REPORT

DIESEL GASOLINE INJECTION

INJECTION PARAMETERS
Members: Date of report completion:
- Mr. Bryan Herrera 17 – 04 – 2016

Career: Course: Group Date of report submission:

Automotive Engineering 6 TE No.3 April 28, 2016

Introduction:

The compression ignition engine was born on February 27, 1892, when the engineer
German Rudolf Diesel, from whom this engine takes its name, presents his patent in Berlin.

Diesel had been working for years on his project for a more efficient engine than the one used until now.
the era, the steam engine, whose energy efficiency was approximately 10%.
His idea was to create an engine based on the isothermal cycle that, according to the theory of the physicist
The Frenchman Sadi Carnot could operate with an efficiency of around 90%.

Thus, Diesel initially developed his engine on paper, based on the Carnot model. This
new engine would be comparatively smaller and more powerful. Diesel was convinced of the
power and functionality of its engine. (Castillejo Calle, 2014) (Hermógenes, 2002)

Illustration 1. Rudolf Diesel inventor

of the Diesel engine.

It was not until 1936 that a car powered by an engine was first manufactured.
diesel, the Mercedes-Benz 260D. It managed to produce a power of 33 kW (45 hp) with a
consumption of 9.5 l/100km.

The diesel engine is an internal combustion engine that operates on the principle of compression ignition.
The combustion of the mixture is initiated by the self-ignition of the fuel after being
injected into the combustion chamber at the end of the compression phase has evaporated and
mixed with the air.

Diesel engines are the most efficient alternative internal combustion engines.

1de14
 REPORT

being able to exceed a performance of 50% in the case of large slow engines. The
lower fuel consumption results in a lower level of pollution, this
highlights the importance of the diesel engine.

Illustration 2. Mercedes Benz

260 D primer car with
Diesel engine.

Objectives:

Analyze the functioning of the main parts that make up the system of
diesel injection of the car.

Know the duration of the diesel injection in the car.

Identify the most relevant parameters of pressure, control, and times of

operating mechanism of the Diesel injection system.

Theoretical framework:

Start of injection and supply.

The starting point of the fuel injection influences several characteristics of the
motor features: the response to starting, the noises, the fuel consumption and finally
in the exhaust emissions. The function of the injection start control device
it is to determine the exact rotation point of the engine at which fuel must be injected.
(aficionadosalamecanica, 2014)

The EDC control unit calculates the start of injection depending on factors.
influential and acts on the advance solenoid valve for injection located in the pump
injector. The high accuracy of the injection onset is ensured by a circuit
regulator. For this, a needle lift detector captures the exact start of injection at
the injector and compares it with the scheduled injection start. A deviation has as
consequence of a modification of the control impulse relationship of the solenoid valve of the
advance variator The relationship of electrical impulses is modified until the deviation of
the regulation has a value of zero. (aficionadosalamecanica, 2014)

2de14
 REPORT

Illustration 3. Elements involved in

the beginning of the injection.

Mapping from the beginning to the injection

The control unit has a stored injection start map. This map
Take the engine RPM and the amount of fuel injected as the main reference.
As a corrective parameter, the engine temperature is also used, which acts on the
beginning of the injection. The cartography has been determined empirically and represents a
optimal balance between good engine performance and emissions control.
(aficionadosalamecanica, 2014)

Illustration 4. Cartography at the beginning

From the injection

3de14
 REPORT

Amount of fuel injected

The amount of fuel to be injected into the cylinders is determined at all times by the
control unit (EDC), for this it uses the information it receives from various sensors and
sends orders in the form of electrical signals to the injection pump (electronic pump) in
concrete to the servomotor that moves the regulation slider via an eccentric pin.
There is no connection between the accelerator pedal and the injection pump.
(aficionadosalamecanica, 2014)

If there is an excess of black smoke in the exhaust, the amount of injection is limited in
function of a characteristic curve that the control unit has memorized to reduce the
pollutant emissions.

From the information received from the various sensors, the control unit takes as
priorities for calculating the amount of fuel to inject into the engine cylinders
those received from:

Accelerator pedal sensor

Engine and fuel temperature sensor
RPM sensor
Flow meter
Position sensor of the electronic pump's injection flow regulator.

As secondary information, it is received:

Clutch pedal contact

Brake pedal contact.

Injection mapping (Smoke map)

The amount of fuel to be injected is determined taking into account also the
injection mapping that is stored in the control unit and that tries in everything
moment to avoid the emission of pollutants (black smoke).
If the volume of air drawn in is too low, the amount of fuel injected is
limited to a value that does not produce black smoke. (aficionadosalamecanica, 2014)

Illustration 5. Injection mapping.

4de14
 REPORT

Duration of the injection

One of the main parameters of the injection curve is the duration of the injection.
During this period, the injector nozzle is open and fuel flows into the
combustion chamber. (Castillejo Calle, 2014)

This parameter is specified in degrees of the crankshaft or the camshaft, or in thousandths of

second. Different injection processes require different injection durations,
for example:

 In cars with direct injection engines, the lifespan is

approximately 32º - 38º of crankshaft rotation.

 In cars with indirect injection engines, approximately 35º - 40º.

 In commercial vehicles with direct injection engines, approximately

between 25º - 36º.

Illustration 6. Crankshaft angles at different times of its

functioning.

5de14
 REPORT

Illustration 7. Direct injection and indirect injection of a

Diesel engine.

An angle of 30º on the crankshaft is equivalent to 15º on the camshaft (4-stroke engines).
A speed of 2000 rpm in the fuel injector pump corresponds to a duration of the injection of
1.25 ms.

In order to minimize fuel consumption and emissions, the duration of the

Injection must be defined based on the operating point and the start of the injection.

It approximately shows the effect of the onset and duration of the injection on the
fuel consumption and the main pollutant emissions. (Castillejo Calle, 2014)

6de14
 REPORT

Illustration 8. Fuel consumption and main emissions based on duration and the
start of injection. (Robert Bosch GmBh)

7de14
 REPORT

Diesel engine injection curves

 Cam-controlled systems.

In cam-controlled fuel injection systems, pressure is generated

continuously throughout the process by the injector pump. Thus, the speed of the pump
directly impacts the fuel supply rate and, therefore, on the pressure of
injection

Inline fuel injectors and mechanically controlled rotary pumps do not

they allow a pre-injection to be carried out. However, with a nozzle and injector holder assembly
With two springs, the flow can be reduced at the start of injection to improve the noise of the
combustion.

Yes, pre-injection is possible in rotary pumps controlled by solenoid valves. Also

there are systems with pump-injector units equipped with hydraulic and mechanical control that
they allow the pre-injection, but with a time limit.

In any case, in these systems, the generation of pressure and the supply of the amount of
Injected fuel is connected to the camshaft and the fuel injector pump. This has an impact on
the characteristics of the injection in:

As the engine speed increases, the injection pressure and the amount of
injected fuel, until reaching maximum pressure.

• La presión se eleva al inicio de la inyección, pero antes del final de la inyección, en el

moment when the supply ends, descends until it reaches the value at which the nozzle closes.
Basic principles of fuel injection 20 This has the following consequences:

Small amounts of fuel are injected at low pressure.

The injection curve has an approximately triangular shape.

The triangular curve favors combustion in partial load and low speed conditions.
motor, since the increase in pressure in the combustion chamber is less pronounced and
this makes the combustion quieter; however, this curve does not favor the
combustion at full load, where a more efficient operation is achieved with a curve
with a more square shape.

In indirect injection engines (with a pre-chamber), nipple injectors are used to

produce a single jet and define the injection curve. This type of injection nozzles
control the output cross-section according to the elevation of a needle. This causes
a gradual increase in pressure and, therefore, a somewhat quieter combustion.

 Common rail systems.

In these systems, a pump generates the necessary pressure in the fuel.

regardless of the injection cycle. This pressure remains practically constant
during the injection process. In a system with a certain pressure, the amount of
injected fuel is proportional to the time the injector remains open, and this is

8de14
 REPORT

independent of the speed of the engine or the pump.

This results in a nearly square injection curve with short injections.

duration and almost constant, with high spraying speeds at full load that allow
increase the specific power of the engine.

However, a high flow at the beginning of injection (during the ignition delay) does not
it is beneficial, in the sense that it increases the pressure in the combustion chamber
suddenly and the combustion process is louder. That's why, as the injection
It can be controlled precisely, and up to two pre-injections can be carried out. With this,
get pre-conditioned combustion chamber, causing the pressure to rise progressively
more progressive, reducing the delay time of the injection and, therefore, achieving
minimize combustion noise and NOx formation.

It is possible due to the electronic control over the injectors that allows varying the curve of
injection according to operating conditions. (Castillejo)

9de14
 REPORT

Injection pressure

The pressure generated in the injection system is intended for the fuel to exit.
the injector in jet form. A system with high injection pressure ensures that the
spray comes out more atomized. The collision of the atomized fuel with the air inside
from the combustion chamber causes the atomization of the fuel. Thus, the greater the
relative velocity between the fuel and the air, and the greater the density of the air, the better it will be
fuel atomization. The injection pressure in the nozzle can be higher than at the
pump discharge, due to the pressure wave being reflected in the section of pipe.

10 out of 14
 REPORT

 Direct injection engines (DI)

In direct injection Diesel engines, the speed of the air in the combustion chamber
it is relatively slow, since it only moves due to the moment of inertia of its mass.
This generates a swirling motion inside the cylinder.
The piston compression intensifies the movement of air inside the cylinder by forcing it to enter.
in the piston cavity, smaller in diameter than the cylinder (squish). Despite this, in
air movement is less than in engines with divided chamber.

Due to the lower airflow, the fuel must be injected at a higher pressure.
peak maximum can be between 1000 and 2200 bar). However, except for the
Common Rail systems, that maximum peak pressure is only reached at high engine speeds.
of the engine.

A decisive factor for achieving an ideal torque curve with low emission levels
particles, it's about injecting the fuel at high pressure when the engine is running at low
speed and full load. As the air density at low speed is relatively low, it
it should limit the maximum injection pressure to avoid fuel deposition on the
cylinder walls. Above approximately 2000 rpm, the maximum is reached.
inlet air pressure, and the injection pressure can be increased.

To achieve maximum engine efficiency, the injection advance must be adjusted to

function of the motor speed. At high motor speeds, a pressure is required
high injection to shorten the duration of the injection.

Influence of the start and injection pressure on fuel consumption and emissions

11 of 14
 REPORT

particles and NOx, (Robert Bosch GmbH)

 Engines with indirect injection (IDI)

In diesel engines with divided combustion chambers, the pressure rise during the
combustion expels the charge out of the pre-chamber or turbulence chamber, resembling
a pneumatic injection. This process occurs at high speed in the turbulence chamber
and in its outlet to the main combustion chamber.

Conclusions:

The injection is a process in which the fuel is injected, but that is not the only thing that occurs.
process since in order to inject they must meet a series of parameters, which
are sent from the sensors to the electronic control unit, and then the actuator which is the
The injector is the one that injects the fuel at a determined pressure.

Questionnaire:

1) What is one of the characteristics that injection influences?

a) The speed at which the vehicle is going.
b) Exhaust emissions
c) The actuators.
d) The RPM

At a speed of 2000 rpm in the injector pump, it corresponds to a duration of the

injection in milliseconds is:

1.25 ms
b) 2.50 ms
c) 1.00 ms
0.50 ms

In direct injection engines, we have that the maximum peak pressure can be
between:
1000 and 2000 bar.
1000 and 1950 bar
1000 and 2200 bar
700 and 800 bar

4) How many fuel injection systems do we present in a diesel engine?

4
b) 3
c) 2
d) 5

12 out of 14
 REPORT

5) What types of injection pumps do we have in diesel engines?

line
b) Rotating
c) Line and rotary
d) By pressure

Bibliography:

Callister, W.D. (2007). Introduction to the science and engineering of...

materials. In W.D. Callister, Introduction to the science and engineering of the
materials (Vol. Volume 1). Barcelona, Spain, Spain: Reverté.

Crouse, W. (1985). The car book. In W. Crouse, The car book

(E. Grau Amador, Trans., pp. 155-156-157). Barcelona, Catalonia, Spain:
Marcombo.

Bosch. Automotive technology manual. In Bosch, Automotive technology manual

of the automobile (Vol. 3, pp. 736-737-738-739). Barcelona, Catalonia, Spain:
Editorial Reverté S.A.

Castillejo Calle, A. (2014). Injection system in Diesel engines.

University of Seville - Higher Technical School of Engineering, Dep. of
Energy Engineering. Seville: Group of Machines and Thermal Engines.

13th of 14
REPORT

14 of 14