This is a part of Lecture Series on Automotive Fuels & Emissions for M. Tech Students at ARAI ACADEMY.

1. COMMON RAIL SYSTEM (CRS)
FOR DIESEL ENGINES
By : Dr.K.C.VORA
SR. ASST. DIRECTOR
ENGINE DEVELOPMENT LABORATORY
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2. CONTENTS
Introduction
System types & Generation
Common Rail & emission strategy
System Validation & tests
Project milestones
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3. INTRODUCTION
TECHNOLOGY DRIVERS
• Emission regulations (Exhaust gas and
Noise)
• Further fuel economy improvements
• Further improvements in
- Reliability
- Durability of engine/vehicles
• Competitive costs and prices
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4. Cam driven FIE
Pressure generation and injection are coupled
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5. ENGINE DEVELOPMENT LABORATORY
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6. Common Rail & EDC FIP
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7. ENGINE DEVELOPMENT LABORATORY
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8. TECHNOLOGY DRIVERS-EMISSION
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9. TECHNOLOGY DEMANDS ON FIE
• High pressure potential (> 2000 bars)
• Realisation of the “ideal” rate of injection via pressure modulation
alone
• Capability of realising staged (boot) as well as pilot injection
where pilot is separated from the main injection
• Flexibility of selecting start of injection as well as end of injection
• Moderate initial rise of main injection
• Sharp cut off of the injection end
• Flexibility of selecting peak injection pressure
• Provide option to automatically change rate shape according to
engine speed and load
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10. Common Rail System
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11. Common Rail System
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12. Common Rail System
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13. Common Rail System
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14. Common Rail System
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15. ENGINE DEVELOPMENT LABORATORY
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16. ENGINE DEVELOPMENT LABORATORY
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17. Common Rail System
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18. ENGINE DEVELOPMENT LABORATORY
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19. ELECTRONIC DIESEL CONTROL
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20. CRS- ELECTRONIC CONTROL UNIT (ECU)
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21. CRS- ELECTRONIC CONTROL UNIT (ECU)
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22. CRS- ELECTRONIC CONTROL UNIT (ECU)
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23. CRS- ELECTRONIC CONTROL UNIT (ECU)
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24. CRS- ELECTRONIC CONTROL UNIT (ECU)
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25. CRS- ELECTRONIC CONTROL UNIT (ECU)
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26. CRS- ELECTRONIC CONTROL UNIT (ECU)
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27. CRS- ELECTRONIC CONTROL UNIT (ECU)
150mm from ECU
4 Plane screwing points
< 60 C
Away from water splash
Away from battery
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28. EDC Sensors
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29. EDC Sensors
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30. Orientation on CRS Component - Common
Rail
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31. Orientation on CRS Component - Common
Rail
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32. Common Rail System
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33. CRS ADVANTAGES
• Separation of pressure generation and injection allowing flexibility
in controlling both the injection rates and timing.
• Fuel pressure does not depend on the engine speed and load
conditions
(This feature differentiates the common rail from conventional
injection systems)
• High injection pressures and good spray preparations are possible
even at low engine speeds and loads.
• Capability to deliver stable, small pilot injections can be used for
decreased NOx emissions and noise.
• Option for post injections may be used together with such emission
control technologies as particulate filters, lean NOx catalysts, or NOx
adsorbers.
• Fuel pump operates with low drive torque.
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34. CONTENTS
Introduction completed.
System types & Generation
Common Rail & emission strategy
System Validation & tests
Project milestones
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35. SYSTEM TYPES
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36. SYSTEM TYPES
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37. Common Rail System – 1600bar
With CP1H, Gear pump (feed), Metering unit, Injector, Rail,
ECU
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38. Common Rail System – 1600bar
With CP1H, Gear pump (feed), Metering unit, Injector, Rail,
ECU
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39. COMMON RAIL SYSTEM-
COMMERCIAL VEHICLE (CRSN)
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40. CRS System for off highway applications- Basic
system
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41. CRS System for off highway applications- Basic
system
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42. System Components : CRS
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43. System Management
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44. Theory 1: Introduction to Common Rail
System
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45. Common Rail System & emission
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46. Common Rail System & emission
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47. Theory 1: Introduction to Common Rail System
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48. ENGINE DEVELOPMENT LABORATORY
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49. Common Rail System
Load Collective measurements
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50. Theory 1: Introduction to Common Rail System
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51. Project mile stones
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52. ENGINE DEVELOPMENT LABORATORY
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53. Common Rail System & Diagnosis
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54. ENGINE DEVELOPMENT LABORATORY
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55. Common Rail System & Fuel
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56. CONCLUSION
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57. ENGINE DEVELOPMENT LABORATORY
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