SEMINAR 2008

Common Rail Direct Injection Engine

Presented By:
JUNET BABU S7 MECHANICAL

What is CRDI ?
CRDI stands for Common Rail Direct
Injection meaning, direct injection of the fuel into the cylinders of an engine via a single, common line, called the common rail which is connected to all the fuel injectors. Instead of providing separate piston pumps for fuel supply, the common rail alone supplies high pressure fuel to each cylinder.

The Technology
Whereas ordinary diesel direct fuel-injection
systems have to build up pressure anew for each and every injection cycle, CRDI engines maintain constant pressure regardless of the injection sequence. This pressure then remains permanently available throughout the fuel line. The electronic control unit (ECU) modifies injection pressure precisely as needed, based on data obtained from sensors on the cam and crankshafts. ie compression and injection occur independently of each other. This technique allows fuel to be injected as needed, saving fuel and lowering emissions.

PRINCIPLE OF CRDi IN DIESEL ENGINES

Is named as GDI( Gasoline Direct Injection) Introduced to remove the drawbacks of

carbureted and MPFI systems Main advantage is that even petrol engines can be run under the very lean mixture ratio of 50:1.

FIGURE SHOWING THAT BY INTRODUCTION OF GDI IN PETROL ENGINES A LEAN MIXTURE OF A\F RATIO OF 50:1 CAN BE BURNT SUCESSFULLY

LAYOUT OF A TYPICAL CRDI ENGINE

DIFFERENCES BETWEEN DI AND CRD

Constant pressure regardless of the injection

sequence Fuel is supplied directly to a common rail from where it is injected directly onto the cylinder head High Pressure of about (1600 bar) , Improved pulverization Electronic engine management system continually adjusts the peak fuel pressure according to engine speed and throttle position Compression and injection occur independently of each other

CIRCUIT DIAGRAM

Electronic Control Unit

ECU monitors Engine variables such as
Temperature , intake pressure , RPM , air mass intake and demand for power (from accelerator) and provides real time control and modifies injection pressure precisely as needed , based on data obtained from cam and crankshaft.

Electronic Fuel Injector

electromagnet moves

the plunger - opening rapid solenoid valve Injector pulse width controlled by ECU

CHARACTERISTICS
Spiral shaped Intake port for optimum swirl of
air entering cylinder spiral port induces optimum swirl in the intake air leading to more efficient mixing and combustion of fuel inside cylinder Integrated port at cylinder head for exhaust gas recycling building up input air temperature, reducing vibrations and cooler exhaust

Precise air flow metering

air-flow meter located in front of the
turbocharger's compressor permitting an exact analysis of the air-mass that is being taken in. Air mass alters depending on temperature or atmospheric pressure. The microcomputer that controls engine timing receives precise data. It is thus able to regulate exhaust-gas recycling according to engine load and speed in the interest of lowering nitrous oxide and particle emissions.

Multiple Pilot and post injection

Leading to smoother compression and expansion

- reducing noise levels More efficient combustion and burning up of fuel leading to quieter engine cycles Reduces unburnt HC , NOx and CO and particles in exhaust

CRDI - Future Trends

Ultra-high pressure common-rail injection (1800
bar) generating ideal swirl in the combustion chamber allowing the air/fuel mixture to form a perfect vertical vortex - uniform combustion and greatly reduced NOx emissions
emissions from exhaust

CRDi and Particle Filter - To reduce particle

CRDi and closed-loop control injection - Using

ion sensor to provide real-time combustion data for each cylinder such as temperature and pressure.

PARTICLE FILTER
Porous silicon carbide unit Decreases Particle emissions Trapped particles burnt up into CO2 and water

ADVANTAGES OF CRDI

Reduced noise and vibration Reduced smoke , particulates and exhaust Increased fuel economy Higher power output even at lower rpm
DISADVANTAGES
Increased Cost due to high pressure pump
and electronic control unit Technology cannot be employed in present engines

Hyundai Accent CRDi

Pioneering new generation CRDi engines in India

3 Cylinder 1.5 litre and 4 cylinder 2 litre engines 81 bhp and 187 NM max torque at 2700 rpm , max 4000 rpm 5 speed gear box , 0 100 in 13 sec , max speed 170 km/hr 26.2 kmpl in highway , 12 kmpl town riding

CONCLUSION

cuts fuel consumption by 20% doubles torque at low engine speeds increases power by 25%. It also brings a significant reduction in the noise and vibrations of conventional diesel engines.

In emission, greenhouse gases (CO2) is reduced by 20%. At

a constant level of NOx, carbon monoxide (CO) emissions are reduced by 40%, unburnt hydrocarbons (HC) by 50%, and particle emissions by 60%.

CRDI principle not only lowers fuel consumption and

emissions possible; it also offers improved comfort and is quieter than modern pre-combustion engines. Common-rail engines are thus clearly superior to ordinary motors using either direct or indirect fuel-injection systems.

THE END