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EN
In the work an attempt was made to replace the conventional system of controlling the dose and angle of advance of fuel injection by an electronically controlled system, which was implemented by attaching a fuel container to the conventional high-pressure fuel system, and an electronically controlled, electro-hydraulic fuel-dosage valve. It was assumed that by controlling the current impulse of the electro-hydraulic valve it would be possible to model the dose of fuel injected into the combustion chamber and to control injection time. The kinematics of the valve slide has been presented taking account of fuel parameters, hydrodynamic phenomena and axial leakage occurring during valve overdrive.
EN
Piston displacement pumps use in common rail fuel injection systems generates very high pressure, reaching even 300 MPa. Maintaining such a high pressure is possible thanks to very precise machining resulting in as little clearance between the piston-cylinder assemblies. Due to very high forces operating in the systems and relatively unfavourable lubrication conditions resulting from using fuel as lubricants, the pumps are subject to wear and consequently lose their operating parameters. The high cost of production of the pumps, resulting from their technological advancement, forced their manufacturers to introduce technologies for diagnosing and regenerating them. The diagnostics consists in removing the pump from the engine and having it verified using a test bed. The first stage consists of evaluating the pump’s flow at null pressure; follow by evaluation of its maximal delivery for the pressure of 100 MPa. The obtained values are compared to the values achieved by a new pump. The effect of negative evaluation on a test bed is the disassembly of the pump, verification of the condition of its parts and replacement of the damaged elements. The authors examined new and used pumps on a tested, aiming to determine the characteristics of delivery of a pump for various pressures. The objective of the research was to identify the actual points in the pump’s operation at which the delivery drops the most due to the wear. The highest difference in delivery was found to exist for the maximal compression pressure. The obtained results were analysed and the possibility of changing the pump diagnostics procedure with the use of a test bed was determined.
PL
Tłokowe silniki spalinowe o zapłonie samoczynnym w ostatnich latach uległy intensywnemu rozwojowi. Rozwój ten był możliwy dzięki wprowadzeniu do stosowania zasobnikowych układów zasilania Common Rail. Układy te pozwalają spełnić rygorystyczne wymagania stawiane silnikom ZS. Ich prawidłowa praca w dużej mierze zależy od jakości paliwa. W artykule przedstawiono analizę uszkodzeń pomp wysokiego ciśnienia z układów zasilania Com-mon Rail różnych producentów i różnych konstrukcji. Przeprowadzona analiza wskazuje, że najczęściej występują-cą przyczyną uszkodzeń pomp wysokiego ciśnienia jest zużycie ścierne współpracujących elementów pojawiające się na skutek zanieczyszczeń mechanicznych zawartych w paliwie lub niewystarczających właściwości smarnych paliwa.
EN
Internal combustion, compression ignition, piston engines have been largely modified in recent years. The development of those engines was possible due to the introduction of the later generation fuel systems, espe-cially the Common Rail. The system allows meeting strict emissions legislation. The quality of fuel is critical to the correct operation of the system. The paper pre-sents the analysis of damages to high-pressure pumps in the Common Rail systems with different design and produced by different manufacturers. The analysis indi-cates that the most frequently, damages to common rail high-pressure pumps originate from abrasive wear of mating components, which results from mechanical impurities in the fuel or poor lubricating properties of the fuel.
EN
The paper aims to present the results of investigations into the engine with Common Rail system that performs multi-phase injection. The scope of investigations included measurements and assessment of fast-changing quantities. The paper provides the research stand description and a block diagram o f the system for taking measurements offast-changing quantities, including the system measuring the intensity of the current that controls the injector operation. The experimental results discussed in the paper were derived from introductory investigations into measurements of the air-fuel mixture pressure in the engine cylinder and those of the injector needle lift, which were assessed on the basis of measurements of the intensity of the injector-controlling current. Tests were performed while the engine operated under external speed characteristics and under load characteristics at the crankshaft rotational speed n=l200 rpm and n =3800 rpm. During tests, depending on speed and load characteristics of the engine operation, the ECU performed different strategies of fuel injection. The fuel injection control system madę it possible to complete three injection stages in a single work cycle of the internal combustion engine (pilot injection, pre-injection and the main injection). The maximum fuel pressure in the common rail amounted to 160 MPa. The engine was fuelled by commercial diesel oil.
EN
The storage supply systems of Common Rail type are characterized by high possibilities in shaping the rate of injection. The possibility to implement multi-injection at high pressure, easiness of adapting the system to the engine, relatively easiness of compensation the arrangement of injector parameters resulting from work tolerance, as well as easiness of making changes in the electronic engine controller enabling the production of engines with various performances, cause that type of these solutions currently are widely used injection systems in diesel engines. Injection system should be characterized above all by high precision fuel dosing into engine cylinders, the accuracy in starts controlling of individual phase of injection, repeatability and reliability and durability, as well as the up keep of these parameters for long time during operating duration. Fuel injection system works in difficult conditions resulting from high pressure, vibrations, electromagnetic interference affecting electronic executive systems and high temperatures. Especially the injector and injection pipes are open to high temperatures. The dimensions of used elements are also important. The article presents selected results concerning the effect of the length of high-pressure pipes on injection process parameters such as fuel amount, overflow in injector, and the fuel pressure course in injection pipe in front of electromagnetic injector socket. The study was conducted with test stand with electronic measurement system of fuel amount. The tests were made at different pressures in the rail and for different durations of the injector opening.
EN
Common Rail systems are most frequently used solution to the fuel supply system of Diesel engines. This is due to their high potential to shape the characteristics of fuel injection. One of the important requirements for each injection system is precision dose control and its onset, that is, as a consequence of the start of the combustion process. The most important parameters affecting the accuracy of dosing injection systems are, of course injection time, pressure of fuel in the rail and the fuel temperature. Influence on the size of the dose but also other factors, which include the supply voltage, which may be subject to significant change during the start-up of engine. The issue of start-up is becoming of interest to EURO standards, as the processes occurring in the course have a significant impact on the level of pollutants in the exhaust of internal combustion engine. Increased in this period, emissions of toxic compounds results from the unstable processes in the engine cylinder, as well as dynamic changes in the parameters of injection and in the start-up system, in particular, changes in voltage resulting from a large collection of current from the battery. Thus, the article attempted to determine the impact of voltage supply on the dosage of fuel in different operation conditions of the injection system. In particular attention was paid to the size of the dose and the actual changes at the beginning of fuel injection voltage changes. The study was conducted on a test stand, which were the main components of the test bench Bosch EPS-815 with electronic measurement of fuel dose and the visualization system AVL Visioscope. Control of the injector was performed using the self-developed controller.
7
Content available Damages to injectors in diesel engines
80%
EN
The article describes damages to high pressure injectors used in common rail injection systems. The conducted analysis of their causes includes the diagnosis of injectors on a test bench and the results of microscopic research of damaged components. The tribological damages of high pressure injectors are local and cavitations pitting. The place of cavitations pitting are mainly check valves, where the reduction in the quan¬tity of injected fuel is forming.
8
Content available Research into electronic control systems EDC
80%
EN
The article present proposed diagnostic procedures of the EDC 1.2.9 system made it possible to carry out tests and compare the results with the results provided by the manufacturer. As part of the research prior to diagnostic tests, verification tests of Siemens and Bosch pumps were carried out. Experimental study, test procedures making it possible to check particular elements of the EDC system were developed. The developed research program included the fuel system and tests were conducted for: the air intake system, engine sensors, vehicle sensors, the exhaust fumes emission system, transmitters and system elements on the controller connection. The second system, which was subject to experimental testing, was the injection system Common Rail (CR), on which tests of three sets of injectors were conducted. The following values were recorded: engine rotational speed, driver injection dose, pre-injection time, fuel dose in the main injection, fuel dose correction, the adjustment of idle running for the first, second, third and fourth cylinder. The conducted diagnostic tests make possible to predict the state of particular EDC systems reliability.
PL
W prezentowanej pracy, przedstawiono w zarysie modernizację silnika a8C22, polegającą na zainstalowaniu w nim wysokociśnieniowego układu wtryskowego typu common rail. Wyniki oraz doświadczenie z tej pracy mogą być wykorzystane bezpośrednio do modyfikacji silników lokomotyw SM42 oraz podobnych. Natomiast opracowane i wykonane stanowisko laboratoryjne , które jest formalnie uniwersalnym osprzętem common rail, umożliwia prowadzenie dalszych badań rozwojowych, badawczych oraz wdrożeniowych w przedmiotowym zakresie.
EN
In the next few decades, the resources of oil will be depleted. From the other hand, growing market and usage of oils cause increase of oil price. Additionally, only some countries have oil deposits large enough to be independent from foreign suppliers. All these reasons show need for searching and development of new fuels, which can replace traditional ones produced from oil. One of the solutions for Diesel engines are bio-fuels produced from various vegetable oils like rapeseed, coconut or palm oil. Nowadays, the majority of new Diesel engines are equipped with Common Rail fuel injections system. It enables to achieve higher power of the engine, lower emissions and lower fuel consumption. This suggests that the Common rail system should be also utilized in Diesel engines supplied with bio-fuels, produced from various plants, as it was mentioned above. However, the bio-fuels have some properties much different from those of conventional Diesel fuel, for example they usually have significantly higher viscosity. In consequence, the fuel supply and fuel injection systems require some modifications. The paper presents results of the experimental test of Common Rail Diesel engine supplied with four fuels: standard Diesel fuel, rapeseed oil and two mixtures of these fuels: 70 percent of Diesel with 30 percent of rape seed oil and 50 percent of Diesel fuel with 50 percent of rape seed oil. For the research, a new test bench was built in Faculty of Production Engineering, Warsaw University of Life Sciences. The main element of the test bench is one cylinder, direct injection engine Farymann Diesel 18W. Originally, the engine was equipped with mechanical Bosh direct injection system, which was replaced with Common Rail system. The test bench enables measurements of various parameters: torque, pressure inside the cylinder, temperature of cooling water and exhaust gases, emissions etc. The tests of the modified engine were conducted with use of several types of piston and injector.
EN
In the paper has been make an attempt to replace the conventional system of fuel dose control and injection passing angle with elecrtronic control system, which has been realized this manner, that selected hydraulic accumulator, injector C-R type and fuel dose controller has been attached the the marine engine. It has been assumed, that by controlling the current impulse of controller it is possible to model whichever/any size of fuel dose, injected to the combustion chamber and to control the injection lasting time. The wave phenomenon and the flow loss in the fuel pipe of high pressure have been presented.
EN
The injection Systems of Common Rail type are becoming widely used in marine combustion engines. The research and development of these systems aims to multi-criterial optimization of the injection process. The authors of the paper present the results of tests on the fuel supply system of the common-rail marine engine. The study was conducted on a special laboratory stand for nominal, average and minimum engine speed. For the analysis were accepted three variants of fuel supply – a single dose, two-piece dose and three-piece dose. There were presented the received characteristics of injection and discussed their most important aspects.
PL
W pracy zaprezentowano innowacyjną technikę diagnozowania wtryskiwaczy silników o zapłonie samoczynnym z systemem Common Rail. Przedstawiono zestaw nowych cech emisji akustycznej dla prawidłowo działających i uszkodzonych wtryskiwaczy.
EN
The article describes the innovative conceptions of diagnoses of injectors in diesel engines with Common Rail system. What is more, the new features of acoustic emission of injectors are described. The correct as well as incorrect oscillograph course of acoustic emission are shown.
PL
W artykule opisano zagadnienia związane z systemami wtryskowymi Common Rail silników o zapłonie samoczynnym. Zaprezentowano obecną sytuację rynkową pojazdów napędzanych tymi silnikami oraz prognozy ich dalszego rozwoju, które pozwalają przypuszczać, iż w przyszłości opisywane silniki będą jednym z głównych źródeł napędu samochodów osobowych. Ponadto przedstawiono rozwiązania konstrukcyjne stosowanych układów Common Rail, ich zalety i wady oraz możliwości spełnienia przyszłych wymagań ekologicznych i rynkowych silników ZS z tego typu układami zasilania.
EN
The paper presents the issue of Common Rail system injection in diesel engines. The Authors describe current market situation of vehicles with these engines and future prognosis of development in these vehicles. In accordance with this prognosis these engines will be an important source of drive in passenger cars. Moreover, the authors present structural solutions so far, their advantages and disadvantages and future trends in environment and market prospects.
EN
The objective of this study was to determine changes in fuel delivery rate by common rail system injectors during their simulated operation on a test stand. Four Bosch injectors used, among others, in Fiat 1.3 Multijet engines were tested. The injectors were operated on a test rig at room temperature for 500 hours (more than 72 million work cycles). During the test, pressure and injection frequency were changed. Changes in the operating parameters were estimated based on obtained injection characteristics and effective flow area determined thereby. The observed changes in fuel delivery rate were compared with results of the surface analysis of control valves and nozzle needles. Despite the stated lack of wear, significant changes in the dynamics of injector operation were observed, particularly at short injection times. Small pilot injections cannot be corrected by the fuel injection control system because they do not affect the changes in torque; however, they do affect the combustion process. This creates conditions for increased emission of toxic exhaust components.
EN
The article presents the laboratory tests results of the influence of the diesel oil content in a mixture with rapeseed oil on the operating parameters of a diesel engine with the CommonRail fuel supply system. Fuel mixtures with a rapeseed content of 0%, 50%, 70%, 100% were used. The article presents the results of tests carried out for various configurations of the object. The measurements included tests of exhaust gases: the content of carbon monoxide, carbon dioxide, hydrocarbons, nitrogen oxides as well as specific fuel consumption and exhaust gas temperature. As a result of the research, it was noticed that the use of rapeseed oil causes a significant increase in fuel consumption and an increase in emissions. At a crankshaft speed of 2500 rpm and a torque generated by the engine crankshaft of 12 Nm, the specific fuel consumption for a 0% rapeseed content is 310 g/kWh. For the same engine operating conditions and the same rapeseed content of the fuel, the fuel consumption for 100% rapeseed content is 330 g/kWh. For the same engine operating parameters, analysis of the carbon dioxide content in the exhaust gas yields a value of 7.8x104 ppm for a rapeseed content of 0%. For the same engine operating conditions and for the oilseed rape content in the fuel is 100% 8.4x104 ppm. The mathematical models describing the effects of engine operating parameters and rapeseed oil content in the mixture on the observed values were created with the Scilab program. The degree of agreement of the determined mathematical models was checked by calculating the coefficient of determination (R2). The results are shown in 3D figures.
EN
In recent years the use of alternative fuels based, among other things, on vegetable oil is causing increasing concern, which is also observed in our country. Such fuels have different physical and chemical properties (especially viscosity) with reference to the standard diesel fuel. Therefore it is important to know the effect of the additive of biocomponents on fuel injection process, in particular of its parameters, which play an important role in the combustion process and formation of pollutions in exhaust gases. In the paper is presented the test results of selected parameters of the injection process executing by four different electromagnetically controlled injectors using diesel fuel without the biocomponents and mixtures of such fuel with esters of rapeseed oil (FAME). Investigations were carried out on a specially prepared test stand which enables the measurement of fuel delivery and fuel returning from the injector together with its density and temperature. Additionally, beside mentioned parameters, there were recorded high-speed courses of pressure in the high-pressure pipe behind the rail and before the injector. Next, using a system of AVL Visioscope, the fuel injection into the visualization chamber filled with fuel was recorded. It determined the basic parameters of the fuel spray. The aim of this study was to determine the impact of fuel type on the injection process executed by the injectors with different constructional parameters.
EN
The paper presents results of studies on the dual fuel engine equipped with the Common Rail high pressure injection system and low pressure natural gas injection into the inlet collector. Impact of some regulation parameters of the feed system on the engine performance parameters was examined. Research of the pilot dose selection showed that the minimal size of the dose was limited to ca 12+13% of the nominal dose. It is a result of some troubles of the electromagnetic injector operation at short times of control. The effect of that is a notable deterioration of smoothness of the engine operation. However, electronic control of the injector opening timing enables to reduce the pilot dose size as the engine load is reduced. The research showed advantageous impact of the decreasing dose on the engine efficiency and exhaust gas toxicity at partial loads of the engine. The tests reconfirmed full usefulness of the system to combustion process optimization. A delay of the injection start at high engine loads enables to reduce nearly twice the NOx concentration in exhaust gas with insignificant decreasing, some 1+1.5%, of its efficiency. The used systems showed their high suitability to control charge quality in dual fuel engines, in traction applications in particular.
EN
The paper describes research work on a full-scale dual-fuel 4-cylinder turbocharged compression ignition engine. Compressed natural gas (CNG) was applied as the main fuel. Selfignition of the air-fuel mixture was initiated from a diesel oil dose injected by a common rail system. The research was aimed to establish maximum CNG share in the mixture delivered into the cylinder. An excessive CNG share may result in "hard" engine operation. It may also lead to the occurrence of vibrations of piston-crank construction parts resulting in failure of this mechanism. These vibrations may originate from knocking combustion (selfignition of the air-fuel mixture in the zone of non-combusted mixture) or vibration excitation as a result of rapid pressure rise after selfignition. Boundary values of the CNG energy share were determined by analysing parameters related to the rate of pressure rise and rate of heat release as well as the engine head vibration amplitude represented by the voltage signal generated by the knock sensor. Boundary values of the above mentioned parameters were determined on the basis of measurements done on the engine fuelled in a standard mode. These parameters were registered at operating points corresponding to the maximum power and load. Then, there were done measurements of basic engine operating parameters at dual fuelling in chosen points of the load characteristic for the engine speed at which the engine fuelled in a standard mode had maximum torque. Load characteristics were done for three various diesel oil doses (constant over the whole range of engine load). Load changes were realized by changes ofCNG energy share in the fuel charge. Analysis of combustion process parameters and engine head vibrations showed that CNG energy share may reach 60%. Maximum torque is possible to obtain at 45% CNG energy share. 15% decrease of maximum torque was obtained.
EN
The article discusses the effect of fuel dose division in the Diesel engine on smoke opacity and composition of the emitted exhaust gas. The research activities reported in the article include experimental examination of a small Diesel engine with Common Rail type supply system. The tests were performed on the engine test bed equipped with an automatic data acquisition system which recorded all basic operating and control parameters of the engine, and smoke opacity and composition of the exhaust gas. The parameters measured during the engine tests also included the indicated pressure and the acoustic pressure. The tests were performed following the pre-established procedure in which 9 engine operation points were defined for three rotational speeds: 1500, 2500 and 3500 rpm, and three load levels: 25, 40 and 75 Nm. At each point, the measurements were performed for 7 different forms of fuel dose injection, which were: the undivided dose, the dose divided into two or three parts, and three different injection advance angles for the undivided dose and that divided into two parts. The discussion of the obtained results includes graphical presentation of contests of hydrocarbons, carbon oxide, and nitrogen oxides in the exhaust gas, and its smoke opacity. The presented analyses referred to two selected cases, out of nine examined engine operation points. In these cases the fuel dose was divided into three parts and injected at the factory set control parameters. The examination has revealed a significant effect of fuel dose division on the engine efficiency, and on the smoke opacity and composition of the exhaust gas, in particular the content of nitrogen oxides. Within the range of low loads and rotational speeds, dividing the fuel dose into three parts clearly improves the overall engine efficiency and significantly decreases the concentration of nitrogen oxides in the exhaust gas. Moreover, it slightly decreases the contents of hydrocarbons and carbon oxide. In the experiment the contents of nitrogen oxides markedly increased with the increasing injection advance angle for the undivided dose and that divided into two parts. This, in turn, led to the decrease of the contents of hydrocarbons and carbon oxide. Fuel dose division into two and three parts leads to the increase of smoke opacity of the exhaust gas, compared to the undivided dose.
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