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Heated Injectors - 2009-01-0615
Heated Injectors - 2009-01-0615
ABSTRACT INTRODUCTION
Ethanol is commonly employed as a transportation fuel in Worldwide oil rationing in the 1970s fostered the belief
Brazil. However, since pure ethanol’s flash point is 12°C, within Brazil that it should become energy self-sufficient.
flex-fuel vehicles marketed in Brazil are currently Since at that time (and still is), the extraction of domestic
equipped with a redundant fuel system which delivers oil was lower than the demand, it was thought that an
gasoline during cold starts below [typically] 18°C. Since alternative fuel should be developed.
these low temperatures are infrequently experienced in
Brazil, gasoline in the auxiliary fuel tank may evaporate Consequently, in 1974 the Brazilian government issued a
and/or varnish during extended dormant periods, strategic plan named National Development Plan - Plano
resulting in poor quality or no-starts. It is therefore Nacional de Desenvolvimento. As part of this national
desirable to eliminate the gasoline system by vaporizing strategy, supported by sugar cane producers, an
a sufficient quantity of ethanol to enable cold starts at low alternative fuel incentive plan, Pró-álcool, was issued in
ambient temperatures. 1975. This plan specified that ethanol would not only be
sold blended with gasoline, but also as a pure ethanol
A port fuel injector capable of rapidly heating ethanol fuel. E22 (a blend of approximately 22% ethanol and
above its flash point has been developed which 78% gasoline) and E100 (~ 94% ethanol, 6% water)
eliminates the need for the redundant fuel system. were produced for the Brazilian market. Consumers
During cold-start conditions, the vehicle’s controller could purchase vehicles either fueled exclusively by E22
commands power to an electrical heater contained within or fueled exclusively by E100. The market expanded and
each injector. The injector heaters raise the temperature in 1986 approximately 80% of the vehicles manufactured
of the delivered ethanol during the engine crank and in Brazil were powered by ethanol fuel.
initial run.
In spite of a decline in consumer demand for ethanol
When these heated injectors are employed in vehicles during the 1990s and early 2000s, due to a
conjunction with engine management system reduction in ethanol production and a poor distribution
enhancements, ethanol cold start performance is similar network, ethanol is still considered a strategic energy
to that of gasoline. In addition, heating ethanol fuel source for Brazil since it reduces gasoline dependence
enables the leaning-out of 20°C cold start fueling, which from other countries. In addition, the Brazilian
has shown to reduce both engine-out and FTP bag government does provide incentives by subsidizing
emissions. ethanol and levying lower tax rates.
Heated injector flow temperature data, low ambient The typical minimum engine cold start temperature
temperature engine cold start performance and vehicle requirement in Brazil is approximately -5°C. This
FTP emission results are presented and discussed. requirement is of course, not as severe as the -20°C or -
30°C ambient cold start requirements found in most
other countries, because Brazil is a sub-tropical country.
20
15
SUB-TANK
Fuel Pump
10
Relay
Switch
5
ECM
PCM PWM INTAKE
Solenoid
Minimum
0
Orifice
-5
2-Jul 6-Jul 10-Jul 14-Jul 18-Jul 22-Jul 26-Jul 30-Jul
ENGINE
July 2004
shows an output of the spray chamber model at the end 0.0001 75 m/s
of the fuel injection pulse. The circles represent the fuel o
-10 C
concentration contours are plotted in color on a plane SMD [u], Vexit [m/s]
Injection timing
200
Intake Port & Valve:
75 u SMD
Ambient Temperature 50 u SMD
Ambient Pressure CFD Analysis Result: 150
Fuel Vapor Fraction &
Cylinder Wall & Piston: Temperature
Ambient Temperature Vs crank angle at spark 100
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Figure 6: Cylinder mixing model representation Delivered Fuel/Air Ratio
In this dynamic model, Figure 7, the fuel enters the Figure 8: Fuel temperature vs. Fuel/Air ratios required to
combustion chamber when the intake valve is open. In- produce 6% vapor in a combustion chamber at TDC
cylinder charge mixing occurs as the piston descends
during the intake stroke and ascends during
The CFD model results presented clearly identify the
compression. The model predicts the amount of vapor
benefit of heating the fuel before it is injected to produce
present throughout the cylinder during the cycle.
more fuel vapor. The model assumptions are that the
Especially important for combustion initiation is the vapor
fuel temperature is prescribed at the injector exit.
concentration near the spark plug at TDC.
Several concepts of how to achieve the heated fuel
Fuel Droplets Fuel Vapor
follow.
Spray begins
At IVO HEATED FUEL RAILS
fuel
• Requires pre-crank PCM turn-on strategy and
30
starter control
20
50
40
Injector Fuel Command [V}
30
40
Injector Fuel Command [V}
30 PCM
Relay Control
20
10
Heater
Diagnostic
0
0 1 2 3 4 5 6 7 8 9 10
Monitor
Test Time [Seconds]
50
40
Figure 14: Injector heater control diagram
Injector Fuel Command [V}
30
1200 110
1000 90
800 70
4
600 50
Heater Duty Cycle 3
400 30
Engine RPM
200 10 2
0 -10
-1 0 1 2 3 4 5 6 7 8 1
Start of 2.9 Seconds 500
Crank RPM Time in Seconds
0
-10 -5 0 5 10 15 20 25
Time (s)
-1
-4
Figure 16 shows a cold start with pre-crank heating. In -5
this case the PCM applies 100% duty cycle to the heater
-6
before cranking commences when a pre-set trigger, such
-7
as the opening of the driver’s door or insertion of the Coolant temperature (ºC)
ignition key, is detected. As in the no pre-heating case, pre-crank heat time crank time w/ pre-crank heat Crank time no pre-crank heating
the PCM reduces the fuel rate as well as the heater’s
duty cycle when the engine fires and begins to run.
Figure 17: 1.8L L4 engine E-100 cold start times with and
Similarly, as the engine settles into its cold idle, a
without pre-crank heating – prototype injectors
minimal duty cycle maintains an elevated stream
temperature to improve warm-up drive-ability.
ENGINE EMISSION PERFORMANCE
However, injector heating is terminated if the engine is
The minimal ethanol vapor concentrations which occur at
not cranked after the pre-heating time has elapsed.
low ambient temperatures (including emission test cold
start temperatures) require a very rich engine fueling
Heater Duty Cycle and Heater Temperature
1200 110
1000 90
emissions as well as delayed catalytic converter light-off.
800 70
600
1.8 s
500
RPM Heater Duty Cycle
50 Heating the ethanol significantly reduces the ethanol
400 30
200 10
fueling requirement for starting and warm-up which
0 -10 permits the use of a lean fuel calibration which reduces
-7 -6 -5 -4 -3
Pre-heat 6.0 Seconds
-2 -1 0
Start of
1 2 3 4 5 6 7 8 9 engine-out HC and CO and improves converter light off
Time in Seconds
Crank
times.
- 42%
0.07
0.05
0.06
- 62%
0.04
0.05
REFERENCES
0.03 0.04
0.03
0.02 1. Ministério da Ciência e Tecnologia – Centro de
0.02
0.01 Previsão de Tempo e Estudos Climáticos
0.01
http://tempo1.cptec.inpe.br/
0 0
0.04
0.03
0.6 Volume I, Chapter I. Revised Chapter 1 to First,
0.4
0.02 Second, Third and Fourth Editions, 1988
0.01
0.2
0 0.00
CONCLUSION