Design and development of variable pressure control for common rail diesel fuel injection system (CRDI) using an EFI.

With the advent of electronic fuel injection, automotive engine efficiency and development has escalated. However, the test benches for common rail fuel injectors are costly and they need to be imported as this technology is not available indigenously. Moreover, the control of fuel injectors is also

Project Title

Design and development of variable pressure control for common rail diesel fuel injection system (CRDI) using an EFI.

Project Area of Specialization

Mechanical Engineering

Project Summary

With the advent of electronic fuel injection, automotive engine efficiency and development has escalated. However, the test benches for common rail fuel injectors are costly and they need to be imported as this technology is not available indigenously. Moreover, the control of fuel injectors is also necessary for timing and controlling the amount of fuel being injected. Hence, in this project, we designed and manufactured a common rail fuel injection test bench. Moreover, a pressure control mechanism was developed along with the control of electronic fuel injection. Finally, fuel spray analysis through image processing inside a high-pressure chamber was carried out to test the fuel atomization. The CAD model for the test bench was made in Autodesk. The electrical circuitry was modeled in proteus that was used for the control aspects. The electronic circuit combined with the PWM, and other modules, were interfaced with the fuel injector and tested at different pressures and frequencies of injection. The high-pressure pump and motor setup were incorporated constituting a complete test bench to be controlled as a final objective of the project. The characterization of the fuel spray by image processing would lead to innovative biofuel testing for use in the future as a renewable energy source compatible with the already commercialized diesel engine technology.

Project Objectives

The test benches for testing common rail fuel injection setup are costly and they need to be imported later to be used for only testing purposes. A locally produced test bench for a common rail fuel injection system would be an immense add-on for testing for research purposes. Furthermore, the growing requirements for carbon control have induced interest in biodiesel usage, which is more viscous as compared to pure diesel thus higher pressure is required for testing purposes. Thus, the requirement for variable pressure control has further detail: that the setup should achieve at least 1000 bar pressure. The control of the solenoid injector and variable pressure is a challenging task that requires a combination of hardware and software knowledge. Moreover, modern tools such as MATLAB, and Simulink will be utilized to complete the required tasks.

Expected Outcomes:

• Design and Development of Common Rail Injection System.
• Variable pressure control in the common rail.
• Design and Development of Electronic Control Circuitry for Solenoid Injector.
• Fuel Spray Control.
• Image Analysis and Characterization of Fuel Sprays at various pressures.

Project Implementation Method

• Thorough Study of the Literature was done and a CAD model using Fusion 360 was prepared. 
• A circuitry was prepared in soft and Hard forms to control the fuel injection amount and frequency. The circuitry included the NE-555 module.
• Experimental Verification and analysis of Electronic Fuel Injector. Various tests were performed to verify the control aspect of the fuel injector.
• Integration of the individual components into the test bench. After the Integration of the components, a camera was utilized to capture fuel spray images for different biodiesel blends at different pressures.
• After the acquisition of images from the camera image processing was performed using MATLAB and Image-J.

Benefits of the Project

The need for carbon neutrality is becoming imminent by the day, and the use of biodiesel is one of the ways this target can be achieved. To control and study the spray of biodiesel; high-pressure levels are required inside the common rail. A Variable pressure control system would help in providing a range of pressure for the common rail which would result in various fuel sprays. Consequently, image analysis would help in fuel spray characterization at different pressures. Fuel Efficiency coupled with a stable system that is also environmentally friendly is also a motivation for the project which can be achieved by the development of an electronic and control system for a common rail fuel injector. The Variable Pressure control; control of the electronic injector; and fuel spray characterization using a high-speed camera will aid in the increase of efficiency, and lower the noise levels and vibration levels of the system.

Technical Details of Final Deliverable

The Final Deliverable includes Electronic Fuel Injection Test Bench. The Test Bench has a PWM and Frequency generator module. From the knob on the module amount of fuel and frequency of the fuel spray can be changed. The Test Bench then includes an electronic fuel injector which is coupled with the testing chamber. The test bench has a pressure control knob where another fuel injector has been used to control the pressure in the common rail. A temperature sensor and a pressure sensor are also incorporated into the setup.

Final Deliverable of the Project

Hardware System

Core Industry

Transportation

Other Industries

Energy

Core Technology

Clean Tech

Other Technologies

Sustainable Development Goals

Affordable and Clean Energy, Climate Action

Required Resources

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