MECHANICAL ENGINEERING

Group members:
ISAIAS PEREIRA
LAURO AUGUSTO
LEIRIVAN JOSE

Teacher: HUMBERTO CAMPOS

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Introduction
The idea of building an engine utilizing the expansive force of gases resulting from combustion of
gunpowder in a closed cylinder was proposed by Father HAUTEFOILLE in 1652, however he left no record.
written about the subject.
In 1680, HUYGENS proposed an engine whose fuel was gunpowder and would work with a cylinder and piston.
In 1687, DÊNISPAPIM developed and described the operating principle of a steam engine with
piston.
In 1767, JAMES WATTS built a steam engine with a cylinder cooling system.
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what was really the first engine to work successfully.
JEAN ETIENNE LENOIR (1852) began working on the design of a gas explosion engine,
from this engine began to think about the possibility of transforming linear motion into rotational motion.
rotation
DUGALD CLERK (1854) built the first two-stroke combustion engine.
GOTTLIEB DAIMLER, 1885, was a pioneer in the construction of two-stroke internal combustion engines.
for automobiles and introduced spark ignition in engines, which made the construction of automobiles viable
years later.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Introduction
BARSANTI and MATTEUCI (1857) built a free-piston engine that operated as follows: the
the expansion of the combustion gases drove the piston vertically upward and when the piston descended, by the
the action of gravity would trigger a ratchet, which in turn would activate a shaft.
BEAU DE ROCHÁS (1862) proposed and patented the operating principles of four-stroke engines.
internal combustion times with pistons.
NIKOLAUS AUGUST OTTO (1876), German, who built after having independently invented the
same cycle, described by BEAU DE ROCHÁS, the engine that was called the silent OTTO. OTTO
associated with engineer EUGEN LOGEN and founded N. A. OTTO & CIA, the first motor factory
combustion of the world
In 1893, RUDOLF DIESEL, a German engineer, invented the type of engine that today bears his name: diesel engine.
After some difficulties in financing his project, he built an engine that exploded after the first injection.
fuel, escaping just enough from dying.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Introduction
Internal combustion engines are classified
in relation to the operating cycle in two
types: OTTO cycle and DIESEL cycle.
The operating cycle is the set of
transformations in the gaseous mass that occur in
interior of the cylinders, from their intake, until the
elimination for the environment. The OTTO cycle was
described by NIKOLAUS A. OTTO (1876) and the cycle
DIESEL by RUDOLF DIESEL (1893).
Both cycles can be completed in two
There are four courses of the piston. When the engine
complete the cycle in two courses of the piston is
called a two-stroke engine when
completing the cycle in four stages is called an engine
of four times.

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Diesel
Diesel is an oil derived from the distillation of crude oil used as fuel in engines.
diesel/gas oil, basically composed of hydrocarbons. Diesel oil is a compound formed
mainly by carbon, hydrogen atoms and in low concentrations by sulfur, nitrogen and oxygen.
It is a slightly flammable product compared to gasoline, moderately toxic, low volatility, clear, free from
suspended material with a strong and characteristic odor. It was named in honor of the German engineer
Rudolf Diesel who invented a mechanical means to exploit the chemical reaction originated from the mixture of oil and
oxygen present in the air.
The density of petroleum diesel is about 0.853 kg/L, which is denser than gasoline by 12%. Each liter
when burned, it provides an energy value of 35.86 MJ (which is also more than gasoline, which is 32.18)
MJ) and releases 2.6 kg of CO2. (Also conveniently expressed as 1 liter/100km = 26.5
g/km CO2 used to calculate the emissions of diesel vehicles). In 2011 turbo diesel engines manage to
efficiencies of the order of 45% between chemical energy and mechanical energy (Higher value than gasoline engines that
it's 30%.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Mechanical Injection
Mechanical diesel injection systems were
developed simultaneously with diesel engines of
internal combustion. Over the years, they have been improved,
however, the essence remained unchanged. The fuel is
sucked from the tank to the injection pump by positive action
from a transfer pump (pre-feeder). In
next, it goes through a filter to remove the particles
contaminants. A transfer pump, then, provides
for the injector pump the fuel at low pressure. The
diesel goes through the fuel filter before reaching the
pump. It compresses the fuel to the injectors, the
which reach high pressures, necessary for atomization
and the burning in the combustion chambers, sending it through lines
individuals, for each injector. Upon reaching the injector, the
compressed fuel triggers the needle activation
that seals the injector holes with the combustion chamber,
overcoming the load of a spring and wedges that determine its
opening pressure and allows the entry of diesel in a way
optimized. The fuel leak around the needle for
Cooling is collected by the return collector, which sends it
for a connection and for the return piping to the tank.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Types of Injection
Indirect injection
A small part of the combustion chamber (pre-chamber) is separated from the part
principal through a narrowing. The fuel, which in its entirety is
injected into the anterior chamber through a plunger dosing pump with
operation of eccentric, with a pressure between 80 and 120 atm,
depending on the engine design, it ignites and burns partially there;
about the instant pressure thus formed, blows the inflamed mixture with a
effect of spraying and violent turbulence through the "firing channel" until
the main chamber rich in air. The walls of the ante-chamber, especially the point of
the impact of the incoming jet is maintained at a higher temperature
possible, as in this way they assist in the preparation and ignition of the fuel.
Although it has the advantage of producing fewer exhaust gas components
harmful to health, produces greater heat loss, due to the multiplication of
permutation surfaces, resulting in greater specific consumption of
fuel and, currently, it is a process little used in engines
modern

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Types of Injection
Direct injection
The fuel is injected directly onto the piston head through a
injector nozzle, with one or several small holes (diameters from 0.1 to 0.3 mm)
directed at an appropriate angle. It works with very high pressures.
high (up to 400 atm) to achieve a very fine spray and a
proper distribution of fuel in the carburetion air. The single jet forms
a mist composed of tiny droplets that tends to ignite in
first place near the entrance. The formation of the mixture is accelerated and
improved when the carburetion air performs a quick movement in
regarding the fuel mist. With this, the circular and turbulent movement
Air is produced in several ways, either through the suction process or with the
compression. Most modern engines use the injection process
fuel direct, due to its better thermal efficiency.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Inline injector pump
The inline injection pumps have a drive shaft that is
activated by the engine's valve command or by a system of
transmission that keeps the fuel injection synchronized
with the movement of the cylinders. Therefore, in the ICO engines of four
At times, the axis of the fuel injector pump must rotate at half the rotation.
of the crankshaft. The inline injection pumps have elements of
pump in equal number to the number of cylinders in the engine. Each
the element consists of a piston and a cylinder. The pistons are
activated by the pump's camshaft through the tappet
of rolls.
At the top of the cylinder, there is a pressure valve whose purpose is
keep the pump line pressurized to the injector nozzle.
The fuel debit in each injection cycle and in each element of
the pump is controlled by the rotary movement of the piston which is actuated by the
rack that is in turn controlled by the vehicle's accelerator. The
The rack operates the adjustment sleeve that moves the piston wing
making the piston move in a clockwise and counterclockwise direction, in addition to
alternative movement of the piston.

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Inline injection pump
The piston has an external longitudinal groove and a helix (milled oblique groove). The cylinder of the element
the pump has two ports, one inclined to promote lubrication of the piston, and the other radial for feeding and relief
of the cylinder of the pump element. When the piston is at the bottom dead center, the oil that is in the suction chamber enters the cylinder.
of the pump element. When the pump cam activates the piston and its top closes the inlet opening, the pressure in the
The interior of the cylinder increases until it overcomes the force of the spring of the discharge valve at the top of the pump element. The piston continues
its upward movement increasing the oil pressure until it is sufficient to open the injector nozzle. The end of the flow
Oil occurs when the groove on the piston screw matches the feed hole. By rotating the piston in the direction
clockwise or counterclockwise the fuel flow is controlled because the helical groove determines the end of the flow upon reaching the
fuel inlet. When the vertical slot of the piston aligns with the fuel inlet, the fuel flow is
null, therefore the engine does not work. The flow control rack is activated by the vehicle's accelerator.

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Rotary injection pump
Allows for fast operation and dimensions smaller than injection pumps
lines are generally used in low-specific power diesel engines and
for automobiles, which are applications with low usage demand, as the pumps
rotary injectors have a lower injection volumetric capacity than the
inline pumps.
The fuel distribution is done by the movement of the two opposing pistons.
situated in a headquarters arranged transversely inside the fixed element that is the
hydraulic head. This set of the rotor and the hydraulic head constitutes the
pump distributor.
The opposite pistons are driven by the eccentrics located in the housing of
body where the rotor moves. usually in the pump body housing
there is an equal number of eccentrics to the number of cylinders in the engine.
When in the rotor movement the opposing pistons are activated by the
eccentrics, send the fuel under high pressure to the channels that are part of
of the distributor that coincide in well-defined intervals with existing holes
in the hydraulic head to supply each of the injectors.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Rotation regulator
The rotation of a compression ignition engine
it tends to vary even if the position remains fixed
from the injector pump control lever. With the
command lever position at idle, by
For example, the engine rotation can drop until it stops.
you can increase indefinitely. Therefore, it is
a rotation regulator is necessary to maintain the
motor with more stable rotation for any position
from the control lever. There are regulators of
rotation that acts in all regimes of
engine operation and there are regulators that
operate in slow motion and at full load. For use
It is more common for regulators to act in
slow march and at full load, because, in the loads
intermediate the driver himself controls
rotation, or speed, changing the position of the
pump control lever via the throttle

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Injector nozzle
Normally installed in the heads, it aims to provide the
sprayed fuel supply in the form of mist. The
the injector needle rises at the beginning of the injection due to
impact of pressure in the fuel line, supplied by the pump
injector. During the time intervals between the injections, if
remains closed automatically by the action of a spring. A
small amount of fuel, used to lubricate and
removing heat from the moving parts of the injectors is returned to
fuel supply system. The injectors, thus
Like bombs, they are manufactured for specific applications and not
are interchangeable between different engine models. In
In many cases, the same engine model, due to
any evolution introduced in your production uses a type of
injector nozzle up to a certain serial number and another starting from
so, without being interchangeable with each other. It is necessary to have
special attention when it comes to replacing nozzles or pumps
injection machines, so that the correct components are used. In
most engines manufactured before 2003 injection pressure
is regulated between 150 and 250 kgf/cm2.
The higher the injection pressure, the smaller the average diameter will be.

Injection Systems for Diesel Engines

the injected drops.
 MECHANICAL ENGINEERING
Mechanical system with injection pump
Advantages:

A more sporty behavior for the diesel engine

Instant start
Very low consumption, even compared to the common-rail.

Disadvantages:

Lower yield than the common-rail system

Higher operating noise
More polluting than common-rail

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Electronic Injection
The electronic diesel injection system represents an advancement
technological in relation to mechanical systems, allowing to dose the
exact amount of fuel for each service moment of the
motor, adjusting the exact start of injection. To meet the most
strict regulations on exhaust gases, offers advantages
special, as it allows processing various engine and
environment. In this way, it is possible to reduce consumption of
fuel and the emission of polluting gases, in addition to obtaining a
significantly improved smoothness of gait.
For the Diesel Injection System to provide all the
benefits and advantages, needs to undergo periodic reviews, being
well regulated and use exclusively original replacement parts.
For the proper maintenance of electronic diesel systems, it is
high precision equipment always calibrated, well
as technicians constantly trained by the manufacturers, since the
technological innovation is constant. Thus, the engine will always receive the
appropriate amount of fuel for each moment of
functioning, generating better performance with lower consumption and
low emission of pollutant gases.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Injector pump
electronics (EDC)
• In this system, the injection is
monitored by sensors;
• Bomb injector electronics.
Also known as "Fly By"
Wire Electronic Pump
• There is no connection
mechanics between the pump and the pedal
of the accelerator;

• It was the first injection system.

diesel electronics, released in
marketed by Bosch in 1989 in
commercial vehicles.

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Unit injection system
Injector System (UIS): unit
injector
• Launched in the market by Bosch in 1994;
• The main feature is to combine the injector pump and the nozzle.
injector in a single unit (Unit Injector);
• It features an injector unit for each cylinder;
• It allows varying the injection period and can generate pressures of
injection of up to 2,200 bar;
• The main components of the electronic injection system
diesel UIS are:
• Injection unit (12);
• Air pressure and temperature sensor (13);
• Temperature sensors, which measure temperatures in
various locations of the engine (16);

• Phase sensor that informs which cylinder is in compression;

• Engine rotation sensor (17).

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Injection system
Common Rail (CRS)
• Launched in the market by Bosch in 1997;
• It has a single high-pressure pump that sends
fuel for all fuel injectors;
• Pressurization and injection processes are independent.
between each other;

• It is possible to perform more than one spraying of

fuel during the expansion phase;
• The 1st Generation of the system operates at pressures of
1.600 bar;
• Currently, the 4th Generation of the system works with
injection pressure of 2,100 bar.

A= filtro primário de combustível; B = filtro secundário de combustível; C = bomba de alta pressão: envia o combustível sob pressão (2000
bar) for the distribution pipe; D = control module (ECU-electronic control unit): controls the fuel supply to the injectors
injectors from information received from sensors (rotation, pressure among others); E = common rail distributor tube:
distribute the fuel to the fuel injectors.

Injection Systems For Diesel Engines

 MECHANICAL ENGINEERING
Common Rail (CRS)
Cutting-edge technology in electronic injection, the
Common Rail stands out for its separation of
pressure generation and injection systems.
This means that the pump generates high pressure.
that is available for all injectors
through a common distributor tube. This
pressure can be controlled independently
from the engine rotation. Fuel pressure,
the start and end of the injection are precisely
calculated by the control unit based on
information obtained from various sensors
installed in the engine. Thus, controlled by
actuation of your solenoid valve, each
injector provides, individually and with
precision, the fuel to the respective cylinder
do motor.

Injection Systems For Diesel Engines

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Injection Systems For Diesel Engines

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Components of the Common Rail System (CRS)

High pressure pump

Bico

RAIL ECU

Injection Systems for Diesel Engines

 MECHANICAL ENGINEERING
Conclusion
With this work we can conclude that the diesel injection system can be two
ways, one analog (mechanical) with the injector pump and another electronic using
the Common Rail system.
We can visualize and understand the main characteristics of each of the systems.
as well as their advantages and disadvantages.
As it is a very extensive topic, the group presented the content summarized, focusing on
two systems and explaining their operation.

Injection Systems for Diesel Engines

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BIBLIOGRAPHY:
<[Link]
[Link]
[Link]
[Link]
Basic Diesel [Link]
[Link]
Cat_Sistemas_de_Injecao_Eletronica_Diesel_2009.pdf>
<[Link]

BRUNETTI, Franco. Motores de Combustão Interna VOL.I. Editora Edgard BlücherLTDA. São Paulo, SP,2012.
BRUNETTI, Franco. Motores de Combustão Interna [Link]. Editora Edgard BlücherLTDA. São Paulo, SP,2013.

Injection Systems for Diesel Engines