SAE T-117-2005 Diesel COMMON RAIL AND ADVANCED FUEL INJECTION SYSTEMS (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf
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1、- a a - - COMMON RAILAND ADVANCED FUEL INJECTION SYSTEMS Philip J. G. Dingle and Ming-Chia D. LaiDieselCommon Rail and Advanced Fuel Injection Systems Philip J.G. Dingle Ming-Chia D. Lai “lnternational Warrendale, PAAll rights reserved. No part of this publicationmaybe reproduced, stored in a retrie
2、val system, or transmitted, inanyform orby anymeans, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission ofSAE. For permission and licensing requests, contact: SAE Permissions 400Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: permissionssae.o
3、rg Tel: 724-7724028 Fax: 724-772-4891 Gilmbl Muility lwaSta AISAEp,s , andselcted booksaeabsractedandindexed in Xt GlbalMoblt Dataae. For multiple print copies, contact: SAE Customer Service E-mail: CustomerServicesae.org Tel: 877-606-7323 (insideUSAand Canada) 724-776-4970 (outside USA) Fax: 724-77
4、6-1615 ISBN 0-7680-1257-0 Library ofCongress Control Number. 2005927223 Copyright 2005 SAE International Positions and opinions expressed in thisbook are entirely those of the authors and donot necessarily represent those ofthe organizations towhich the authors are affiliated orSAE. The authors are
5、solely responsible for the content of thisbook. SAE Order No. T-117 Printed in the United States of America.OtherSAE titles of interest: The Diesel Engine By Daniel J. Holt (Order No. PT-109) Diesel Engine Reference Book By Bernard Challen and Rodica Baranescu (Order No. R-183) Practical Diesel-Engi
6、ne Combustion Analysis By Bertrand D. Hsu (Order No. R-327) Diesel Particulate Emissions Landmark Research 1994-2001 ByJohn H. Johnson (Order No. PT-86) Diesel Nitrogen Oxide Emissions Landmark Research 1995-2001 ByJohn H. Johnson (Order No. PT-89) Formore information or to order abook, contactSAE a
7、t 400Commonwealth Drive, Warrendale,PA 15096-0001; phone (724) 776-4970; fax (724) 776-0790; e-mail CustomerServicesae.org; website http:/store.sae.org.Contents Preface .7 Executive Summary .9 ChapterOne History and Background 15 ChapterTwo Injector Nozzle and Spray Technologies and Their Impact on
8、Emissions .25 ChapterThree Common Rail Fuel Injection Equipment 43 Chapter Four Hydraulic Electronic Unit Injectors 75 Chapter Five Unit Injectors and UnitPumps .81 Chapter Six CurrentApplication Issues 91 Chapter Seven Future Outlookand Technology Trends .99 References 127 Acronyms and Definitions
9、133 About the Authors 137 5Preface It is a strange dichotomy, but true, that while in the heavy-duty sector NorthAmerican manufacturers arguably lead theworld with their diesel truckengine technology, to the extent that the engines are emulated and sold across the globe, in the dieselpassenger car s
10、ectorNorthAmerica lags behind the world. Tosome extent, this is due to anunhappy experience with passenger car diesel engines in the early 1980s, but there are also several socioeconomic reasons for this situation. As a result, NorthAmerica today is a strongbastion ofspark ignition (SI)hegemony, a s
11、ituation thatmight easily be expected to continue well into the future. However, the times are chang- ing. ProposedCO2 reduction legislation ostensibly favors the diesel engine, and the forward-thinking product planners can see that a gasoline/dieselmix in the fleetcan open anew niche andbring flexi
12、bility to the Corporate Aver- age FuelEconomy (CAFE) calculations. Elsewhere in the world, diesel engine penetration into the light-duty vehicle markethas advanced rapidly over the pasttwenty years and particularly over the last five years. In large measure, this recent growth spurt is due to the av
13、ailability of the so-called“common rail“ fuel injection system, which has almost single-handedly transformed the diesel engine, making it seriously competitive with the gasoline engine as a private vehicle powerplant. Now, a number of factors are converging thatimprove the prospect for the availabil
14、- ity of diesel engines in the NorthAmerican light-duty market, not the least ofwhich is the market shifttoward sport utility vehicles (SUVs), forwhich diesel engine characteristics are most admirably suited. These characteristics include fueleconomy, invincible low-speed torque, and all-around good
15、 driv- ability enabled inpartby sophisticated engine subsystems such as the fuel injection system and variable geometry turbochargers (VGTs). 7However, ifpassenger car diesels are to return toNorthAmerica inany volume, either through the import ofenginesproduced elsewhere or particu- larly in the ca
16、se ofnew engines designed and assembled locally, it is neces- sary to get all aspects of the process right this time. No onewants a repeat of the dismal experience ofthe early 1980s. Many factors are different this time. There is a greater understanding of dieselcombustionnowwithin the global diesel
17、 community, extensive experience with light-duty engines is available from Europe, and precision inmanufacture has improved. However,by the same token, the performance and emissions challengeshave intensified, too. Some thingshave notchanged. The engineers inproduct developmentand manufacturingwho w
18、illbe charged with specifying, optimizing, and pro- ducing these engines will perforcebe steeped in the lore and language of SI engines andmaynotbe attuned to the subtlebut important differences with the compression ignition (CI) engine. If thatwerenot the case, therewould beno need for thisbook. He
19、re, then, in fairly general terms, is a resource that addresses the important aspects relating to the diesel fuel injection system, explaininghowwehave arrivedwherewe are,what systems are available today, providing pointers for what aspects are importantandwhat aspects are not, and finally looking a
20、t the current state ofdevelopmentand projecting the likely technologypath for the future. There isno doubt that dieseldevelopment requires a slightly different mindset, and thisbookshould help in establishing that. Thebook isnotaimed exclusively at either the light-duty orheavy-duty sector, but itpo
21、ints out where those sectors diverge in their solutions to thecommonproblems. 8Executive Summary n the 110-year history of the diesel engine and its associated fuel system, therehavebeen threewatershed periods inwhich technological progress was particularly rapid. The firstandmost spectacular occurr
22、ed in the 1920s,when “air-blast“ injection gaveway to “solid“ injection. A less spectac- ular revolution took place 35 years later in the mid-1950s and into the 1960s when the rotary distributorpump came onto the market. Finally, the intro- duction of themodem electronically controlledcommon rail in
23、jection system in the late 1990s has significantly changed the outlook for the diesel engine. In each case, technological advancesmade to the injection systemopened hugenew market opportunities that previouslyhad notbeen accessible. In the case of solid injection, itbrought the diesel engine into th
24、e automotive truck market. Rotary distributorpumpsopened the light-duty automotive market for indirect injection (IDI) diesels, andcommon rail has enabled the emissions-controlled direct injection (DI) diesel engine tobe successful in sev- eralmarket sectors. Most visible of these is the light-duty
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