EXPERIMENTAL ANALYSIS OF DIESEL ENGINE BY VARYING INJECTION PRESSURE

Project Report- Phase I

On

‘EXPERIMENTAL ANALYSIS ON DIESEL ENGINE BY

VARYING INJECTION PRESSURE’
Submitted to

In Partial Fulfillment of the Award of

BACHOLAR OF MECHANICAL ENGINEERING

To

SHIVAJI UNIVERSITY, KOLHAPUR.

Submitted By,

Karan Yadav (karan.24yadav@gmail.com

)

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INDEX

Sr. No. CONTENT PAGE NO.

1. ABSTRACT 6

2. INTRODUCTION 7

3. LITERATURE REVIEW 8

4. PURPOSE OF PROJECT 10

5. OBJECTIVES 11

6 METHODOLOGY 12

7 ACTION PLAN 13

8 EXPERIMENTAL ANALYSIS 14

8.1 CRDI SYSTEM 14

8.2 ECU 16

8.3 CONVERSION OF SINGLE 18

CYLINDER TO CRDI
19
9 BILL OF MATERIAL
20
10 POSSIBLE OUTCOMES
21
11 REFERENCES

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LIST OF FIGURES

FIGURE NO. FIGURE NAME PAGE NO.

14
1. COMMON RAIL TECHNOLOGY

2. ECU 17

3. COMMON RAIL SYSTEM 18

CIRCUIT

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1. ABSTRACT
`

The influence of injection parameters like injection pressure and injection duration on performance and
emission of a common rail direct injection system assisted diesel engine has been evaluated using central
composite design (CCD). The tests have been carried out on a four stroke, single cylinder DI diesel engine.
The fuel injection system of the diesel engine used was the high pressure common rail direct injection system.
From the experiments, it is observed that the brake thermal efficiency (BTE) is improved and fuel consumption
reduced due to better atomization. It is also observed that carbon monoxide (CO), unburned hydrocarbons
(HC) and smoke emissions are reduced and NOx emissions increased when increasing the injection pressures.
This is due to injected fuel droplets find smaller as the injection pressure increases, which leads to improve
atomization of the fuel.

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2. INTRODUCTION

Important role for better atomization of injected fuel and allows it for complete combustion and to reduce
the emission . Fuel injection pressure will be low, fuel particle diameters will become wider and ignition delay
period will increase during the combustion and engine performance will decrease and cause CO, HC and
smoke emissions and the injection pressure increases than the fuel particle diameter decreases and the
mixing of air with fuel becomes better during combustion, this leads to better engine performance and
reduces smoke level and HC, CO emissions. In this study, effect injection pressure on engine performance and
emissions characteristics have been experimentally investigated in single cylinder diesel engine equipped
with common rail direct injection (CRDI) fuel injection system.

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3. LITERATURE REVIEW

Srithar Rajoo, has conducted experiment to evaluate the coolant temperature effect on gasoline engine
particularly the fuel consumption. Recent researches in automotive field have been concentrated on alternative
fuel due to the fact that crude petroleum oil is becoming scarce. Apart from this, it is equally essential to study
into currently available engines and improvise it to reduce fuel consumption. In order to manually alter the
coolant temperature, an independent cooling tower was built to be attached to the test engine via hose
connection. It was found that, when coolant temperature increased from 70°C to 100°C, the fuel consumption
of the engine decreases gradually and stabilizes after 90°C.
Venkataramana Reddy, presented some findings of the use of honge oil and diesel fuel blend in direct
injection diesel engine with increased injection opening pressure (IOP). The performance, emissions and
combustion parameters of 20% honge oil and 80% diesel fuel (volume basis) were found very close to neat
diesel fuel where as higher blend ratios were found inferior compared to neat diesel fuel. Improved premixed
heat release rate were noticed with H30 when the IOP is enhanced
M. Al-Hasan, conducted experiment on a four-stroke four-cylinder spark ignition engine alternatively
equipped with CIS and EIS. Fuel consumption; and exhaust emissions included hydrocarbon, carbon monoxide
and carbon dioxide were measured as a function of ambient temperature; i.e. 7, 25 and 40ºC. In order to
simulate engine operation condition during warm - up period under various ambient temperatures axillaries
cooling water and cooling air systems were designed and coupled to the engine being tested. Results show that
as the ambient temperature increases the concentration of both hydrocarbon and carbon monoxide and fuel
consumption decreases while the carbon dioxide increases. Also, the time required for the engine to fully
warm-up is shortened. Moreover, operating the engine when equipped with EIS has a greater effect on HC, CO
and fuel consumption reduction compared to When equipped with CIS at the same operation conditions.
Rosli Abu Bakar, investigated effects of fuel injection pressure on engine performance. Experiments have
been performed on a diesel engine with four-cylinder, two-stroke, direct injection. Engine performance
values such as indicated pressure, brake horse power, break mean effective pressure and fuel consumption
have been investigated both of variation engine speeds - fixed load and fixed engine speed – variation loads
by changing the fuel injection pressure from 180 to 220 bars. According to the results, the best performance
of the pressure injection has been obtained at 220 bars, specific fuel consumption has been obtained at 200
bars for fixed load – variation speeds

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4. PROPOSED WORK OF PROJECT

The setup consists of single cylinder, four stroke, CRDI engine connected to eddy current
dynamometer. It is provided with necessary instruments for crank-angle, airflow, fuel flow,
temperatures and load measurements. These signals are interfaced with the help of ECU device.

CRDI engine works with programmable ECU for Diesel injection, fuel injector, common rail with
rail pressure sensor and pressure regulating valve, crank position sensor, fuel pump and wiring
harness. The setup enables study of CRDI VCR engine performance with programmable ECU at
different compression ratios and with different EGR.

Engine performance study includes brake power, indicated power, frictional power, BMEP, IMEP,
brake thermal efficiency, indicated thermal efficiency, Mechanical efficiency, volumetric

efficiency, specific fuel consumption, Air fuel ratio, heat balance and combustion analysis.

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5. OBJECTIVES

Majority of the work done by the researchers in diesel engine is based on blends using bio-fuels,
instead of using these kind of fuels we are going to use diesel. This work was carried out on direct
injection not on CRDI engine. The DI engines have injection pressure limitations due to its
operational mechanism. The injection system must satisfy high pressure capability, injection
pressure control, flexible timing control, and injection rate control.

The injection system must satisfy high pressure capability, injection pressure control, flexible
timing control, and injection rate control.

Hence we are going to increase injection pressure & finding out the performance & emission
characteristics at different injection pressure & load.

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6. METHODOLOGY

i. Study on Literature for finding out, how injection pressure will affect the
performance.
ii. Theoretical study of CRDI engine. Also work on various ECU (engine control unit)
iii. Study on conversion of single cylinder diesel engine to a CRDI engine.
iv. Experimental performance analysis on single cylinder CRDI engine by varying the
injection pressure & finding out performance & emission characteristics.
v. Analyzing the results and deriving conclusions from it.
vi. Report writing

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7. ACTION PLAN
The action plan for proposed work is as follows:

SR. MONTH JUL AUG SEPT OCT NOV DEC JAN

NO. 2017 2018
ACTIVITY

01 Literature Review

02 Performance Testing

03 Result Analysis

04 Report Submission

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8. EXPERIMENTAL ANALYSIS

8.1 CRDI (Common Rail Direct Injection):

CRDI stands for Common Rail Direct Injection meaning, direct
injection of the fuel into the cylinders of a diesel engine via a single, common line, called the
common rail which is connected to all the fuel injectors. Whereas ordinary diesel direct fuel-
injection systems have to build up pressure anew for each and every injection cycle, the new
common rail (line) engines maintain constant pressure regardless of the injection sequence. This
pressure then remains permanently available throughout the fuel line. The engine's electronic
timing regulates injection pressure according to engine speed and load. The electronic control unit
(ECU) modifies injection pressure precisely and as needed, based on data obtained from sensors on
the cam and crankshafts. In other words, compression and injection occur independently of each
other. This technique allows fuel to be injected as needed, saving fuel and lowering emissions.

Common rail technology

Fig. NO. 1

In common rail systems, a high-pressure pump stores a reservoir of fuel at high pressure —
up to and above 2,000 bars (psi). The term "common rail" refers to the fact that all of the fuel
injectors are supplied by a common fuel rail which is nothing more than a pressure accumulator

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where the fuel is stored at high pressure. This accumulator supplies multiple fuel injectors with
high-pressure fuel.

8.1.1 Advantages

    CRDI engines are advantageous in many ways. Cars fitted with this new
engine technology are believed to deliver 25% more power and torque than the normal direct
injection engine. It also offers superior pick up, lower levels of noise and vibration, higher mileage,
lower emissions, lower fuel consumption, and improved performance.

     In India, diesel is cheaper than petrol and this fact adds to the credibility of the common rail
direct injection system.

8.1.2 Disadvantages
This engine also have few disadvantages as follows,
 Disadvantage of the CRDi engine is that it is costly than the conventional engine.
 High degree of engine maintenance and costly spare parts.

8.1.3 Applications
CRDI engines are now being used in almost all Mercedes-Benz, Toyota Hyundai, Ford and
many other diesel automobiles

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8.2 Engine Control Unit (ECU)

An engine control unit (ECU), also commonly called an engine control
module (ECM), is a type of electronic control unit that controls a series of actuators on
an internal combustion engine to ensure optimal engine performance. It does this by
reading values from a multitude of sensors within the engine bay, interpreting the data
using multidimensional performance maps and adjusting the engine actuators accordingly.
Before ECUs, air-fuel mixture, ignition timing, and idle speed were mechanically set and
dynamically controlled by mechanical and pneumatic.

8.2.1 Functioning of ECU

 Controlling the air-fuel mixture: This is the one of the most Important function
of ECU as it controls the fuel mixture used by the engine. It determines the amount
of air-fuel mixture injecting into the engine. The program received the necessary
data and computes it and gives the appropriate amount of mixture. It also decides
whether it is the right time to deliver the air-fuel mixture in a proper ration or not.
This process is also called injection duration.
 Controlling the ignition timing: ECU adjust the exact timing of the spark or the
ignition timing to provide the better power and economy. ECU detects itself
whether there is the problem in the compression stroke or not and works according
and set the timing of ignition. This is mainly happened in the condition whenever
there is unburned air-fuel mixture left and it is subjected to combination of heat and
pressure. This results in detonation also known as Knocking or pinking. ECU
detects the knocking and delayed the time of spark to prevent it.
 ECU Also Increases the Torque and BHP: As it governs the fuel injection into
the cylinder, it is programmed for the efficient performance of the engine at any
environment whenever ECU  encounters increase in load then it initiates a signal for
more fuel injection & thus engines generates more BHP.

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ECU
Fig. No.2

8.3 Conversion of single cylinder diesel engine to a CRDI engine.

In diesel combustion the air fuel mixing and chemical kinetic efforts control the rate of soot
formation. The combustion temperature and the presence of Oxygen create high NOX formation.
Changes in injector protrusion can result in opposite smoke trends at different engine speed and
load condition. The EGR (Exhaust gas recirculation and timing retardation may assist on NOX
reduction. During combustion process, the rich mixture creates incomplete combustion by products
of UBHC, CO. Hence operating the engine with high air excess ratio may assist on CO, HC
reduction. It is clear that each emission has close interaction with each other; reduction of one
pollutant may have an adverse effect on other. Hence in this report, implementation of CRDI
technology
CRDI system consists of High pressure pump, Common rail, Solenoid / Piezo
Injectors, and engine equipped ECU control. The main purpose of this development program was
to retain the relatively inexpensive and simple base engine with CRDI set up and waste-gated
turbocharger, and achieving the current BS3 emission without after treatment devices and EGR.
The presented work will document the development of low cost and high efficient diesel engine

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which meets emission.

Common rail system circuit

Fig. No.3

9. BILL OF MATERIAL

Sr. No. Category Price (Rs.)

1. Software Cost 4000/-

2. Performance Cost 4000/-

3. Setup cost 8000/-

4. Total Cost 16000/-

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10. Probable Outcomes

By performing this experiment we are finding out the performance & emission characteristics at
different injection pressure & load. With the help of Engine-soft software we find out
characteristics such as Engine performance study includes brake power, indicated power, frictional
power, BMEP, IMEP, brake thermal efficiency, indicated thermal efficiency, Mechanical
efficiency, volumetric efficiency, specific fuel consumption, Air fuel ratio, heat balance and
combustion analysis

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11. REFERENCES

 1. Avinash Kumar Agarwal, Atul Dhara ,"Effect of fuel injection pressure and injection
timing on spray characteristics and particulate size–number distribution in a biodiesel
fuelled common rail direct injection diesel engine",0306-2619/2014 Elsevier Ltd

 2. Junheng Liu, Anren Yao , Chunde Yao,"Effects of diesel injection pressure on the
performance and emissions of a HD common-rail diesel engine fueled with diesel/methanol
dual fuel", Fuel 140 (2015) 192–200 0016-2361/2014 Elsevier Ltd.

 3. S.k.jain & g. A.sivasankaran,“Effect of fuel injection pressure on performance of diesel

engines at high altitudes",indian institute of petroleum, Dehradun (received 12 march,
1976)

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