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E-book: Common Rail Fuel Injection Technology in Diesel Engines [Wiley Online]

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  • Format: 360 pages
  • Pub. Date: 11-Jun-2019
  • Publisher: John Wiley & Sons Inc
  • ISBN-10: 1119107253
  • ISBN-13: 9781119107255
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  • Wiley Online
  • Price: 163,88 €*
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Common Rail Fuel Injection Technology in Diesel EnginesLarger Image
  • Format: 360 pages
  • Pub. Date: 11-Jun-2019
  • Publisher: John Wiley & Sons Inc
  • ISBN-10: 1119107253
  • ISBN-13: 9781119107255
Other books in subject:
Wiley Online E-booksMore info about Wiley Online
Companion website: https://onlinelibrary.wiley.com/doi/book/10.1002/9781119107255

A wide-ranging and practical handbook that offers comprehensive treatment of high-pressure common rail technology for students and professionals 

In this volume, Dr. Ouyang and his colleagues answer the need for a comprehensive examination of high-pressure common rail systems for electronic fuel injection technology, a crucial element in the optimization of diesel engine efficiency and emissions. The text begins with an overview of common rail systems today, including a look back at their progress since the 1970s and an examination of recent advances in the field. It then provides a thorough grounding in the design and assembly of common rail systems with an emphasis on key aspects of their design and assembly as well as notable technological innovations. This includes discussion of advancements in dual pressure common rail systems and the increasingly influential role of Electronic Control Unit (ECU) technology in fuel injector systems. The authors conclude with a look towards the development of a new type of common rail system. Throughout the volume, concepts are illustrated using extensive research, experimental studies and simulations. Topics covered include:

  • Comprehensive detailing of common rail system elements, elementary enough for newcomers and thorough enough to act as a useful reference for professionals
  • Basic and simulation models of common rail systems, including extensive instruction on performing simulations and analyzing key performance parameters
  • Examination of the design and testing of next-generation twin common rail systems, including applications for marine diesel engines
  • Discussion of current trends in industry research as well as areas requiring further study

Common Rail Fuel Injection Technology is the ideal handbook for students and professionals working in advanced automotive engineering, particularly researchers and engineers focused on the design of internal combustion engines and advanced fuel injection technology. Wide-ranging research and ample examples of practical applications will make this a valuable resource both in education and private industry.

Preface xiii
Introduction xv
1 Introduction 1(14)
1.1 The Development of an Electronic Control Fuel Injection System
2(5)
1.1.1 Position Type Electronic Control Fuel Injection System
3(1)
1.1.2 Time Type Electronic Control Fuel Injection System
4(1)
1.1.3 Pressure-Time Controlled (Common Rail) Type Electronic Control Fuel Injection System
4(3)
1.1.3.1 Medium-Pressure Common Rail System
5(1)
1.1.3.2 High-Pressure Common Rail System
6(1)
1.2 High-Pressure Common Rail System: Present Situation and Development
7(8)
1.2.1 For a Common Rail System
7(4)
1.2.1.1 Germany BOSCH Company of the High-Pressure Common Rail System
8(2)
1.2.1.2 The Delphi DCR System of the Company
10(1)
1.2.1.3 Denso High-Pressure Common Rail Injection System of the Company
10(1)
1.2.2 High-Power Marine Diesel Common Rail System
11(4)
1.2.2.1 System Structure
11(1)
1.2.2.2 High-Pressure Oil Pump
12(1)
1.2.2.3 Accumulator
13(1)
1.2.2.4 Electronically Controlled Injector
13(2)
2 Common Rail System Simulation and Overall Design Technology 15(28)
2.1 Common Rail System Basic Model
15(8)
2.1.1 The Common Rail System Required to Simulate a Typical Module HYDSIM
16(5)
2.1.1.1 Container Class
16(1)
2.1.1.2 Valves
17(2)
2.1.1.3 Runner Class Module
19(1)
2.1.1.4 Annular Gap Class Module Physical Model Shown in Figure 2.6
20(1)
2.1.2 The Relevant Parameters During the Simulation Calculations
21(2)
2.1.2.1 Fuel Physical Parameters
21(1)
2.1.2.2 Fuel Flow Resistance
21(1)
2.1.2.3 Partial Loss of Fuel Flow
22(1)
2.1.2.4 Rigid Elastic Volume Expansion and Elastic Compression
22(1)
2.2 Common Rail System Simulation Model
23(3)
2.2.1 High-Pressure Pump Simulation Model
23(1)
2.2.2 Injector Flow Restrictor Simulation Model
24(1)
2.2.3 Simulation Model Electronic Fuel Injector
25(1)
2.2.4 Overall Model Common Rail System
25(1)
2.3 Influence Analysis of the High-Pressure Common Rail System Parameters
26(17)
2.3.1 Influence Analysis of the High-Pressure Fuel Pump Structure Parameters
26(7)
2.3.1.1 Frequency of the Fuel Supply Pump
27(1)
2.3.1.2 Quantity of the Fuel Supply by the High-Pressure Supply Pump
27(2)
2.3.1.3 Diameter of the Oil Outlet Valve Hole of the High-Pressure Pump
29(2)
2.3.1.4 Influence of the Pre-tightening Force of the Oil Outlet Valve
31(2)
2.3.2 Analysis of the Influence of the High-Pressure Rail Volume
33(1)
2.3.3 Influence of the Injector Structure Parameters
34(6)
2.3.3.1 Control Orifice Diameter
34(2)
2.3.3.2 Influence of the Control Chamber Volume
36(1)
2.3.3.3 Influence of the Control Piston Assembly on the Fuel Injector Response Characteristics
36(2)
2.3.3.4 Influence of the Needle Valve Chamber Volume
38(1)
2.3.3.5 Influence of the Pressure Chamber Volume
38(1)
2.3.3.6 Influence of the Nozzle Orifice Diameter on the Response Characteristics of the Injector
39(1)
2.3.4 Influence of the Flow Limiter
40(2)
2.3.4.1 Influence of the Plunger Diameter
40(1)
2.3.4.2 Influence of the Flow Limiter Orifice Diameter
41(1)
2.3.5 Common Rail System Design Principle
42(1)
3 Electronically Controlled Injector Design Technologies 43(84)
3.1 Electric Control Fuel Injector Control Solenoid Valve Design Technology
43(29)
3.1.1 Solenoid Valve 33 Mathematical Analysis Model
43(6)
3.1.1.1 Circuit Subsystem
43(3)
3.1.1.2 Magnetic Circuit Subsystem
46(1)
3.1.1.3 Mechanical Circuit Subsystem
47(1)
3.1.1.4 Hydraulic Subsystem
48(1)
3.1.1.5 Thermodynamic Subsystem
48(1)
3.1.1.6 Dynamic Characteristic Synthetic Mathematical Model of the Solenoid Valve
49(1)
3.1.2 Solenoid Magnetic Field Finite Element Analysis
49(4)
3.1.2.1 Model Establishment and Mesh Creation
50(1)
3.1.2.2 Loading Analysis
51(2)
3.1.2.3 Result Display After ANSYS
53(1)
3.1.3 Solenoid Valve Response Characteristic Analysis
53(18)
3.1.3.1 The Influence of Spring Pre-load on the Dynamic Response Time of the Solenoid Valve
57(3)
3.1.3.2 The Influence of Spring Stiffness on the Dynamic Response Time of the Solenoid Valve
60(1)
3.1.3.3 The Influence of Driving Voltage on the Dynamic Response Time of the Solenoid Valve
60(2)
3.1.3.4 Influence of Capacitance on the Dynamic Response Time of the Solenoid Valve
62(1)
3.1.3.5 Influence of Structure of the Iron Core on the Response Characteristics of the Solenoid Valve
63(4)
3.1.3.6 Influence of Coil Structure Parameters on the Response Characteristics of the Solenoid Valve
67(1)
3.1.3.7 The Influence of Working Air Gap (Electromagnetic Valve Lift) of the Solenoid Valve
68(1)
3.1.3.8 Material Selection of the Electromagnetic Valve
69(2)
3.1.4 What Should Be of Concern When Designing the Solenoid Valve
71(1)
3.2 Nozzle Design Technology
72(55)
3.2.1 Mathematical Model and Spray Model Analysis of the Nozzle Internal Flow Field
72(18)
3.2.1.1 CFD Simulation of the Nozzle Flow Field
73(5)
3.2.1.1.1 Description of the Computational Model
73(5)
3.2.1.2 Determination of the Calculation Area and Establishment of the Calculation Model
78(3)
3.2.1.3 Discrete Computational Model of the Finite Volume Method
81(3)
3.2.1.3.1 Computational Mesh Generation
81(1)
3.2.1.3.2 Definition of Boundary and Initial Conditions
82(1)
3.2.1.3.3 Numerical Solution
83(1)
3.2.1.4 Spray Model of the Nozzle
84(6)
3.2.1.4.1 Hole Type Flow Nozzle Model
85(1)
3.2.1.4.2 WAVE Model
86(2)
3.2.1.4.3 KH-RT Model
88(1)
3.2.1.4.4 Primary Breakup Model of Diesel Engine
89(1)
3.2.2 Analysis of the Influence of Injection on the Electronically Controlled Injector
90(29)
3.2.2.1 The Effect of Injector Orifices
91(4)
3.2.2.2 The Influence of the Ratio of the Length to the Diameter of the Orifice
95(6)
3.2.2.3 The Influence of the Round Angle at the Inlet of the Orifice
101(5)
3.2.2.4 The Influence of the Shape of the Needle Valve Head
106(4)
3.2.2.5 Effect of the Injection Angle
110(6)
3.2.2.6 The Influence of the Number of Orifices
116(3)
3.2.3 Simulation and Experimental Study of Spray
119(8)
3.2.3.1 Test Scheme
119(1)
3.2.3.2 Simulation Calculation of the Nozzle Flow Field
119(4)
3.2.3.3 Simulation and Test Verification of Spray
123(4)
4 High-Pressure Fuel Pump Design Technology 127(84)
4.1 Leakage Control Technique for the Plunger and Barrel Assembly
127(27)
4.1.1 Finite Element Analysis of the Fluid Physical Field in the Plunger and Barrel Assembly Gap
130(8)
4.1.1.1 Similarity Principle
130(1)
4.1.1.2 Similarity Criterion
131(1)
4.1.1.3 Dimensional Analysis and the Pion Theorem
132(1)
4.1.1.4 Similarity Model and Finite Element Analysis of the Clearance Flow Field
133(5)
4.1.2 Finite Element Analysis of the Plunger and Barrel Assembly Structure
138(2)
4.1.2.1 Three-dimensional Solid Finite Element Model
138(1)
4.1.2.2 Constraint Condition of Structure Field
139(1)
4.1.2.3 Structural Field Solution
140(1)
4.1.3 Structural Optimization of the Plunger and Barrel Assembly
140(8)
4.1.3.1 Analysis of the Preliminary Simulation Result
140(4)
4.1.3.2 Deformation Compensation Optimization Strategy
144(1)
4.1.3.3 ANSYS Optimization Analysis
144(3)
4.1.3.4 Evaluation of the Optimization Result
147(1)
4.1.4 Experimental Study on the Deformation Compensation Performance of the Plunger and Barrel Assembly
148(6)
4.1.4.1 Test for the Sealing Performance of the Plunger and Barrel Assembly
148(3)
4.1.4.2 Plunger and Barrel Assembly Deformation Test
151(3)
4.2 Strength Analysis of the Cam Transmission System for a High-pressure Fuel Pump
154(22)
4.2.1 Dynamic Simulation of the Cam Mechanism of a High-Pressure Pump
155(3)
4.2.1.1 Solid Modeling
155(1)
4.2.1.2 Rigid-Flexible Hybrid Modeling and Simulation of the Camshaft Mechanism
156(2)
4.2.2 Stress Analysis of the Cam and Roller Contact Surface
158(11)
4.2.2.1 Contact Stress Calculation Method
159(3)
4.2.2.2 Calculation of Contact Stress under the Combined Action of Normal and Tangential Loads
162(2)
4.2.2.3 Analysis of the Cam Working State
164(5)
4.2.3 Experimental Study on Stress and Strain of the High-Pressure Fuel Pump
169(7)
4.2.3.1 Test and Analysis of the Pressure of the Plunger Cavity
169(5)
4.2.3.2 Stress Test and Analysis of the Camshaft
174(2)
4.3 Research on Common Rail Pressure Control Technology Based on Pump Flow Control
176(35)
4.3.1 Design Study of a High-Pressure Pump Flow Control Device
177(17)
4.3.1.1 Overview of a High-Pressure Pump Flow Control Device
177(4)
4.3.1.2 Structure and Working Principle of the High-Speed Solenoid Valve
181(2)
4.3.1.3 Simulation of the Static Characteristic of the Solenoid Valve
183(5)
4.3.1.4 Simulation of Dynamic Characteristics of the Solenoid Valve
188(3)
4.3.1.5 Design and Optimization of the One-Way Valve
191(3)
4.3.2 Conjoint Simulation Analysis of a Flow Control Device and the Common Rail System
194(2)
4.3.2.1 Simulation of the Flow Control Device
194(2)
4.3.3 Analysis of Simulation Results
196(4)
4.3.4 Experimental Study on the Regulation of Common Rail Pressure by the Flow Control Device
200(11)
4.3.4.1 Test Device
200(1)
4.3.4.2 Sealing Performance Test of the One-Way Valve
201(1)
4.3.4.3 Experimental Study on the Dynamic Response Characteristics of the Electromagnet
202(2)
4.3.4.4 Test of Pressure Control in the Common Rail Chamber
204(1)
4.3.4.5 Test Results
205(3)
4.3.4.6 Experimental Study of the Influence of the Duty Ratio of the Solenoid Valve on the Pressure Fluctuation of the Common Rail
208(3)
5 ECU Design Technique 211(62)
5.1 An Overview of Diesel Engine Electronically Controlled Technology
211(6)
5.1.1 The Development of ECU
212(3)
5.1.1.1 The Application of Control Theory in the Research of an Electronically Controlled Unit
212(1)
5.1.1.1.1 Adaptive Control and Robust Control
212(1)
5.1.1.1.2 Neural Network and Fuzzy Control
213(1)
5.1.1.2 Function Expansion of the Engine Management System
213(2)
5.1.1.2.1 Fault Diagnosis Function for an Electronically Controlled Engine
214(1)
5.1.1.2.2 Field Bus Technology
214(1)
5.1.1.2.3 Sensor Technology
214(1)
5.1.1.3 Development of Computer Hardware Technology
215(1)
5.1.2 Development of Electronically Controlled System Development Tools and Design Methods
215(2)
5.1.2.1 Application of Computer Simulation Technology
215(1)
5.1.2.2 Computer-Aided Control System Design Technology
216(1)
5.2 Overall Design of the Controller
217(11)
5.2.1 Controller Development Process
217(2)
5.2.2 Hierarchical Function Design and Technical Indicators of the Controller
219(2)
5.2.3 Input Signal
221(2)
5.2.3.1 Man-Machine Interactive Interface Input Signal
222(1)
5.2.3.1.1 Switching Signal
222(1)
5.2.3.1.2 Continuous Signal
222(1)
5.2.3.2 Sensor Input Signal
222(1)
5.2.3.2.1 Temperature Input Signal
222(1)
5.2.3.2.2 Pressure Input Signal
223(1)
5.2.3.2.3 Pulse Input Signal
223(1)
5.2.4 Output Signal
223(5)
5.2.4.1 Starting Motor Control Switch Signal
225(1)
5.2.4.2 Drive Signal of the Electronically Controlled Injector
225(2)
5.2.4.2.1 Time Precision Requirements
225(1)
5.2.4.2.2 Current Waveform Requirements
226(1)
5.2.4.2.3 Power Requirements
226(1)
5.2.4.3 The Driving Signal of the Solenoid Valve Controlled by the Common Rail Chamber Pressure
227(1)
5.3 Design of the Diesel Engine Control Strategy Based on the Finite State Machine
228(7)
5.3.1 Brief Introduction of the Finite State Machine
228(1)
5.3.1.1 Finite State Machine Definition
228(1)
5.3.1.2 State Transition Diagram
229(1)
5.3.2 Design of the Operation State Conversion Module
229(3)
5.3.3 Design of the Self-Inspection State Control Strategy
232(1)
5.3.4 Design of the Starting State Control Strategy
232(1)
5.3.5 Design of a State Control Strategy for Acceleration and Deceleration
233(1)
5.3.6 Design of a Stable Speed Control Strategy
234(1)
5.3.7 Principle of the Oil Supply Pulse
234(1)
5.4 Design of the ECU Hardware Circuit
235(20)
5.4.1 Selection of Core Controller Parts
235(3)
5.4.1.1 Characteristics of FPGA
236(1)
5.4.1.2 Selection of Core Auxiliary Devices
237(1)
5.4.2 Control Core Circuit Design
238(4)
5.4.2.1 FPGA Circuit Design
238(2)
5.4.2.1.1 Power Supply Design
239(1)
5.4.2.1.2 Configuration Circuit Design
239(1)
5.4.2.1.3 Logic Voltage Matching Circuit
239(1)
5.4.2.2 Circuit Design of SCM
240(2)
5.4.3 Design of the Sensor Signal Conditioning Circuit
242(6)
5.4.3.1 Design of the Signal Conditioning Circuit for the Temperature Sensor
242(2)
5.4.3.2 Design of the Signal Conditioning Circuit for the Pressure Sensor
244(1)
5.4.3.3 Design of the Pulse Signal Conditioning Circuit
245(3)
5.4.4 Design of the Power Drive Circuit
248(7)
5.4.4.1 Design of the Power Drive Circuit of the Pressure Controlled Solenoid Overflow Valve in the Common Rail Chamber
248(1)
5.4.4.2 Design of the Power Drive Circuit for the Solenoid Valve of the Injector
249(6)
5.5 Soft Core Development of the Field Programmable Gate Array (FPGA)
255(18)
5.5.1 EDA Technology and VHDL Language
256(2)
5.5.1.1 Introduction of EDA Technology and VHDL Language
256(1)
5.5.1.2 Introduction of EDA Tools
257(1)
5.5.2 Module Division of the FPGA Internal Function
258(3)
5.5.3 Design of the Rotational Speed Measurement Module
261(5)
5.5.3.1 Measuring Principle
261(2)
5.5.3.2 Structure Design
263(3)
5.5.4 Design of the Control Pulse Generation Module for the Injector
266(7)
5.5.4.1 The Function, Input, and Output of the Injector Control Pulse Generation Module
266(5)
5.5.4.1.1 Shortening Timing Compensation Method
268(1)
5.5.4.1.2 Increasing the Advance Angle Compensation Method
269(2)
5.5.4.2 The Realization of the Control Pulse Generation Module of the Injector
271(2)
6 Research on Matching Technology 273(20)
6.1 Component Matching Technology of the Common Rail System
273(8)
6.1.1 Matching Design of the High-Pressure Fuel Pump
273(1)
6.1.2 Matching Design of the Rail Chamber
274(1)
6.1.3 Matching Design of the Injector
274(7)
6.1.3.1 Modeling and Verification of Diesel Engine Spray and the Combustion Simulation Model
276(2)
6.1.3.2 Optimal Parameters and Objective Functions
278(1)
6.1.3.3 Simulation Experiment Design (DOE)
278(2)
6.1.3.4 Establishment of an Approximate Model for the Response Surface
280(1)
6.2 Parameter Optimization and Result Analysis of the Injection System
281(4)
6.2.1 DoE Optimization
281(1)
6.2.2 Global Optimization Based on the Approximate Model
282(1)
6.2.3 Optimization Results Analysis
283(2)
6.3 Optimization Calibration Technology of the Jet Control MAP
285(1)
6.3.1 Summary
285(1)
6.3.2 Optimal Calibration Method
285(1)
6.3.3 Optimization of Target Analysis
286(1)
6.4 Off-line Steady-State Optimization Calibration of the Common Rail Diesel Engine
286(7)
6.4.1 Mathematical Model for Optimization of the Electric Control Parameters
287(1)
6.4.2 Experimental Design
287(1)
6.4.3 Establishment of the Performance Prediction Response Model
288(1)
6.4.4 Optimal Calibration
289(2)
6.4.5 Test Result
291(2)
7 Development of the Dual Pressure Common Rail System 293(50)
7.1 Structure Design and Simulation Modeling of the Dual Pressure Common Rail System
295(4)
7.1.1 Design of the Dual Pressure Common Rail System Supercharger
295(4)
7.1.2 Modeling of the Dual Pressure Common Rail System
299(1)
7.2 Simulation Study of the Dual Pressure Common Rail System
299(14)
7.2.1 Study of the Dynamic Characteristics of the System
299(13)
7.2.1.1 Simulation of the Dynamic Characteristics of the System
300(3)
7.2.1.2 Sensitivity Analysis of the Structural Parameters of the Supercharger
303(5)
7.2.1.3 Study on Pressure Oscillation Elimination of the Supercharger Chamber in the Dual Pressure Common Rail System
308(7)
7.2.1.3.1 Scheme I
309(2)
7.2.1.3.2 Scheme II
311(1)
7.2.2 Prototype Trial Production
312(1)
7.3 Control Strategy and Implementation of the Dual Pressure Common Rail System
313(12)
7.3.1 Control Strategy of the Dual Pressure Common Rail System
314(1)
7.3.2 Hardware and Software Design of the Controller Based on the Single Chip Microcomputer
315(4)
7.3.2.1 The Basic Composition of the Control System
315(1)
7.3.2.2 Performance of Control Chip and Its Circuit Design
316(3)
7.3.2.2.1 The Circuit Design of the Minimum System of the Single Chip Microcomputer
316(1)
7.3.2.2.2 Design of the Serial Communication Circuit
316(2)
7.3.2.2.3 Pulse Signal Conditioning Circuit
318(1)
7.3.2.3 Programming of Control System
319(1)
7.3.3 Drive Circuit Design
319(6)
7.3.3.1 Design Requirements of the Driving Circuit
319(2)
7.3.3.2 Design of the Power Drive Circuit
321(4)
7.3.3.2.1 Power Drive Circuit of the GMM Actuator
321(2)
7.3.3.2.2 Power Drive Circuit of the Solenoid Valve
323(2)
7.4 Experimental Study on the Dual Pressure Common Rail System
325(18)
7.4.1 Test of Pressurization Pressure and Injection Law
325(11)
7.4.1.1 Test Platform for Pressurization Pressure and Fuel Injection
325(3)
7.4.1.2 Simulation and Test
328(1)
7.4.1.3 Effect of the Turbocharging Ratio on Pressure and Fuel Injection Law
329(5)
7.4.1.4 Effect of the Control Time Series on Pressurization Pressure and Fuel Injection Law
334(1)
7.4.1.5 Test of System High-Pressure Oil Consumption
334(2)
7.4.2 Test on Spray Characteristics of the Dual Pressure Common Rail System
336(4)
7.4.2.1 Spray Photography Test Platform
336(2)
7.4.2.2 Effect of the Fuel Injection Law on Fuel Injection Quantity
338(1)
7.4.2.3 Effect of the Injection Rate Shape on Spray Penetration and the Spray Cone Angle
338(2)
7.4.3 Experimental Research Conclusions
340(3)
Index 343
Guangyao Ouyang is a Professor at the Naval University of Engineering, China. He has close to three decades of experience in the design and optimization of power machinery.

Shijie An is an Associate Professor at the Naval University of Engineering, China.

Zhenming Liu is a scholar at the Naval University of Engineering, China.

Yuxue Li is an Associate Professor at the Naval University of Engineering, China.
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