Chapter 27 - Common Rail

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4/14/2020

Chapter 27
Common Rail Fuel Systems

Introduction

• Common rail fuel injection is the most


recent development in high-pressure
injection systems
• Currently used by the majority of diesel
engines in production

Fundamentals of
Common Rail Fuel Systems
(1 of 19)

• Supply fuel at injection pressure to nozzle


that electrically controls injection event

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(2 of 19)

Fundamentals of
Common Rail Fuel Systems
(3 of 19)

• New technology allows precise control of


injectors while managing fuel pressures up
to 37,500 psi
• Helped engines produce almost no
emissions and increased fuel efficiency

Fundamentals of
Common Rail Fuel Systems
(4 of 19)

• Common Rail Advantages


– High-injection pressures, fast-acting injectors,
and electronic controls = injection system of
choice for today’s fuel-efficient and low-
emission diesel engines

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(5 of 19)

• Pressurization of Fuel Independent of


Engine Speed
– Regardless of speed, fuel is pressurized for
optimal fuel efficiency and low emissions

Fundamentals of
Common Rail Fuel Systems
(6 of 19)

Fundamentals of
Common Rail Fuel Systems
(7 of 19)

• Higher Pressurization
– Amplified common rail systems produce
injection pressures up to 37,500 psi
– Systems in development could reach more
than 45,000 psi

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(8 of 19)

• Multiple Injection Events


– CR injectors use servo-hydraulic design,
allowing electrical solenoid to trigger servo
valve and provide a short duration injection
– First generation CR injectors could only
produce 2 or 3 injections per combustion
cycle; newest versions deliver up to 8

Fundamentals of
Common Rail Fuel Systems
(9 of 19)

Fundamentals of
Common Rail Fuel Systems
(10 of 19)

• Injection Rate Shaping


– CR injectors change injection discharge
volume during each injection event to suit
speed and load conditions

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(11 of 19)

Fundamentals of
Common Rail Fuel Systems
(12 of 19)

Fundamentals of
Common Rail Fuel Systems
(13 of 19)

• Modular System Design


– Common rail system components are
interchangeable across a wide range of
engine platforms

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(14 of 19)

Fundamentals of
Common Rail Fuel Systems
(15 of 19)

• Defining Features of High-Pressure


Common Rail
– Tube or rail stores pressurized fuel at levels
for current speeds/loads through steel lines
– Electrical actuators control timing and
metering during injection events
– An engine-driven high-pressure fuel pump
that supplies the rail (accumulator)
– Microprocessor control of fuel system

Fundamentals of
Common Rail Fuel Systems
(16 of 19)

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4/14/2020

Fundamentals of
Common Rail Fuel Systems
(17 of 19)

• Defining Features of High-Pressure


Common Rail
– CR fuel systems are classified by type of fuel
injectors

Fundamentals of
Common Rail Fuel Systems
(18 of 19)

Fundamentals of
Common Rail Fuel Systems
(19 of 19)
• Defining Features of High-Pressure
Common Rail
– Share high-pressure stage consisting of fuel
pump with:
• Pressure regulator
• High-pressure fuel rail with rail pressure sensor
and pressure-regulating valves
• Fuel injectors
• Electronic control system
• Short fuel lines

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4/14/2020

Types of
Common Rail Fuel Systems
(1 of 70)

• Found on a wide range of engines in many


different applications
– Injector Requirements
• Common design requirements include:
– Very high injection pressure for optimal fuel atomization
– Flexible timing of beginning and end of injection
– Flexible timing of multiple injections
– Rapid reaction to signal commands
– Compact design to permit centralized location of injector

Types of
Common Rail Fuel Systems
(2 of 70)

• Types of Common Rail Injectors


– Three main types of injectors; as new
generations came along, a variety of
technology was introduced

Types of
Common Rail Fuel Systems
(3 of 70)

• Electro-Hydraulic
Solenoids
– Older technology
but still used for
many medium-
and heavy-duty
diesel engines

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4/14/2020

Types of
Common Rail Fuel Systems
(4 of 70)

• Piezoceramic Electric Actuators


– Hundreds of piezoceramic wafers form the
actuator mechanism

Types of
Common Rail Fuel Systems
(5 of 70)

Types of
Common Rail Fuel Systems
(6 of 70)

• Piezoceramic Electric Actuators


– Material instantly changes shape when
electrical current is applied; no lag when
magnetic fields need to build and dissipate

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4/14/2020

Types of
Common Rail Fuel Systems
(7 of 70)

Types of
Common Rail Fuel Systems
(8 of 70)

• Piezoceramic Electric Actuators


– Changing polarity of signal to injector
causes instantaneous change in injector
control valve

Types of
Common Rail Fuel Systems
(9 of 70)

• Piezoceramic Electric Actuators


– Faster response and more frequent
injections per combustion cycle

10
4/14/2020

Types of
Common Rail Fuel Systems
(10 of 70)

Types of
Common Rail Fuel Systems
(11 of 70)

• Hydraulically Amplified
Common Rail
– Bosch design
introduced in 2008
(HADIS)

Types of
Common Rail Fuel Systems
(12 of 70)

• Hydraulically Amplified Common Rail


– Found in Detroit Diesel DD series heavy-
duty engine

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4/14/2020

Types of
Common Rail Fuel Systems
(13 of 70)

Types of
Common Rail Fuel Systems
(14 of 70)

• Hydraulically Amplified Common Rail


– Amplifier piston similar to HEUI injector is
used, but piston ratio is much less (2:1)
– Allows pump, rail, and lines to be less
stressed because of lower pressures
feeding the injectors

Types of
Common Rail Fuel Systems
(15 of 70)
• Bosch Common Rail Injectors
– 3 of 4 Bosch-developed generations are still
produced
– First-generation injectors handled 19,580 psi
fuel pressure and produced three injection
events per combustion cycle
– Second-generation injectors reacted faster
and with more precision
– Third-generation injectors featured
piezoelectric actuators
– Fourth-generation injectors have a second set
of spray holes (coaxial injector)

12
4/14/2020

Types of
Common Rail Fuel Systems
(16 of 70)

Types of
Common Rail Fuel Systems
(17 of 70)

• CRS1 and CRS2


– Hydraulically Balanced Nozzle Valves
• Needle valves are actuated using high-
pressure fuel controlled electronically
• Needle valve has two surfaces slightly different
in diameter; when the same fuel pressure acts
on both surfaces, the valve is held closed
• When fuel pressure is drained on top of the
needle valve, it lifts to allow fuel past it for an
injection event

Types of
Common Rail Fuel Systems
(18 of 70)

• CRS1 and CRS2


– Hydraulically
Balanced Nozzle
Valves
• When pressure is
applied to the top,
needle valve quickly
closes to stop
injection; needle
valve springs are
much smaller

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4/14/2020

Types of
Common Rail Fuel Systems
(19 of 70)

• CRS1 and CRS2


– Hydraulically Balanced Nozzle Valves
• Solenoid valves control fuel pressure applied
to the injector; this is referred to as a servo-
hydraulic actuator

Types of
Common Rail Fuel Systems
(20 of 70)

Types of
Common Rail Fuel Systems
(21 of 70)

• CRS1 and CRS2


– Hydraulically Balanced Nozzle Valves
• Servo actuators use electromagnetism to move
a control valve, which can be a ball or
mushroom type

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4/14/2020

Types of
Common Rail Fuel Systems
(22 of 70)

Types of
Common Rail Fuel Systems
(23 of 70)

• CRS1 and CRS2


– Hydraulically Balanced Nozzle Valves
• Four steps to an injection event:
– Magnetic solenoid is actuated by an electrical signal
from the control module
– Servo-hydraulic valve opens
– Fuel pressure is released from control chamber
– Rail pressure lifts the nozzle valve

Types of
Common Rail Fuel Systems
(24 of 70)

• CRS1 Operation
– Denso uses a command piston to hold the
needle valve on its seat

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4/14/2020

Types of
Common Rail Fuel Systems
(25 of 70)

Types of
Common Rail Fuel Systems
(26 of 70)

• CRS1 Operation
– An electrically controlled ball valve permits
rapid movement of the needle valve for
quick precise injection events

Types of
Common Rail Fuel Systems
(27 of 70)

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4/14/2020

Types of
Common Rail Fuel Systems
(28 of 70)

• Pre-Injection
– Drain orifice is closed by ball valve, which
is held down by spring force
– Fuel pressure throughout injector is equal

Types of
Common Rail Fuel Systems
(29 of 70)

• Beginning of Injection
– Injector solenoid is energized by signal
from ECM, and ball is lifted from its seat

Types of
Common Rail Fuel Systems
(30 of 70)

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4/14/2020

Types of
Common Rail Fuel Systems
(31 of 70)

• Beginning of Injection
– Fuel is drained from the top of the control
rod; needle valve lifts because high
pressure acts on its bottom surface
• End of Injection
– Signal to solenoid is stopped and the ball
closes the outlet orifice; fuel pressure
builds rapidly above the control rod and
the needle valve closes

Types of
Common Rail Fuel Systems
(32 of 70)

• CRS2 Operation
– CRS2 injectors use a double spring
armature for faster action of the control
valve, allowing injection events to end
quicker

Types of
Common Rail Fuel Systems
(33 of 70)

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4/14/2020

Types of
Common Rail Fuel Systems
(34 of 70)

• CRS3 Piezo Injectors


– All manufacturers’ CR injectors feature
piezoceramic material in place of coil wired
solenoids
– Piezoceramic material will change shape
when an electrical signal is applied
– This eliminates inductive reactance that
occurs with electromagnetic devices and
dramatically improves response time

Types of
Common Rail Fuel Systems
(35 of 70)

Types of
Common Rail Fuel Systems
(36 of 70)

• CRS3 Piezo Injectors


– Stacks of piezoceramic material control
the needle valve action in CR injectors

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4/14/2020

Types of
Common Rail Fuel Systems
(37 of 70)

• CRS3 Piezo Injectors


– Reaction times are reduced, allowing up to
8 injection events per combustion cycle
and reducing their weight by almost half
– Hundreds of wafers are stacked together
to provide enough travel to operate the
injector

Types of
Common Rail Fuel Systems
(38 of 70)

Types of
Common Rail Fuel Systems
(39 of 70)

• CRS3 Piezo Injectors


– Variable nozzle lift is possible by varying
the voltage applied to the injector
– Up to 250V can be used for some injectors

20
4/14/2020

Types of
Common Rail Fuel Systems
(40 of 70)

• Piezo CRS3 Operation


– Electrical signal actuates a control valve
which controls fuel pressure, allowing
needle valve to move

Types of
Common Rail Fuel Systems
(41 of 70)

• Piezo CRS3 Operation


– Electrical signal actuates a control valve
which allows needle valve to move
• Beginning of Injection
– Servo valve has two seats: one controls high-
pressure fuel passage; the other controls low-
pressure drain passage
– At rest with the engine running, the control valve is
held closed by high-pressure fuel
– Electrical signal applied to the piezoelectric material
causes it to expand and open the drain passage,
causing needle valve to lift

Types of
Common Rail Fuel Systems
(42 of 70)

• Piezo CRS3 Operation


– End of Injection
• Current to the piezoelectric actuator is
reversed to make the material retract in length
• This closes drain passage and opens high-
pressure passage to direct high-pressure fuel
to top of needle valve
• A wear factor with the piezoceramic material
makes their life shorter than solenoid actuated
injectors

21
4/14/2020

Types of
Common Rail Fuel Systems
(43 of 70)

• Piezo CRS3 Operation


– CRS3 Hydraulic Coupler
• Coupler transfers and amplifies piezoelectric
action to the control valve and compensates
for heat expansion; it also prevents injector
from continuously injecting fuel in case of an
electrical fault

Types of
Common Rail Fuel Systems
(44 of 70)

Types of
Common Rail Fuel Systems
(45 of 70)

• CRS4: Hydraulically Amplified Injector


– Fourth generation injector uses an internal
amplifier to increase rail pressure by a
ratio of 2:1
– Currently used in Detroit Diesel DD series
using ACR system

22
4/14/2020

Types of
Common Rail Fuel Systems
(46 of 70)

Types of
Common Rail Fuel Systems
(47 of 70)

• CRS4: Hydraulically Amplified Injector


– Rate shaping is accomplished; five
injection events are possible
– Supply pressure to the injector can be
greatly reduced, reducing size and
capacity of the pump, rail, and lines
– Latest version is capable of 37,500 psi

Types of
Common Rail Fuel Systems
(48 of 70)

• Pressure Amplification
– ACR injector has two control valves:
needle solenoid control valve and amplifier
control valve
– NSV controls opening/closing of needle
valve by draining fuel pressure on top of it

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4/14/2020

Types of
Common Rail Fuel Systems
(49 of 70)

Types of
Common Rail Fuel Systems
(50 of 70)

• Pressure Amplification
– This injector can function in both amplified
and non-amplified modes
– ACV determines in which state the injector
operates

Types of
Common Rail Fuel Systems
(51 of 70)

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4/14/2020

Types of
Common Rail Fuel Systems
(52 of 70)

• Pressure Amplification
– When ACV valve is energized, it opens a
drain passage that drains fuel below the
amplifier piston to allow fuel to move the
piston down. This permits pressure
amplification.

Types of
Common Rail Fuel Systems
(53 of 70)

Types of
Common Rail Fuel Systems
(54 of 70)

• Pressure Amplification
– With two solenoids in the injector, two fuel
return circuits connect to the injectors

25
4/14/2020

Types of
Common Rail Fuel Systems
(55 of 70)

• Rate Shaping
– After needle valve opening, rate shaping
can occur with three different profiles
possible: boot, ramp, and square

Types of
Common Rail Fuel Systems
(56 of 70)

Types of
Common Rail Fuel Systems
(57 of 70)

• CR14 Coaxial Variable Nozzle


– Features a two-stage nozzle lift with two
rows of spray holes

26
4/14/2020

Types of
Common Rail Fuel Systems
(58 of 70)

Types of
Common Rail Fuel Systems
(59 of 70)

• CR14 Coaxial Variable Nozzle


– Lower row is used for low-speed delivery
at low pressurization
– Second row is used for high-load, high-
rpm operation

Types of
Common Rail Fuel Systems
(60 of 70)

• Siemens CR Injectors
– Produced since 2001; most common North
American application is the Ford
PowerStroke 6.4L

27
4/14/2020

Types of
Common Rail Fuel Systems
(61 of 70)

Types of
Common Rail Fuel Systems
(62 of 70)

• Siemens CR Injectors
– Overview
• Needle valve is held closed by fuel pressure;
when drained, the valve opens to allow
injection

Types of
Common Rail Fuel Systems
(63 of 70)

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4/14/2020

Types of
Common Rail Fuel Systems
(64 of 70)

• Siemens CR Injectors
– Overview
• Energization of stack of piezo wafers allows
mushroom-shaped control valve to open and
drain fuel from top of needle valve

Types of
Common Rail Fuel Systems
(65 of 70)

Types of
Common Rail Fuel Systems
(66 of 70)

• Siemens CR Injectors
– Overview
• De-energizing piezoceramic actuator closes
drain; fuel pressure seats needle valve

29
4/14/2020

Types of
Common Rail Fuel Systems
(67 of 70)

Types of
Common Rail Fuel Systems
(68 of 70)

• Siemens CR Injectors
– Pre-Injection
• High-pressure fuel from rail enters injector and
holds needle valve closed
• Mushroom valve is held on its seat by spring
and seals fuel on top of needle valve
• Larger surface area above control piston
applies greater pressure than force of fuel
against nozzle valve annulus

Types of
Common Rail Fuel Systems
(69 of 70)

• Siemens CR Injectors
– Injection
• Piezo actuator is energized and mushroom
valve is lifted from its seat
• Fuel pressure on top of needle valve drains
and fuel pressure lifts needle valve and
injection begins
• Fuel enters control chamber through a
restriction that permits pressure buildup
because mushroom valve opening is much
larger

30
4/14/2020

Types of
Common Rail Fuel Systems
(70 of 70)

• Siemens CR Injectors
– End of Injection
• Piezo actuator is de-energized, spring seats
mushroom valve, and pressure builds in
control chamber
• Control piston moves down and needle valve is
seated to end injection

Components of
Common Rail Fuel Systems
(1 of 22)

• Pumps, pressure control valves, and


pressure regulators are used by all
common rail systems
• Major differences exist between these
components, depending on size of
engine, fuel system pressure control
strategy, and manufacturer designs

Components of
Common Rail Fuel Systems
(2 of 22)

• High-Pressure Pump
– Supplies high pressure to injectors

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4/14/2020

Components of
Common Rail Fuel Systems
(3 of 22)

• High-Pressure Pump
– Can be single piston or multiple piston,
depending on volume requirements
– Pumps can have inlet or outlet valves to
control pump flow

Components of
Common Rail Fuel Systems
(4 of 22)

Components of
Common Rail Fuel Systems
(5 of 22)

• High-Pressure Pump
– Newer pumps use inlet metering valve, so
pump only delivers the amount of fuel
required for current conditions

32
4/14/2020

Components of
Common Rail Fuel Systems
(6 of 22)

Components of
Common Rail Fuel Systems
(7 of 22)

• High-Pressure Pump
– Several generations of pumps have
evolved over the years
– Bosch CP4.2 features an aluminum body
and steel heads

Components of
Common Rail Fuel Systems
(8 of 22)

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4/14/2020

Components of
Common Rail Fuel Systems
(9 of 22)

• Rail Pressure Control Valve


– Regulates amount of fuel admitted into a
pump

Components of
Common Rail Fuel Systems
(10 of 22)

Components of
Common Rail Fuel Systems
(11 of 22)

• Rail Pressure Control Valve


– Closed loop feedback circuit exists
between rail pressure control sensor and
fuel pump regulator

34
4/14/2020

Components of
Common Rail Fuel Systems
(12 of 22)

Components of
Common Rail Fuel Systems
(13 of 22)

• Rail Pressure Control Valve


– PWM signal regulates valve; a low-duty
cycle produces high volume
– Can be used with a rail pressure regulator
to control rail pressure

Components of
Common Rail Fuel Systems
(14 of 22)

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4/14/2020

Components of
Common Rail Fuel Systems
(15 of 22)

• Inlet Volume Metering Control


– Pump is driven at half engine speed; if
high rail pressures are needed, can
consume 5 hp or more
– Bosch pumps can deactivate pistons to
reduce parasitic losses

Components of
Common Rail Fuel Systems
(16 of 22)

Components of
Common Rail Fuel Systems
(17 of 22)

• Inlet Volume Metering Control


– Solenoid holds open inlet check valve to
allow piston to move without moving fuel
– Fuel stays cooler, pump is more efficient
• High-Pressure Fuel Rail
– Thick-walled tube keeps pressurized fuel
ready for injectors to use
– Stores fuel and reduces pumping pulses

36
4/14/2020

Components of
Common Rail Fuel Systems
(18 of 22)

• Pressure-Protection Valve
– All rails have a pressure-limiting valve in
case of overpressurizing to protect
components from catastrophic failure

Components of
Common Rail Fuel Systems
(19 of 22)

Components of
Common Rail Fuel Systems
(20 of 22)

• Pressure-Protection Valve
– Opens at 3000 psi above maximum
operating pressure

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4/14/2020

Components of
Common Rail Fuel Systems
(21 of 22)

Components of
Common Rail Fuel Systems
(22 of 22)
• Fuel Rail Pressure Sensor
– Three-wire, variable capacitance sensor
mounted in fuel rail to give feedback to ECM
– Uses 5V reference signal and operates in
closed loop with ECM and pump control valve
• Flow-Limiting Valve
– If injector allows continuous flow of fuel into
the engine, a flow-limiting valve restricts the
flow to safe levels
– These valves are between the rail and each
injector line

Service and Maintenance of


Common Rail Fuel Systems
(1 of 19)

• Common rail fuel systems are typically


very reliable and most problems will be
detected with fault codes

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4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(2 of 19)
• Service Precautions for CR3 Injectors
– Operate with voltages up to 240VDC
– Certified insulated gloves must be used
when working near these injectors
• On-Board Diagnostics for Common Rail
Fuel Systems
– HD-ODB legislation requires
manufacturers to detect potential
malfunction that could cause emissions to
rise above standard

Service and Maintenance of


Common Rail Fuel Systems
(3 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– Fuel pressure is monitored

Service and Maintenance of


Common Rail Fuel Systems
(4 of 19)

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4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(5 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– Injector internal wear leads to an MIL light
turning on

Service and Maintenance of


Common Rail Fuel Systems
(6 of 19)

Service and Maintenance of


Common Rail Fuel Systems
(7 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– High-pressure lines need to be tightened
properly to prevent leaks

40
4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(8 of 19)

Service and Maintenance of


Common Rail Fuel Systems
(9 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– Three return flows can be measured to
identify a leak: injector fuel return, high-
pressure pump return, high-pressure relief
valve return
– Return flow to tank can be measured and
components isolated to find leakage

Service and Maintenance of


Common Rail Fuel Systems
(10 of 19)

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4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(11 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– Injectors can be blocked off one at a time
to find the one leaking

Service and Maintenance of


Common Rail Fuel Systems
(12 of 19)

Service and Maintenance of


Common Rail Fuel Systems
(13 of 19)

• Fuel System Monitors—Fuel System


Pressure Control
– Quill tubes that aren’t installed properly
can cause leaks

42
4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(14 of 19)
• Measuring Injector Back Leakage
– Leaking control valves are the most likely
cause of back leakage
– To determine excessive back leakage, remove
return lines from injectors and install short
tubes that will spill fuel into graduated
cylinders.
– If injectors don’t have return lines, use
diagnostic software, measure total return
leakage, and block off injectors one at a time
to determine leaky injector

Service and Maintenance of


Common Rail Fuel Systems
(15 of 19)

• Measuring Fuel Leakage from Other


Fuel System Components
– Excessive cranking at startup can indicate
fuel leakage
– Follow manufacturer’s service procedures
to find leaky component

Service and Maintenance of


Common Rail Fuel Systems
(16 of 19)
• Fuel Mass Observer
– An algorithm that detects deviations from
normal delivery volumes from all injectors
– Oxygen sensor signal can be used in
calculation
• Injection Timing
– Camshaft and crankshaft position sensors
evaluate when beginning of combustion
takes place by measuring crankshaft
acceleration rate

43
4/14/2020

Service and Maintenance of


Common Rail Fuel Systems
(17 of 19)

• Fuel Balance Control


– Strategy used by the ECM to adjust fuel
delivery quantities to each cylinder
– Determined by fluctuations in crankshaft
speed
• Injector Voltage
– Injector voltages are measured at
beginning/end of energization period

Service and Maintenance of


Common Rail Fuel Systems
(18 of 19)

• Pressure Wave Correction Factor


– A correction factor applied to a specific
injector’s electrical pulse width as a result
of rail pressure changes
– Ensures equal delivery between injectors

Service and Maintenance of


Common Rail Fuel Systems
(19 of 19)
• Zero Fuel Mass Calibration
– Injector wear changes operating
characteristics
– To compensate for wear, a calculation is
performed when the vehicle is driving the
engine
– ECM energizes one injector at a time to detect
voltage applied to start an rpm increase
– Different voltage levels interpreted as injector
wear, and a compensation can be made when
engine load increases

44
4/14/2020

Summary
(1 of 11)

• Common rail (CR) fuel injection is the most recently


developed high-pressure injection system used by
the majority of current diesel engines.
• The basic concept of CR injection is to supply fuel at
injection pressure to a fuel nozzle that electronically
controls the injection event.
• Diesel fuel injection systems that rely on engine-
driven camshaft s to pressurize fuel cannot meet
legislated emission targets.

Summary
(2 of 11)

• Modern CR refers to a classification of high-


pressure fuel-injection systems in which
pressurization of fuel is accomplished independently
of engine speed. This means that regardless of
engine rotational speed and load, fuel injection
pressure is matched to optimal values required for
the most efficient combustion, lowest emissions, and
superior fuel economy.

Summary
(3 of 11)

• Enormous technical and manufacturing


accomplishments have enabled CR systems to not
only meet rigid requirements, but have combined to
secure a place for diesel technology in the future.
• CR systems are capable of multiple injection events
during one engine cycle.
• The biggest advantage CR injection offers is injection
rate-shaping capabilities. Making substantial
reductions in exhaust emissions and fuel consumption
without hurting performance requires a changing
injection discharge volume during the injection event.

45
4/14/2020

Summary
(4 of 11)

• Separate modular components used in CR systems


means the fuel system is easily adapted to different
engine types.
• There are three main types of CR injectors:
electrohydraulic solenoids, piezoceramic actuators,
and hydraulically amplified using servo-hydraulic
valves.
• Bosch has developed four generations of CR
injectors; three are currently in production.

Summary
(5 of 11)

• In the first and second generations of Bosch’s CR


injectors, the injection events are controlled by
changing the balance of hydraulic pressure acting
on the nozzle needle valve using magnetic
solenoids inside the injectors.
• The third generation of Bosch’s CR injectors uses
stacks of piezoceramic wafers to control injection
events inside the injector.
• Piezo technology enables the fastest switching time
for injectors, currently allowing up to seven injection
events in one injection sequence.

Summary
(6 of 11)

• One of the biggest problems with electromagnetic


actuators is the long response time required to build a
magnetic field strong enough to move valves inside an
actuator. Longer response time contributes to injection
lag.
• One of Bosch’s fourth-generation CR injectors is the
CRS4, also referred to as HADIS, uses an internal
hydraulic amplifier to multiply injection pressure by 2:1.
One benefit of the two-stage pressure amplification
concept is that the highest pressure is limited to the
injector nozzle where the maximum pressure is required
instead of the high pressure pump, lines, and fuel rail.

46
4/14/2020

Summary
(7 of 11)

• Another fourth-generation injector concept from Bosch


is the CRI4-PV injector. It uses a nozzle featuring two
rows of spray holes in the nozzle tip. This design
permits either row of nozzles to be opened
independently, which optimizes mixture preparation to
achieve a more homogenous distribution of fuel and
air in the cylinder.
• Siemens has developed and manufactured piezo
injectors since 2001 for a variety of OEMs. The
injector uses a conventional six-hole nozzle valve
which operates using the principle of hydraulically
balancing the nozzle valve.

Summary
(8 of 11)

• The fuel system generally referred to today as a


common rail injection is more precisely termed high-
pressure accumulator rail or high-pressure common
rail (HPCR). Combined with operational features of
the unique CR fuel injector, the most flexible rate
shaping of injection events are possible with HPCR
fuel systems.
• High-pressure fuel pumps develop the pressure
required for injection under all engine operating
conditions, including for quick starting of the engine.

Summary
(9 of 11)

• The volume and pressure control valves use a PWM


electrical signal to regulate fuel pressure in the fuel
rail.
• The high-pressure pump is driven at one-half engine
speed and coupled to the engine through a gear
drive mechanism. To minimize parasitic loss, newer
pumps have inlet metering capabilities to reduce fuel
heating and improve fuel economy.

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4/14/2020

Summary
(10 of 11)

• The fuel rail is a thick-walled reservoir for highly


pressurized fuel used to supply fuel to the injectors. It
is continuously filled with pressurized fuel supplied by
the high-pressure fuel pump. Not only can the rail
store pressurized fuel, but it also provides some
dampening action for the pressure pulsations of the
high-pressure pump.
• On many systems a pressure-limiting valve is a
mechanical valve that serves the same function as an
over-pressure protection valve. In the event of over-
pressurization of the fuel rail, it opens and fuel flows to
the fuel return circuit.

Summary
(11 of 11)

• A fuel rail pressure sensor is mounted in the high-


pressure fuel rail and provides data to the ECM for
closed-loop adjustment to the fuel pressure control
regulator.
• In the event of an injector failure causing continuous
flow of fuel through the injector, a mechanical safety
valve shuts off the flow of fuel to the failed injector.
Flow-limiting valves are threaded into the fuel rail for
each injector.

48

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