Combustion Engines

Faculty of Engineering
Department of Maritime Studies
Prof. Dr.– Ing. Karsten Wehner
Mail: karsten.wehner@hs–wismar.de
www.sf.hs-wismar.de
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 2

Module Agenda

History of Diesel Air Supplying Combustion and this

Engine Process

Fuel Mixture and Forces and Super

Combustion Moments Charging

Heat Characteristic Maps

Transmission of Diesel Engines
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 3 3

Fuel-Mixture Generation and Combustion

Basic procedures of fuel-mixture generation

Injection

Design of injection systems

CR injection

Optimizing of fuel injection

EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 4

Motor characteristics The Complete Process

Noxious matter
Noxious matter decomposition/
Combustion/Heat release generation exhaust gas
treatment

Ignition

Fuel-mixture generation

Stream Stream-/ wall Current,

dispersion interaction turbulence

Primary stream
break-up

Injection Injection Inlet port Piston bowl

systems nozzle Piston moving geometry geometry Source: Diss. Henle
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 5

Influences on Fuel-Mixture Generation (Diesel)

Air Fuel

Motor-Air supply Injection

Speed and air Speed and fuel Begin of

mass mass injection

Movement Distribution Compression Injection pressure Injection discharge

rate

Direction Velocity Pressure Temperature Drop-size Duration of Number of streams

injection and direction of
injection

Air conditioning Fuel conditioning

Fuel-mixture generation
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 6

Conditioning of Liquid Fuels

Liquid fuels

Otto engine Diesel engine

Carburater Injection system Injection system

system DI / IDI

External fuel-mixture PPN-system

generation (Pump-Pipe-Nozzle)
Air intake injection

Internal fuel-mixture PN-system

gneration (Pump-Nozzle)
Direct injection

CR-system
(Common Rail)
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 7

Comparison Direct Injection & Turbulence

Chamber System
Turbulence chamber system
1. Cylinder cover
2. Combustion chamber
3. Piston
6. Injection valve
7. Heater plug
8. Turbulence chamber

Direct injection
ࢊࢗ
࢖, Chamber system
Direct injection ࢊ࣐

BDC TDC BDC

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 8

Configuration of Injection Systems

Injection system Diesel

Without reservoir With reservoir

Central Pump Segregated per  Common Rail

engine cylinder
 In-line pump  Solenoid valve
 Distributor  Pump-Nozzle injectors
pump  Piezo-injectors
 Pump-Pipe-  Special
Nozzle executions

Source: Mollenhauer
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 9 9

source:
dieselpowermag.com

source:
emissionslos.com
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 10

Configuration of Injection Systems

Pump-Pipe- Pump-Nozzle Distributor-
Nozzle system system unit injection pump
Electronic-controlled
conventional

Pressure reservoir / Rail

Injector

High-
pressure
pump
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 11

Configuration of Injection Systems

- Injection Pump -
In-line pump PE
1 Pressure valve holder;
2 Filler element;
3 Pressure valve bearing;
4 Flange cylinder;
5 Element-piston;
6 Ball;
7 Regulation rack;
8 Regulation sleeve;
9 Piston rim;
10 Spring;
11 Spring seat;
12 Roller plunger;
13 Camshaft
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 12

Configuration of
Injection Systems
- Injection Pump -

Picture 4-28: In-line (P9, Fa. Bosch)

1 Static pressure valve; 2 Impact cover; 3 Cylinder; 4 Piston; 5 Regulation rack; 6 Roller plunger;
7 Camshaft; 8 Inside bearing
Picture 4-29: One-piston-pump with integrated roller-plunger (PFR1CY, Fa. Bosch)
1 Static pressure valve; 2 Cylinder; 3 Piston; 4 Housing; 5 Roller plunger
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 13

PPN- Injection System Physical Coherence

pp

pps
Injection pipe
φDStart φIp φDelivery Stop
Back flush
regulator
Pressure valve
Release piston

Plunger with
control edge Hole type
nozzle Throttling pintle nozzle

Camshaft
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 14

PPN- Injection System Physical Coherence

φDStart φDelivery Stop

φDStart φIS φDS

top

φDStart φDelivery Stop

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 15

Configuration of Injection Systems

- Injection Pump - Fuel Delivery Control -

Picture 4-12: Fuel delivery control at injection pumps by twisting the plungers.
Left side: zero delivery; Middle: partly delivery; Right side: Full delivery.
1. Plunger cylinder; 2. Inlet bore; 3 Plunger; 4. Control edge; 5 Regulating
rack
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 16

Configuration of Injection Systems

- Injection Valve -
Left side: Nozzle holder combination
with hole-type nozzle. 1. Inlet; 2.
Holding element; 3 Nozzle tension nut;
4. Intermediate washer; 5 Injection
nozzle; 6 Sleeve nut with pressure
pipe; 7 Filter bar; 8 Leaking fuel
connection; 9 Pressure setting washers;
10 Pressure channel; 11 Pressure
spring; 12 Pressure bolt; 13 Positioning
pins
Right side: Holder element with two
springs 1. Holding element; 2.
Compensating washer; 3 Pressure spring;
4. Pressure bolt; 5 Guide washer; 6
Pressure spring; 7 Pressure pin; 8 Spring
seat; 9 Compensating washer; 10 Stop
sleeve; 11 Intermediate washer; 12 Nozzle
tension nut
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 17

Configuration of Injection Systems - Injection Valve

-

Solenoid

Inlet
Piston rod
Solenoid valve
Solenoid keeper

Drain
regulator
Regulating
element
Inlet regulator

Inlet
bores
Intermediate
Injection valve
nozzle
Nozzle needle
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 18

Configuration of Injection Systems

- Injection Valves -

Injection nozzles a) throttling pin nozzle b) Blind-hole nozzle c) Seat-hole nozzle

1. Pressure pin; 2. Nozzle body; 3 Nozzle needle; 4. Inlet bore; 5 Pressure chamber; 6 Injection
hole; 7 Injection pin; 8 Blind hole
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 19

Common Rail Injection System (in principle )

High pressure reservoir

Pressure
sensor

Injector

Fuel
return
Reservoir pressure
Speed
Reservoir pressure
regulation

Further
signals

High pressure
High pressure pump Low pressure
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 20

Common Rail Injection System (MTU)

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion 21

Actuating variable
Injection spray angle bigger
Direction of injection
Improvement of Injection
Injection spray angle smaller
Injection pressure higher
Injection pressure lower Fuel
More injection holes At same
conditioning (Direct injecting
Less injection holes diameter

Command variable
diesel-engines )
X Fuel consumption lower (at low speed)
X Fuel consumption higher (at high speed)
X Combustion chamber temperature lower
X Combustion chamber temperature higher
X Exhaust gas temperature lower
X Exhaust gas temperature higher
X Black smoke emission lower
X Black smoke emission higher
X Particle emission lower
X Particle emission higher
X HC-emission lower
X HC-emission higher
X NOx-emission lower
X NOx-emission higher
X Combustion noise lower
X Combustion noise higher
X X Danger for gas-back-blowing to the nozzle more uncritical
X X Danger for gas-back-blowing to the nozzle higher
X X Nozzle coking reduced
X X X Nozzle coking increased
X X Stability increasing
X X Stability more critical
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Fuel Mixture and Combustion

Thanks for your attention!
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