance calculations, when the cylinder head temperature sensor has an
issue, it can negatively affect the performance of the vehicle. Usually a bad or
failing cylinder head temperature sensor will produce a few symptoms that
can alert the driver of a potential problem that should be serviced.