Electronically controlled Fuel Injection j

http://www.youtube.com/watch?v=XlXwMTbL26Y http://www youtube com/watch?v=XlXwMTbL26Y Ford I4 gasoline engine HCS SOHC

Main components in an EFI system: Fuel injector - delivering and atomizing fuel Fuel pump - increasing the fuel pressure to required level Fuel pressure regulator - maintaining the pressure at the required level by throttling the fuel flow. flow Common rail (pressure accumulator) - high pressure fuel rail feeding individual fuel injectors. ECM - Engine Control Module, including a digital computer and circuitry to communicate with sensors and control outputs. Wiring harness g Sensors and transducers such as - engine speed sensor - crank/cam position: hall effect sensor k/ iti h ll ff t - fuel flow: pressure transducer - airflow: mass airflow (MAF) sensor for sensing the mass flow rate of the air for ( ) g the controller to determine the mass of fuel to be injected in the engine. - exhaust gas oxygen: O2 Sensor for determining the air/fuel ratio.

http://autospeed.com.au/cms/title_Bosch-DIMotronic-Gasoline-Direct-Injection/A_1761/article.html

Schematic diagram of piezo pintle-type nozzle injector

http://iopscience.iop.org/1742-6596/85/1/012037

Images of gasoline fuel spray visualization in the constant volume chamber at atmospheric pressure as a function of time after start of fuel injection, for an injection duration of 0.33 ms and injection pressure of 200 bar.

http://iopscience.iop.org/1742-6596/85/1/012037

Diesel fuel injection

http://www.aa1car.com/library/fuel_pump.htm

http://www.python-injection.com/electric_fuel_pump.php

 Port/manifold fuel injection (PFI)

The li id fuel is injected in the intake Th liquid f l i i j t d i th i t k manifold. if ld The fuel vaporizes and mixes with the air in the intake i before it gets i t th combustion i t k pipe b f t into the b ti chamber.

Direct fuel injection (DFI)

The liquid fuel is directly injected into the combustion chamber.

Advantages of PFI
Allowing a long duration of mixture formation before reaching the combustion chamber. g g Utilizing the air waves propagation within the intake ducts as beneficial support of droplets atomization and distribution. Steady and homogeneous mixture in the intake manifold, free of burned gas zones. Lower fuel pressure required.

Disadvantages of PFI
Charge losses caused by distribution overlap (valve timing overlap). The direct contact of fuel with the walls of the duct and combustion chamber, leading to g incomplete combustion. Poorer engine performance at part load.

www.enginuityinc.com

Direct fuel injection (DFI)

Fig. B Fi 2 Bosch common rail direct fuel injection system for V8 diesel engines h il di t f l i j ti t f di l i

Audi A2 1.6 FSI (direct petrol fuel injection with common rail) [http://www.audiworld.com/news/02/geneva/a2/content2.shtml]

http://www.audiworld.com/news/02/fsi/content4.shtml

Audi 2.0 FSI common fuel rail [http://www.audiworld.com/news/02/fsi/content3.shtml]

Audi A di A4 2 0 FSI exhaust receirculation 2.0 h t i l ti http://www.audiworld.com/news/02/fsi/content.shtml

Different DFI systems

Direct injection of liquid fuel Direct injection of fuel/air pre-mixture

Figure 4 Direct injection with high pressure common rail [Stan]

Fig. 5 Air assisted direct mixture injection system [Stan]

Orbital air assisted direct injection system

Factors Affecting mixture formation in DFI g

Fuel - injection start and duration, - injector location and spark geometry, and - injection rate modulation and q j quantity. y Air - intake duct which determines the flow structure and structure, - valve timing which determines the flow rate and the quantity of the air. Spark - ignition start and duration, and - spark plug position. Combustion chamber and intake ducts

Table 1 Fuel injection and ignition timing (summarized from [1])

Full load at high speed Start of injection Duration of injection Start of ignition As early as possible Short Late

Part load at low speed Late Longer Earlier

Different mixture formation concepts p

Internal mixture formation (DFI) p yg (spark-assisted) internal ) - Spray-guided ( p mixture formation - Wall guided internal mixture formation - Air-guided internal mixture formation External mixture formation

Internal mixture formation f ti

http://autospeed.com.au/cms/title_Bosch-DIMotronic-Gasoline-Direct-Injection/A_1761/article.html

Advantages of DFI
Precise control of fuel quantity and injection timings. No throttle loss. Cooling effect caused by in-cylinder evaporation significantly reducing the knocking tendency and allowing an increase in efficiency via an increased compression ratio Reduced response time to rapidly changing inputs, e.g., rapid throttle movements. Deliver an accurate and equal mass of fuel to each cylinder of the engine. h i Improved mixture formation control until the start of ignition. Improved combustion control by better control of the mixture p y formation.

Leading to the following benefits..

With DFI DFI Significantly reduced pollutant emissions of the exhaust gas; Permitting additional increase of the compression ratio, leading to improved g thermal efficiency. Smoother function during transitions. Optimized fuel system performance at all engine operating conditions

Combustion modules in GDI systems

Ultra lean combustion partial load, Diesel like
- the first zone with stratified fuel/air mixture at stoichiometric ratio, enveloping the spark source, - the second zone of pure air, enveloping the first zone, which avoids chemical reaction or an intensive heat transfer on the surface of the combustion chamber chamber.

Stoichiometric combustion medium load Homogeneous combustion full load

1. Carbon canister 2. Shutoff valve 3. Canister-purge valve 4. Fuel-pressure regulator p g 5. Injector 6. Pressure actuator 7. Ignition coil 8. Phase sensor 9. Secondary-air pump 10. Secondary-air valve 11. Air-mass meter 12. ECU 13. Throttle-valve sensor 14. Idle actuator 15. Air-temperature sensor 16. EGR valve 17. Fuel filter 18. Knock sensor 19. Engine-speed sensor 20. Engine-temperature sensor g p 21. Lambda oxygen sensor 22. Diagnosis interface 23. Diagnosis lamp 24. Pressure differential sensor 25. Electric fuel pump

System diagram of Motronic M5 with integrated diagnostics

The Main Components of Bosch DI-Motronic System

http://autospeed.com.au/cms/title_Bosch-DIMotronic-Gasoline-Direct-Injection/A_1761/article.html

Components of Bosch KE-Jetronic: 1. Air-flow sensor 2. Mixture-control 2 Mixture control unit 3. Fuel distributor 4. Pressure actuator 5. ECU 6. Fuel filter 7. Fuel accumulator 8. Electric fuel pump 9. Fuel injection valves (injectors) 10. Throttle-valve switch 11. Thermo-time switch 12. Cold-start valve 13. Engine-temperature sensor 14. 14 Auxiliary-air device 15. Primate-pressure regulator

http://www.ffp.fi/index.php?mid=2&pid=105

Fig. MED M t Fi 4 MED-Motronic Engine management system developed by Bosch i E i t t d l db B h

http://rb-k.bosch.de/resources/literatur/leseproben/u241e.pdf on 31 July 2006

http://mitworld.mit.edu/video/743 http://mitworld mit edu/video/743