Fuel Injection Systems

UNIT-IV

Presented By:
Dr. B. JOGA RAO
[Link]
Dept. of Mechanical Engg.
Lecture Details: GIET(A)
Sub: Modern Vehicle Technology
Fuel Injection Systems
IV [Link]. I Sem.- Mech, 2024-25.
 UNIT- IV
• FUEL SUPPLY SYSTEM: SPFI, MPFI, DI, Pilot injection, unit
injection, CRDI, Two wheeler Technology : DTS-i ,DTS – Fi , DTS
– Si Four wheeler Technology: VVT, Camless engine GDI engine
• Emission and Noise Pollution Control: Introduction, Engine
emissions, Types of catalytic conversion, open loop operation to the
oxidizing catalytic converter, closed loop operation to the oxidizing
catalytic converter, Evaporative emissions, Internal and External
Noise, Identification of Noise sources, Noise Control Techniques
 FUEL SUPPLY SYSTEM
Components of Fuel Supply System in Petrol Engine
In automobiles, the basic fuel supply
system with a petrol engine consists of the following
components:
• Fuel tank
• Fuel pump
• Fuel lines
• Air cleaner
• Fuel filter
• Carburettor
• Inlet manifold
• Supply and return pipelines
Components of Fuel Supply System in Petrol Engine

Fuel Tank
The fuel tank stores gasoline or diesel fuel and is typically located at the rear of the
vehicle, providing a reservoir for the engine's fuel needs.
Fuel Pump
Responsible for pressurising the fuel and delivering it to the engine, the fuel pump
ensures a consistent flow of fuel to meet engine demands.
Fuel Lines
These pipes transport fuel from the tank to the engine, maintaining its flow
under pressure and ensuring a steady supply for combustion.
Air Cleaner
The air cleaner filters incoming air, removing impurities and contaminants to ensure
clean air for the combustion process.
Components of Fuel Supply System in Petrol Engine

• Fuel Filter
• Positioned along the fuel line, the fuel filter removes debris and impurities from the fuel,
preventing clogs and maintaining fuel system integrity.
• Carburettor
• In older engines, the carburettor mixes fuel with incoming air to create a combustible air-
fuel mixture before it enters the engine's cylinders.
• Inlet Manifold
• The inlet manifold distributes the air-fuel mixture evenly to each cylinder's intake valve,
ensuring uniform combustion.
• Supply and Return Pipelines
• These pipelines are used in fuel injection systems to deliver fuel to the engine (supply) and
return excess fuel to the tank (return) to regulate fuel pressure and prevent overheating.
Fuel Supply System of S.I Engine

• In a S.I engine, a measured quantity of petrol or gas is already mixed with

air in a calculated proportion before being sucked by engine.
• Then this combustible charge having right quantity of fuel-air is ignited at
the appropriate time at the end of compression stroke in the engine with the
help of a spark plug.
• The operation of spark plug is timed along with the moment of crank shaft
with the help of ignition system. Low voltage of battery is given to primary
winding of ignition coil through an ignition switch and contact breaker.
• The secondary winding is connected to spark plugs through distributor (in
case of multi-cylinder engines).
• A cam on cam shaft breaks the contact and causes the electric primary circuit to
open and close.
• When the circuit is broken or the current flow is stopped in the primary winding,
the magnetic field collapses inducing a high voltage in the secondary winding due
to which a spark occurs instantaneously in the spark plug.
• This spark initiates the combustion of compressed air-fuel mixture in the engine
cylinder.
• Depending on the method of mixing petrol or gas in the air in right proportion as
per the requirement of engine, the fuel supply system of S.I engine is
conventionally is of two types
Carburetion
• In the carburetion method, fuel stored in the fuel tank is supplied to
carburetor by means of a simple diaphragm pump through a fuel filter.
• The job of pump is only to supply fuel from fuel tank to float chamber of
carburetor.
• Sometimes when the fuel tank is above the carburetor like in 2-wheeler
engine, fuel will come by gravity and fuel pump is not needed.
• The design & working of a simple carburetor fitted in the suction line or
Inlet manifold of engine is very simple.
• there is a venturi in the flow passage of air being sucked by engine? A jet is
situated in the venturi and connected to the float chamber of carburetor,
where fuel is stored at atmospheric pressure
• The float keeps the fuel at a constant level in the float chamber.
• While passing through the venturi, pressure of air reduces and a pressure difference is
created across the fuel jet connecting float chamber with venturi.
• Due to this pressure difference fuel is continuously supplied to air flowing through
venturi. As jet is of very small inner diameter, fuel i.e. petrol is sprayed in the flowing
air and due to its high volatility, it vapourizes and forms a combustible mixture of
fuel vapour plus air.
• The fuel air ratio is automatically controlled by the speed of air through the venturi
which eventually depends on speed/rpm of engine.
• The size of venturi and jet are designed on the basis of desired fuel air ratio. In an
actual carburetor, some additional systems are there to satisfy the demands of engine
under varying conditions like cold starting, engine idling, requirement of additional
power at high speed & load etc.
Electronic fuel injection (MPFI system)

The Multi-Point Fuel Injection system is a way of injecting the fuel in an internal
combustion engine through multiple ports located on the intake valve of every cylinder
the motor has. These ports work together to deliver the optimum quantity of fuel at the
right time to every cylinder.

• In this system an electrically driven fuel pump draws fuel from fuel tank and supplies
it to a common header or tube.
• A pressure regulator fitted at the end maintains a constant pressure of fuel approx.
• 3 bars in the header.
• The header is connected to different branches of inlet manifold through fuel injectors.
For each cylinder of engine there is separate fuel injector which injects fuel in the
corresponding air passage of that cylinder. Due to this the system is called multi-point
fuel injection (MPFI) system.
Electronic fuel injection (MPFI system)

• The fuel injectors are precision built solenoid valves having single or multiple orifices.
• Due to constant pressure of fuel maintained in the common header, the quantity of fuel
injected depends only on the time period for which the solenoid valve type fuel injectors
are kept in open position.
• An on-board ECU (Electronic control unit) i.e. microprocessor controls the quantity of
fuel injected to each cylinder individually and also the ignition timing of each cylinder.
• The data input to the ECU comes from a number of sensors located all over the engine.
• These sensors collect the following data continuously.
• Based on programmed interpretation or processing of this data, ECU calculates the
amount of fuel needed to maintain stoichiometry i.e. air/fuel ratio of 14.7:1 and converts
it into required pulse width i.e. time period for which it keeps the solenoid injector
energized.
• ECU also gives command to spark ignition system. In this way ECU ensures overall
satisfactory performance of the engine from start to shut down including emission
control by sending right quantity and quality of fuel air mixture to each cylinder of
engine at right time based on requirement of engine and also ignites it at right time.
Fuel Supply System of C.I Engine

The primary requirement of a C.I engine is to inject the right quantity

of fuel at a very high pressure either directly over the piston in the cylinder of
engine or indirectly in a combustion chamber in the cylinder head which is
connected to cylinder of engine. In any method the fuel injection system has to
control injection timing, injection period and injection pressure. Now in most
of the diesel engines direct injection is used with improved injection
technology.
Direct Injection (DI)

The injectors spray the diesel fuel directly inside the combustion
chamber. And no, no special glow plug is required as the cooling surface of the
cylinder is fairly small. This allows better control over the fuel delivery inside the
engine.
Firstly, Diesel Direct Injection (DI) is a basic type of fuel injection
system which many earlier generation diesel engines used. The simple DI
diesel engines inject the fuel into the combustion chamber above the piston
directly. The compression of air inside the combustion chamber raises its
temperature above 400oC. Then, it ignites the diesel-fuel injected into the
combustion chamber. Hence, the diesel engines are also known
as ‘Compression Ignition’ engines.
 This technology i.e. simple DI engine differs in the method by which it
supplies the diesel to the injectors and operates them to its successor Common-Rail
Direct injection (CRDi). Moreover, it was in vogue until the development of the latter.
At present, some heavy diesel vehicles such as utility vehicles, trucks, buses &
generators still use DI technology.
The fuel system of DI Technology consists of following parts:

[Link] Injection Pump (FIP)

[Link]
[Link]-Pressure Lines
[Link] feed pump
[Link] Filter
[Link]
The fuel system of DI Technology consists of following parts:
• The sole function of the Fuel Injection Pump is to supply the accurately
measured amount of fuel to each cylinder at specific time intervals in accordance
with the position of the piston
• The fuel injection pump compresses the fuel to high pressure and meters the fuel
quantity to be injected according to the engine load & speed. Then, it supplies the
pressurized diesel to injectors through separate fuel lines.
• Technically, there are two different types of FIPs which the DI engines widely use.
One is an in-line pump (plunger type) while the other is a rotary pump (distributor
type) with a mechanical/pneumatic governor. Furthermore, the governor regulates
the engine idling and also maximum speed by controlling the amount of fuel
delivery.
• Fuel Injection Pump’s parts are machined with narrower tolerances in order to
achieve a high degree of precision.
• The engine oil poured into it from the oil port provides lubrication to the parts of an
in-line injection pump whereas the rotary fuel pump is self-lubricating type by
diesel.
Advantages of conventional DI Technology:
• Higher low-end torque
• Sturdiness
• Lower maintenance
• Longer engine life

Disadvantages of conventional DI Technology:

• Higher NVH (Noise, Vibrations & Harshness) levels
• Sluggish in operation
• Lower engine speeds & BHP
• Heavier engine components
Common Rail Direct Injection (CRDI)

• A type of direct injection is the common rail direct injection system. Like in
the DI, the injectors the CRDI also atomize the diesel fuel straight into the combustion
chamber. Also, the working and the injection timing is similar to that of the DI system.
• The difference lies in the fuel lines of the injectors. In the DI, the injectors are straight
connected to the fuel pump that regulates the pressure and the amount of diesel being
injected into the chamber.
• In CRDI all the injectors are connected with a common rail that receives the flow of
the fuel from the fuel pump.
• There it is the common rail that regulates the pressure and the amount of diesel being
injected. The advantage of CRDI is that here we have better control over the injection
than in the DI. This means the engine runs more efficiently.
• Hyundai is among the companies that use CRDI technology in their diesel engines.
Pilot injection
• A locomotive going in advance of a train to make sure that the way is clear is a
shorter injection before the main fuel injection, which can provide an environment of high
temperature and pressure for the main injection resulting in a smoother pressure rise and
shortened ignition delay for the main injection.
• Pilot injection timing is a very important parameter at the start of ignition which will affect
engine performance and emissions on diesel dual-fuel engines, especially at high loads.
• The pilot system runs all the time, even when the engine switches to 'Diesel mode'. This is
necessary to avoid blockage of such small holes.
• Pilot injections are a fundamental strategy for reducing noise and emissions in common rail
engines. While a single pilot injection is sufficient to reduce noise in many cases, double
and even triple pilots can provide additional noise reductions
• Dual fuel engines operate on a primary (main) fuel and a secondary (pilot) fuel. The
primary fuel source is typically a gaseous fuel such as hydrogen or syngas or natural gas,
which is injected into the intake manifold.
Unit injection

• A unit injector (UI) is a high pressure integrated direct fuel injection system for diesel
engines, combining the injector nozzle and the injection pump in a single component.
• The plunger pump used is usually driven by a shared camshaft. In a unit injector, the
device is usually lubricated and cooled by the fuel itself.
• High pressure injection delivers power and fuel consumption benefits over earlier lower
pressure fuel injection by injecting fuel as a larger number of smaller droplets, giving a
much higher ratio of surface area to volume.
• This provides improved vaporization from the surface of the fuel droplets and so more
efficient combining of atmospheric oxygen with vaporized fuel, delivering more
complete and cleaner combustion.
Two wheeler Technology
DTSi Engine Work

The DTSi engine employs two spark plugs to ignite the air-fuel mixture
alternatively so as to increase the flame diameter and burn the fuel
instantaneously. This process of firing the spark, coupled with the swirl caused
in the air-fuel mixture results in incomplete combustion.

DTSI is Digital Twin Spark Ignition. In normal engines, there will be only one
spark plug generating sparks at a regular interval. DTSI has twin spark plugs
which create sparks alternately. This means that in a given time frame there
will be double the nunber of sparks than in the normal engine.
Digital Twin Spark ignition (DTS-i system)

• The DTSi engine employs two spark plugs to ignite the air-fuel mixture
alternatively so as to increase the flame diameter and burn the fuel
instantaneously. This process of firing the spark, coupled with the swirl
caused in the air-fuel mixture results in incomplete combustion.
• The Digital Twin Spark – ignition, equipped combustion chamber takes care
of the slow rate of combustion in a simple but novel way. The cylinder head
is equipped with two spark plugs, instead of the conventional single spark
plug.
What is the difference between DTS Si and Dtsi?

DTS-SI stands for digital twin spark swirl Induction this is

a technology similar to that of DTSI but here the position of the
intake and outtake port are such that it generates a swirl inside
the combustion chamber resulting in better flame propagation
hence a higher efficiency. DTSI- digital twin spark ignition.
What is DTS I technology?

DTSi, or Digital Twin Spark Ignition System, is a

technology developed and patented by Bajaj Auto Limited. It was
first used in their Pulsar and Avenger models. At the time of its
introduction to the market, it was considered revolutionary as it
both saved fuel and improved engine performance.
What Is DTSi Or Digital Twin-Spark Ignition And How It Works?
• DTSi, or Digital Twin Spark Ignition System, is a technology developed and
patented by Bajaj Auto Limited.
• It was first used in their Pulsar and Avenger models. At the time of its introduction to the
market, it was considered revolutionary as it both saved fuel and improved engine
performance.
• In automobile engineering, achieving perfect combustion is impossible due to the losses
that occur in the combustion chamber, due to the design of the internal combustion engine
and because fuel does not burn instantaneously.
• However, the DTSi engine attempts to achieve complete combustion by making the
combustion process as fast as possible.
• The DTSi engine gives twice the power of a regular two-stroke engine along with a
significant power boost, and it has a sizable power-to-weight ratio as compared to a few
four-stroke engines.
• It can also adjust idling speed and even cuts off fuel feed when the throttle is released and
thus controls the enrichment of the air-fuel mixture for cold starts and acceleration.
How Does DTSi Engine Work?

• The DTSi engine employs two spark plugs to ignite the air-fuel mixture alternatively
so as to increase the flame diameter and urn the fuel instantaneously.
• This process of firing the spark, coupled with the swirl caused in the air-fuel mixture
results in incomplete combustion. The Digital Twin Spark Ignition system controls
this process electronically.
• The two spark plugs are fixed on opposite ends of the combustion chamber, creating
efficient and speedy combustion. It is an electronic system with a static spark advance
and no moving parts, and therefore no wear and tear occur.
• The system is mapped by an integrated digital electronic box that also controls valve
timings and fuel injection.
• It has two plugs per cylinder and has the combustion chambers,
and piston heads positioned to produce a broad and fast
flame front to ignite the air-fuel mixture.
• This technology enables lesser ignition advance and leaner mixtures and thus
can provide both a light weight and powerful engine.

Main Features of DTSi Engine

• Great balance and a comfortable, compact design.
• High specific power.
• Integrated electronic twin spark ignition coupled with an injection fuel
system.
• Digital electronic ignition.
• Two plugs per cylinder and two ignition distributors.
Advantages of DTSi Engine
• Engine parts being not subjected to wear, have a long life. This means fewer expenses
for part replacement such as piston rings and valve stems. Buying a bike with DTSi
engine is easy with Two wheeler loans.
• Better handling and comfort levels due to fewer vibrations and noise in the bike. This
DTSi engine gives you a smoother ride than most other bikes.
• The specific fuel consumption is less due to the DTSi technology, so it offers better
mileage than other bikes.
• The engine does not overheat, and you can go long rides without any discomfort.
• The engine’s thermal efficiency is higher.
• It can bear higher loads due to its increased power.
 Advantages of DTSi Engine

•The engine will easily start in cold weather, winter season, low temperatures and
so on because of the high compression ratio.
•This ensures that you do not have to get worried about your bike not starting in
cold weather.
•The twin spark technology causes an increase in the diameter of the flame,
resulting in instantaneous fuel combustion, leading to better work output due to
the increased work it exerts on the piston.
•Increased and enhanced throttle response.
•Resistant to breakdowns and temperature fluctuations, making it a sturdy,
dependable bike for commute purposes.
Disadvantages
• Due to twin spark plugs , it has a problem of overheating and loss of
power.
• In order to compensate the overheating problem, it requires an
elaborate cooling system .
• It also causes increase in wear and tear of engine parts.
Four wheeler Technology:
VVT
Variable Valve Timing or VVT is the timing for which the valves open.
The VVT system controls the duration for which the intake and the exhaust
valves open and the incline of the lift. All this activity happens within the engine
while it's operating.

Purpose and operation of the VVT

As a rule, when more revolutions our engine has, more air is needed by
cylinders. That’s where variable valve timing comes in. Its main function is
to modify the phase angles of the distribution diagram, adjusting the camshaft
according to the needs of the moment.
Main components of a VVT system
• ECU (Engine Control Unit).
• Sensors.
• VVT Camshaft adjuster consisting of stator, rotor, vanes and locking element.
• Camshafts.
• Solenoid valves.
• Oil.
• This VVT system is controlled by the ECU, the electronic control unit that regulates
the engine and is responsible for activating this gear through the flow of engine oil.
• Oil pressure is sent through the VVT gear to fill up cavities to advance or retard timing.
Filling the VVT ​gear with oil unlocks its stationary pin and makes it two independent
rotating parts, causing angular displacement between the input (chain) and output
(camshaft), advancing, or retarding the timing.
• To obtain the maximum efficiency of the engine, the valves must open and
close depending on the revolutions per minute at which it is turning, and
this is only possible if we have a variable timing.
• There are different types of timing that have unique characteristics, the main
difference being in the placement of the camshaft. Depending on the engine,
VVT configurations are differentiated and can be run only on the intake
valves or on both camshafts.
The two main ones, when it comes to varying the distribution, are:
Variation of the valve lift, varying the advance and closure of the valve at the
same time.
Displacement of the camshaft with respect to the crankshaft.
Difference Between: VVL / VVEL / VVTL

VVL, VVEL, and VVTL are all abbreviations for technologies that involve
altering the lift of engine valves for improved performance.

VVL stands for “Variable Valve Lift,”

VVEL stands for “Variable Valve Event and Lift,” and
VVTL stands for “Variable Valve Timing and Lift.”

• In particular, VVTL is an advanced supporting system that allows for

precise control of valve lift. In modern engines, the VVL system is often
combined with Variable Valve Timing (VVT) systems to achieve even
greater performance improvements.
Advantages of Variable Valve Timing (VVT)

Improved efficiency, increased torque, and power.

The variable valve timing system allows higher RPM to be achieved, and consequently
greater engine power.
More precise engine timing.
It allows minute and precise control of the internal valves (opening and closing) of the
engine while driving, therefore it will also obtain an increased engine lifespan.
Reduction of fuel consumption.
Thanks to this effective management of the engine valves, the VVT allows a smoother
idle offering better fuel consumption as well as lower carbon emissions.
Better fuel economy.
By having a greater direction and control of the gases, the system performs a
recirculation that can reduce emissions.
Gasoline direct injection
GDI is a fuel delivery system in gasoline internal combustion engines.
The system represents the very latest technology in fuel injection. It utilises a
high-pressure common rail accumulator assembly which injects the fuel
mixture directly into the engine's combustion chambers.

Working
Engines with gasoline direct injection produce the air-fuel mixture
directly in the combustion chamber. Only fresh air flows into the intake port
through the open intake valve. The fuel is injected directly into the combustion
chamber by high-pressure injectors.
Which vehicles have GDI engines?

Nearly 75% of all vehicles manufactured by the largest manufacturers are

made with GDI. Some manufacturers include Audi, BMW, Buick, Chrysler-
Jeep Wrangler, Ford, Honda, Hyundai, Infiniti, Kia, Lexus, Mazda, Nissan,
Saab, Subaru, and Volkswagen.
CONCLUSIONS
Engine emissions
Emissions is the term used to describe the gases and particles which
are put into the air or emitted by various sources. National Trends. The amounts
and types of emissions change every year.
Regulated emissions include engine exhaust smoke ( SN ),
hydrocarbons ( HC ), carbon monoxide ( CO ), and oxides of nitrogen ( NO x), for
certain classes of engines.
causes
Some common causes for the emission light on car illuminating
are: Emission system fault – This is when the engine is burning too much fuel,
increasing your carbon footprint. The emission light on car could also be on
because the system is not burning enough fuel, or if the sensor is broken. Elicits
its effect through the binding of hemoglobin.
Effects of engine emissions
Carbon monoxide is caused by the incomplete combustion of fuel.
Elevated levels of carbon dioxide can cause poisoning; symptoms
include dizziness, weakness, headache, vomiting, and loss of
consciousness. Carbon monoxide

Can Do to Reduce Pollution from Vehicles and Engines

[Link] less.
[Link] wise.
[Link] fuel efficient vehicles.
[Link]'t idle.
[Link] home deliveries.
[Link] efficient lawn and gardening equipment.
Which emission is harmful?

Toxic, or hazardous, air pollutants are substances that cause or

are suspected of causing cancer, birth defects, or other serious harms.
They can be gases, such as hydrogen chloride, benzene and toluene or
compounds and metals suck as asbestos, cadmium, mercury and
chromium.
Why reduce emissions?

Reducing GHG emissions slows the rate of temperature rise, sea-level

rise, ice melting, and ocean acidification. Reducing GHG emissions
lessens the likelihood and severity of extreme weather events,
improves air and water quality, maintains biodiversity, and supports
a healthy food supply
Types of catalytic converter

Two-way
A two-way (or “oxidation”) catalytic converter has two simultaneous tasks:
• Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2
• Oxidation of hydrocarbons (unburnt and partially burnt fuel) to carbon
dioxide and water: CxH2x+2 + [(3x+1)/2] O2 → xCO2 + (x+1) H2O (a
combustion reaction)
• This type of catalytic converter is widely used on diesel engines to reduce
hydrocarbon and carbon monoxide emissions. They were also used on
gasoline engines in American- and Canadian-market automobiles until 1981.
Because of their inability to control oxides of nitrogen, they were
superseded by three-way converters.
There are 3 types of Catalytic Converters used in cars, namely:
Oxidation Catalyst (OC) In the type of CCO (Catalytic Converter for
Oxidation), Oxygen will react with CO and HC to form CO2 and H2O which
do not contain pollution. ...
Three-Way Catalyst & Oxidation Catalyst (TWC-OC)
Evaporative Emissions Control

That means if the fuel system is open to the atmosphere, it can

pollute 24 hours a day even if the engine is not running. The Evaporative
Emission Control System (EVAP) is used to prevent gasoline vapors from
escaping into the atmosphere from the fuel tank and fuel system at all times.

Where is evaporative emissions

For starters, when the fuel in your tank evaporates, the vapors are
contained by a charcoal canister in the front of the vehicle. Once the fuel-air
mixture is normal, it goes back to the engine. Then, the valve creates a
vacuum and draws all the vapors into the engine.
EVAP Importance

• The oil and fuel in vehicles give off vapors that are very harmful to the
environment, which is why Evaporative Emissions Control Systems (EVAP) are
required in all cars and trucks. The EVAP system captures these vapors and directs
them into the engine to be burned—sort of like a built-in recycling system!

• They are used in cars' fuel systems to prevent gasoline fumes from leaking into the
atmosphere. The EVAP system runs diagnostics for possible fuel vapor leaks and
will trigger a fault code if they're present. It will also activate the check engine light
on the dashboard.