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Chapter 27 - Common Rail
Chapter 27 - Common Rail
Chapter 27 - Common Rail
Chapter 27
Common Rail Fuel Systems
Introduction
Fundamentals of
Common Rail Fuel Systems
(1 of 19)
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Fundamentals of
Common Rail Fuel Systems
(2 of 19)
Fundamentals of
Common Rail Fuel Systems
(3 of 19)
Fundamentals of
Common Rail Fuel Systems
(4 of 19)
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Fundamentals of
Common Rail Fuel Systems
(5 of 19)
Fundamentals of
Common Rail Fuel Systems
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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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Fundamentals of
Common Rail Fuel Systems
(8 of 19)
Fundamentals of
Common Rail Fuel Systems
(9 of 19)
Fundamentals of
Common Rail Fuel Systems
(10 of 19)
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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)
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Fundamentals of
Common Rail Fuel Systems
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Fundamentals of
Common Rail Fuel Systems
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Fundamentals of
Common Rail Fuel Systems
(16 of 19)
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Fundamentals of
Common Rail Fuel Systems
(17 of 19)
Fundamentals of
Common Rail Fuel Systems
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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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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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• Electro-Hydraulic
Solenoids
– Older technology
but still used for
many medium-
and heavy-duty
diesel engines
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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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)
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Types of
Common Rail Fuel Systems
(13 of 70)
Types of
Common Rail Fuel Systems
(14 of 70)
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)
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
(21 of 70)
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Types of
Common Rail Fuel Systems
(22 of 70)
Types of
Common Rail Fuel Systems
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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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Types of
Common Rail Fuel Systems
(25 of 70)
Types of
Common Rail Fuel Systems
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• 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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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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Types of
Common Rail Fuel Systems
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• 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
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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• 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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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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• 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
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Types of
Common Rail Fuel Systems
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• 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
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Types of
Common Rail Fuel Systems
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• Pressure Amplification
– With two solenoids in the injector, two fuel
return circuits connect to the injectors
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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
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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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
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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• 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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Types of
Common Rail Fuel Systems
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• 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
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Types of
Common Rail Fuel Systems
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• Siemens CR Injectors
– Overview
• De-energizing piezoceramic actuator closes
drain; fuel pressure seats needle valve
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Types of
Common Rail Fuel Systems
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Types of
Common Rail Fuel Systems
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• 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
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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)
Components of
Common Rail Fuel Systems
(2 of 22)
• High-Pressure Pump
– Supplies high pressure to injectors
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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
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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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Components of
Common Rail Fuel Systems
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Components of
Common Rail Fuel Systems
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Components of
Common Rail Fuel Systems
(11 of 22)
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Components of
Common Rail Fuel Systems
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Components of
Common Rail Fuel Systems
(13 of 22)
Components of
Common Rail Fuel Systems
(14 of 22)
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Components of
Common Rail Fuel Systems
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Components of
Common Rail Fuel Systems
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Components of
Common Rail Fuel Systems
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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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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
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Summary
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Summary
(2 of 11)
Summary
(3 of 11)
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Summary
(4 of 11)
Summary
(5 of 11)
Summary
(6 of 11)
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Summary
(7 of 11)
Summary
(8 of 11)
Summary
(9 of 11)
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Summary
(10 of 11)
Summary
(11 of 11)
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