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CRDi Engine

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

Disadvantages of Diesel Engine


They were cam driven, and injection pressure was proportional to engine
speed. This typically meant that the highest injection pressure could only
be achieved at the highest engine speed and the maximum achievable
injection pressure decreased as engine speed decreased. This relationship
is true with all pumps, even those used on common rail systems; with the
unit or distributor systems, however, the injection pressure is tied to the
instantaneous pressure of a single pumping event with no accumulator,
and thus the relationship is more prominent and troublesome.
They were limited in the number and timing of injection events that could
be commanded during a single combustion event. While multiple
injection events are possible with these older systems, it is much more
difficult and costly to achieve.

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

Layout of typical CRDi System

Traditional injection system


An auxiliary cam on the engine camshaft drives a single-cylinder injection pump.
Early in the stroke of the plunger, the inlet port is closed and the fuel trapped
above the plunger is forced through a check valve into the injection line. The
injection nozzle has several holes through which the fuel sprays into the cylinder.
A spring-loaded injection needle keeps the injection valve closed until the pressure
in the injector volume, acting on parts of the needle surface, overcomes the spring
force and opens the valve.
Thus, the phase of the pump camshaft relative to the engine crankshaft controls
the start of injection, while the force given by the initial displacement of the spring
gives the opening pressure. Injection is stopped when the inlet port of the pump is
uncovered by a helical groove in the pump plunger, and thehigh pressure above
the plunger and in the injector volume is released. The injection pump cam design
and the position of the helical groove determine the amount of fuel injected into
the cylinder. Thus for a given cam design, the rotating plunger and its helical
groove controls the load.

Traditional injection system

Common rail injection system


Contrary to the traditional injection system, pressure generation and
injection are decoupled in the common rail system. A prerequisite for this
decoupling of pressure generation and injection in common rail systems is
the high-pressure accumulator, which consists of the rail and the high
pressure fuel lines to the nozzles.
In order to control the opening and closing time of the needle, a small
chamber of pressurised fuel is present at the top of the needle. This volume
is connected to the rail through a small orifice that assures that same pressure
between the nozzle and the chamber when the valve is closed.

EQUIPMENT SETUP
1: fuel tank with low pressure
pump
2: fuel filter,
3: high pressure pump
4: pressure regulating valve,
5: high pressure vessel (rail),
6: fuel injector with solenoid
valve and nozzle,
7: safety valve,
8: heat exchanger,
9: control unit,
10: pressure transducer

IGNITION AND COMBUTION


The common-rail fuel injection system produces droplets of less than 20Mm,
which evaporate rapidly. This led to a short ignition delay and a continued
combustion of the fuel during the injection. Therefore, together with pilot
injection, a significant reduction of the ignition delay of the main injection can
be realized, especially when the fuel jet of the main injection penetrates through
the flame of the pilot injection.
Common Rail System it is conceivable to apply up to pilot/post injections for
each single compression stroke obtaining acceptable spray properties.

A view of Common rail

COMPARISSION BETWEEN NORMAL ENGINE & CRDI ENGINE

Normal Diesel Engine

CRDI engine

Pressures ranging from 200 - 400 bar

Pressures exceeding 1200 bar, uniformly maintained

Indirect injection of fuel

Direct injection of high pressure fuel

Noisy engine

Less engine noise (Pilot injection prior to main


injection.

Fuel injection pressure varies during the Injection

Fuel injection timing mechanically controlled by Fuel

Pump & variable with

High fuel consumption at low engine speed (due to

Engine speed

imperfect air-fuel ratio)

High emission at low engine speed

Low emission at all engine speeds

Used in normal cars.

Used in Hundai i30

ADVANTEGES

More power is developed.


Increased fuel efficiency.
Reduced noise.
More stability.
Pollutants are reduced.
Particulates of exhaust are reduced.
Exhaust gas recirculation is enhanced.
Precise injection timing is obtained.
Pilot and post injection increase the combustion quality.
More pulverization of fuel is obtained.
A very high injection pressure can be achieved.

DISADVANTAGE
The main disadvantge is the cost of the engine. It is costly than conventional
engines.

APPLICATIONS
Marine & Locomotive engines
Following car manufacturers applied the CRDi system:

Ashok Leyland's CRS Engines (used in U Truck and E4 Busses)


BMW's D-engines (also used in the Land Rover Freelander TD4)
Chevrolet's VCDi (licensed from VM Motori)
Fiat Group's (Fiat, Alfa Romeo and Lancia) JTD (also branded as MultiJet, JTDm, Ecotec
CDTi, TiD, TTiD, DDiS, Quadra-Jet)
Ford Motor Company's TDCi Duratorq and Powerstroke
Honda's i-CTDi
Hyundai CRDi
Mahindra's CRDe
Mazda's MZR-CD (1.4 MZ-CD, 1.6 MZ-CD manufactured by joint venture Ford/PSA Peugeot Citron) and
earlier DiTD
Mitsubishi's DI-D (recently developed 4N1 engine family uses next generation 200 MPa (2000 bar) injection system))
Nissan's dCi, Infiniti uses dCi engines, but not branded as dCi.
Opel's CDTI
Proton's SCDi
PSA Peugeot Citron's HDI or HDi (1.4HDI, 1.6 HDI, 2.0 HDI, 2.2 HDI and V6 HDI developed under joint venture
with Ford)

REFERENCES
Websites:
http://en.wikipedia.org/w/index.php?title=Common_rai
http://www.thegeminigeek.com/what-is-a-crdi-engine/
http://en.wikipedia.org/w/index.php?title=Hyundai_i30
http://seminarprojects.com/Thread-common-rail-direct-injection-crdi-engines--1368
Books:
Internal Combustion Engines By: Anand V Domkundwar.
Thermal Engineering by R.S.Khurmi

Conclusion
From learning about the CRDi ttechnology I hereby
concludde that it is a revolutionary technology as it makes
the engine 33% more efficient than the ordinary fuel
injection system

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