Fuel System
FUEL SYSTEM
Introduction
Air is compressed in the cylinders of a diesel engine until it is hot enough to
ignite fuel.
Fuel is injected during the compression stroke, when cylinder pressure is already high.
In other words, the work of compression precedes fuel induction.
Injection pressures range from about 1600psi to more than 35,000 psi for modern
designs. The amount of fuel supplied varies with load and speed requirements.
Conceptual Model of Diesel Spray
Combustion by John Dec
3.Spark ignition
3.Fuel injection
Incoming air is compressed
until its temperature reaches
about 1000°F (540°C).
Torque is the ability to do work.
Power is the rate of doing work.
Fuel Systems Circuits 1. Fuel Tank 5. Air Bleed Plug
The fuel system consists of 3 2. Gauge Filter 6. High Pressure Line
circuits, each operating at a
3. Priming Pump 7. Fuel Injection Nozzle
different pressure namely:
(1) The Low-pressure circuit (Feed Pump) 8. Governor and Fuel
(2) The High-pressure circuit 4. Fuel Filter Injection Pump
(3) The Fuel-return circuit
Low Pressure Fuel Pump
(Gear Driven)
(Belt Driven)
Fuel Filter
Types of Fuel System
There are four main types of diesel injection systems
Mechanical Fuel Injection Pump (Inline or Rotary)
Mechanical Individual Control Pump (Unit Pump)
Common Rail
Unit Injector
Fuel Injection Pump
Automotive type diesel engines use “solid-injection "systems; that is, the fuel is
injected in the liquid state and small high-pressure fuel pumps are required force the
correct amount of fuel in against the compression pressure.
Injection must begin at the exact time that the correct temperature of the air
from compression is reached.
Port and Helix
(B)
(A)
(C)
A B
C
(C) (B) (A)
Feed Pumps
To supply a constant fuel flow at a fixed pressure to port and helix fuel injection pumps.
1. Pump camshaft 6. Piston
10. Non-return valve
2. Eccentric 7. Piston spring (suction side)
3. Roller cam 8. Non-return valve 11. Inlet
4. Thrust bolt (discharge side) 12. Outlet
5. Discharge chamber 9. Suction chamber
PUMP GOVENOR
Distributor Injection Pump
Injection pumps are usually driven by
the camshaft at the front of the engine.
As the injection pump shaft rotates,
the diesel fuel is fed from a fill port to a
high-pressure chamber.
A distributor diesel injection pump is
a high-pressure pump assembly with
the exact same length lines leading to
each individual injector.
Fuel Injector
consist of a nozzle holder and an injection nozzle
nozzle holder to provide a pressure adjustment mechanism
injection nozzle is to direct and atomize the metered fuel into the combustion chamber
Hole-type nozzle
Pintle-type nozzle
Hole type Nozzle
Schematic view of
a multi-hole nozzle
Spray patterns of various nozzle types
Unit Pump Systems Unit Injector System
DaimlerChrysler, Mack, DAF Volvo, Iveco, DDC, CAT
DEUTZ liquid cooled VW passenger car
• High peak pressure
• Favourable injection
rate
Common-Rail
Almost every • Pressure flexibility
passenger car • Multiple injection
RVI, JohnDeere, • Silent gear train
Cummins, CAT
Individual ( Unit ) Pump
VOLVO Unit Pump Engine
Common Rail System
The common rail system uses a type of accumulation chamber called a rail to store
pressurized fuel, and injectors that contain electronically controlled solenoid valves
to inject the pressurized fuel into the cylinders.
Common Rail Fuel System
Pressure sensor
Injector
FCU
Pmin > 0,5 - 1,0 bar
Pmax = 5 - 7 bar
Psystem = 300 - 1600 bar
Pressure
Pback, max < 1,2 bar sensor
PRV
Prefilter with HP-pump
water separator
FCU
Supply Main
pump filter
Hand- Thermostatic V1048196
primer valve
ECU: Electronic Control Unit
FCU: Fuel Control Unit
PRV: Pressure Relief Valve
VOLVO D7E Common Rail Engine
1
2
9
7 8
3 6
1.Ball socket
5
2.Return spring
3.Return duct
4.Nozzle spring shim Unit Injectors
5.Nozzle (5 holes) Each cylinder has a so-called unit injector fitted inside the
6.Inlet duct cylinder head. The unit injector replaces the injection pump,
pressure pipes and injectors.
7.Coolant valve stop
The unit injector consists of a pump piston (1), solenoid
8.Control valve
valve (2), nozzle (3), and a number of fuel ducts (4). The
9.Solenoid piston is driven via a rocker arm (5), by the engine’s over-
head camshaft (6).
Unit Injector Fuel System
Unit Injector Fuel System
Injection phase (B)
When the fuel valve (1)
shut the fuel duct is
blocked and pressure
increases considerably.
Filling phase (A) Fuel under high pressure presses the nozzle
When the pump piston moves needle (2) upwards so that the nozzle opens
upwards fuel is sucked from the and a fine mist of fuel is sprayed in under ex-
cylinder head’s fuel ducts (1), tremely high pressure into the combustion
through the open fuel valve (2), chamber.
into the injector.
Flow phase (C)
When the piston moves downward fuel is
pressed back past the open solenoid valve
out into the cylinder’s head fuel chambers.
Pressure-reduction phase (D)
Injection is interrupted when the solenoid
valve reopens thus causing pressure to
drop and the nozzle to shut.
If the fuel injection timing is too early, the
maximum pressure inside the combustion
chamber will be reached before the piston
reaches top dead center. This means that force
will be applied to prevent the piston from rising,
and the force pushing down the piston on the
down-stroke will also be lost, so the higher the
maximum pressure, the more power will drop.
If the maximum pressure becomes too high,
there will be an adverse effect on the life of the
engine.
If the fuel injection timing is too late, the
exhaust valve will open before the combustion
is completed, so the pressure will be lost and
the power will drop. The maximum pressure
will drop, but the exhaust gas temperature will
also rise, so there will be an adverse effect on
parts such as the turbocharger.
Therefore, the timing for starting injection of fuel is set so that the maximum pressure inside the
combustion chamber is reached after the piston passes the top dead center and begins to go down.
The problems of over injecting fuel
Causes
• Improper injection timing
• Overheating
• Water leakage into the combustion chamber
Piston Sintered The cracked cylinder head Failed valves
WEAR OF INJECTION PUMP PLUNGER SEIZURE of DELIVERY VALVE MELTING OF VALVE SEIZURE OF PISTON
Any Questions?
