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RT Flex and ME Fuel Injection System
RT Flex and ME Fuel Injection System
In this early common rail system the engine driven fuel pumps pressurised a fuel rail to about
400 bar from which pipes led to the fuel valves operated by cams and rocking levers.
Independently driven pumps were provided to prime the system for starting.
Later systems used hydraulically operated injectors, the delivery of fuel being controlled by a
cam operated valve. Fuel quantity was controlled by an eccentric on the cam follower.
With the integration of industrial electronics into marine engineering systems coupled with the
giant strides made in the development of computer technology, it has now become possible to
re-introduce the fuel injection common rail along with other fuel injection systems, using this
modern technology to time the injection of fuel without mechanical aids.
In addition to this, it has become possible to dispense with the timed camshaft altogether by
using similar systems to control operation of valves and the air start system.
The two major manufacturers of two stroke crosshead engines have both introduced a
camshaft-less engine. Sulzer call theirs the RT Flex engine, and MAN B&W call theirs the
ME intelligent engine. Both engines use electrical and engine driven axial piston pumps to
pressurise servo oil rails to 200 bar which are then used for fuel injection and exhaust valve
operation. In addition MAN B&W use the servo oil to drive the cylinder lubricator units
(Alpha system)
Although they both work without a camshaft and use computers to control, fuel injection,
exhaust valve operation and air starting, the method of fuel injection is different.
Sulzer use a pressurised fuel rail using a
set of jerk type pumps driven by a three
lobe cam geared to the crankshaft. The
pumps are variable delivery, based on the
ZA40 fuel pump, controlled by an
electrically driven fuel pump shaft linked
to the engine computer.
At low engine load the control system cuts out one of the
three injection valves per cylinder.
At very low load two of the three injection valves are cut
out. This is used to avoid visible smoke emission and to
reduce fuel consumption. It is possible to reduce engine
load to 10% with engine revolutions as low as 7RPM.
To be able to time the fuel injection the Control Systems must know the crank angle of the
individual units. To do this two crank angle sensors are fitted at the free end of the engine.
These sensors are accurate to 0.1°. Cylinder pressures and powers are continually monitored
by using strain gauges built into the cylinder head, and the computer automatically
compensates for twist in the crankshaft when relating crankshaft position to cylinder pressure.
the systems give complete flexibility over start and end of injection and take into account fuel
quality, dead time (the time between injection start command being given and actual
injection), and Variable Injection Timing (VIT).