Electronic control systems for diesel injection

Mechanical control systems have proven their reliability and

precision for many years.
The first electronic diesel control (EDC) was used in 1983 with
distributor pumps which used electronic controls:
It is possible to adjust the start of injection more accurately and
flexibly according to the engine requirements.
Electronic control systems improves fuel economy and reduce
the amount of pollutants in the exhaust.
In overall the electronic control systems has provided greater
degree of flexibility and accurate control in many key parameters
like;
Injection quantity
Injection duration
Injection beginning
Idling speed and many others.
The diesel fuel injection system consists of an injection pump, delivery
pipes and fuel injector nozzles
The fuel injection process controls only four basic functions:
1. Timing and duration of injection
2. Injection rate
3. Injection quantity
4. Spray quality


o Camshaft drives a single-cylinder
injection pump
o The injection nozzle has several holes
through which the fuel sprays into the
cylinder.
o A spring-loaded injection needle
keeps the injection valve closed until
the pressure in the injector volume,
acting on parts of the needle surface,
overcomes the spring force and opens
the valve.

Types of Injection System
Diesel injection systems - two types
Air injection system ( 60-70 bar)
Air less injection system- solid injection for high
pressure system
Air less injection system- solid injection
Individual pump & injector or jerk pump system
Common rail system
Distributor system
Common-Rail Direct Injection (CRDI)
The manner in which fuel is injected into the cylinder determines
the engine's torque, fuel consumption, emission and noise level.
Critical factors which influence the Injections are;
Injection pressure.
Shape of injector and no of holes
No. of injections
Imp. components are:
High Pressure Pump- For generating high pressure fuel in the rail.
Rail- Reservoir of high pressure fuel.
Injectors- Inject the required amount of fuel into the combustion
chamber.
Electronic Control Unit (ECU)- Acts as a control center with inputs
from a number of sensors.



Common-Rail Direct Injection (CRDI)
Common-Rail Direct Injection (CRDI)
Requirement for CRDI:
Common rail with electronic control unit eliminate the problems
associated with interconnecting pipes in traditional pump-line-
injector systems.
CRDI have scope for pilot injection and more desirable injection
pressure characteristics.
Pilot injection means: It is an additional small amount of fuel
injection before the power producing main fuel pulse.
Modern engines use a pilot injection before the power producing
main fuel pulse. This smoothens the pressure spike and
dramatically reduces the engine noise.
Pilot injection also reduces peak combustion temperature which
helps to reduce NOx emissions drastically.
It means it controls the amount of fuel injected during the ignition
delay period

In the Common Rail System, the two functions, namely pressure
generation and injection are performed separately.
Firstly pressure generation and storing the fuel under high
pressure in a central rail.
Secondly, delivering the fuel to the individual cylinders through
the electronically-controlled injectors on demand.
High-pressure pump generates in an rail - a pressure of up to 1,600
bar.
Pump runs independently of the engine speed and the quantity of
fuel injected.
Whenever the injector opens, the high-pressure fuel in the rail is
injected into combustion chamber quickly.
Here injector acts as a valve rather than a pressure generator.


Common-Rail Direct Injection (CRDI) ECU
The ECU controls all the injection parameters such as the
pressure in the rail, the timing and duration of injection, as
well as performing other engine functions.
This ensures that incredibly high injection pressures are
available at all times, even at low engine speeds.
The electronic control unit is able to collect different data
from the engine and operating conditions with sensors


Common-Rail Direct Injection (CRDI)