Electronically controlled unit injector

Last updated

An electronically controlled unit injector (EUI) is a unit injector (UI) with electronic control. It performs the same function as a conventional unit injector in an internal combustion engine, such as in an on-road or off-road vehicle or a diesel-electric locomotive. The pressurized delivery of fuel is camshaft-driven, but the timing of the injector's internal operations are controlled by the engine control unit so as to achieve certain advantages.

Unit injector

Unit injector (UI) is an high pressure integrated direct fuel injection system for diesel engines, combining the injector nozzle and the injection pump in a single component. The plunger pump used is usually driven by a shared camshaft. In a unit injector, the device is usually lubricated and cooled by the fuel itself.

Internal combustion engine engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber

An internal combustion engine (ICE) is a heat engine where the combustion of a fuel occurs with an oxidizer in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal combustion engine, the expansion of the high-temperature and high-pressure gases produced by combustion applies direct force to some component of the engine. The force is applied typically to pistons, turbine blades, rotor or a nozzle. This force moves the component over a distance, transforming chemical energy into useful mechanical energy.

Camshaft shaft to which a cam is fastened

A camshaft is a shaft to which a cam is fastened or of which a cam forms an integral part.

Contents

Advantages

In the United States, emissions standards are managed nationally by the Environmental Protection Agency (EPA). State and local governments may apply for waivers to enact stricter regulations.

Construction

Central to the EUI is the built-in plunger pump, which, just as in a UI, allows for low-pressure fuel delivery and return to all injectors, yet provides exceptionally high pressure and concomitant injection and atomization of the fuel to a cylinder during the engine's power cycles. As in a UI, the injector is connected to common banks of fuel supply and fuel return. Fuel is always circulating within the EUI as two of its functions, other than injection for combustion, are injector lubrication and injector cooling. Connections on UIs are by formed steel tubes. Connections on EUIs are by stainless steel-reinforced hoses.

Plunger pump

A plunger pump is a type of positive displacement pump where the high-pressure seal is stationary and a smooth cylindrical plunger slides through the seal. This makes them different from piston pumps and allows them to be used at higher pressures. This type of pump is often used to transfer municipal and industrial sewage.

The controlled part of the injector is a solenoid-operated spill valve. Normally, it is open, allowing the fuel to return to the supply line when the pump plunger descends. When the solenoid is energized, the spill valve closes, and the fuel is forced through the spray tip into the cylinder.

The four phases of EUI operation are:

Fill phase
As the pump plunger retracts, fuel is drawn into the pump chamber from the fuel supply line.
Spill phase
The pump plunger begins descending, but the spill valve is open, and fuel recirculates back to the return line.
Injection phase
Partway through the pump stroke, the solenoid is energized, which closes the spill valve. The fuel is forced into the cylinder through the spray tip.
Pressure reduction phase
Toward the end of the pump stroke, the spill valve is re-opened, allowing the fuel to recirculate again and ending the injection phase.

Thus, although the mechanical plunger pump has a fixed stroke, electronic control can select any part of that stroke to deliver to the cylinder, thereby controlling the volume and timing of fuel delivery.

Users

This system is employed primarily on Electro-Motive Diesel (EMD) locomotive, marine and stationary engines, and primarily on the 710 family of diesel engines.

Electro-Motive Diesel (EMD) is an American manufacturer of diesel-electric locomotives, locomotive products and diesel engines for the rail industry. The company is owned by Caterpillar through its subsidiary Progress Rail Services.

EMD 710 two-stoke diesel engine of 710 cu.in. per cylinder

The EMD 710 is a line of diesel engines built by Electro-Motive Diesel. The 710 series replaced the earlier EMD 645 series when the 645F series proved to be unreliable in the early 1980s 50-series locomotives which featured a maximum engine speed of 950 rpm. The EMD 710 is a relatively large medium speed two-stroke diesel engine that has 710 cubic inches displacement per cylinder, and a maximum engine speed of 900 rpm.

Locomotive use

When implemented in a locomotive, the ECU may also be incorporated into the Locomotive Control Unit (LCU), which performs a variety of functions, such as wheel-slip control, "phone home" for incident reporting and scheduling of delivery of service parts, etc. EMD's LCU is often GPS-assisted, and maintenance personnel can effectively monitor the performance of perhaps thousands of locomotives at all times.

EMD has released updated LCU software, and EIUs which complement that software, which allows mixing Tier-1 and Tier-0 injectors within the same engine, and yet meets the applicable emissions tier for that engine. A specific benefit is reduced inventory of injectors.

A significant feature of the new EUIs is reduced "smoke". Also improved fuel economy. Indeed, the new "Tier 1/Tier 0" injectors [1] are also applicable to locomotives which are not certified to any Tier, and the same "smoke" reduction and fuel economy benefits apply thereto.

Related Research Articles

Diesel engine Internal combustion engine with quality rotational frequency governing, internal mixture formation, lean air-fuel-ratio, diffusion flame and compression ignition

The Diesel engine, named after Rudolf Diesel, is an internal combustion engine in which ignition of the fuel, which is injected into the combustion chamber, is caused by the elevated temperature of the air in the cylinder due to the mechanical compression. Diesel engines work by compressing only the air. This increases the air temperature inside the cylinder to such a high degree that atomised Diesel fuel injected into the combustion chamber ignites spontaneously. With the fuel being injected into the air just before combustion, the dispersion of the fuel is uneven; this is called a heterogenous air-fuel mixture. The process of mixing air and fuel happens almost entirely during combustion, the oxygen diffuses into the flame, which means that the Diesel engine operates with a diffusion flame. The torque a Diesel engine produces is controlled by manipulating the air ratio; this means, that instead of throttling the intake air, the Diesel engine relies on altering the amount of fuel that is injected, and the air ratio is usually high.

Fuel injection

Fuel injection is the introduction of fuel in an internal combustion engine, most commonly automotive engines, by the means of an injector.

Fuel pump pump

A fuel pump is a frequently essential component on a car or other internal combustion engined device. Many engines do not require any fuel pump at all, requiring only gravity to feed fuel from the fuel tank or under high pressure to the fuel injection system. Often, carbureted engines use low pressure mechanical pumps that are mounted outside the fuel tank, whereas fuel injected engines often use electric fuel pumps that are mounted inside the fuel tank. Fuel pressure needs to be within certain specifications for the engine to run correctly. If the fuel pressure is too high, the engine will run rough and rich, not combusting all of the fuel being pumped making the engine inefficient and a pollutant. If the pressure is too low, the engine may run lean, misfire, or stall.

Ford Power Stroke engine

Power Stroke is a name used by a family of diesel engines for trucks produced by Ford Motor Company since 1994. Along with its use in the Ford F-Series, applications include the Ford E-Series, Ford Excursion, and Ford LCF commercial truck; the name was also used for a diesel engine used in South American production of the Ford Ranger.

Indirect injection in an internal combustion engine is fuel injection where fuel is not directly injected into the combustion chamber. In the last decade, gasoline engines equipped with indirect injection systems, wherein a fuel injector delivers the fuel at some point before the intake valve, have mostly fallen out of favor to direct injection. However, certain manufacturers such as Volkswagen and Toyota have developed a 'dual injection' system, combining direct injectors with port (indirect) injectors, combining the benefits of both types of fuel injection. Direct injection allows the fuel to be precisely metered into the combustion chamber under high pressure which can lead to greater power, fuel efficiency. The issue with direct injection is that it typically leads to greater amounts of particulate matter and with the fuel no longer contacting the intake valves, carbon can accumulate on the intake valves over time. Adding indirect injection keeps fuel spraying on the intake valves, reducing or eliminating the carbon accumulation on intake valves and in low load conditions, indirect injection allows for better fuel-air mixing. This system is mainly used in higher cost models due to the added expense and complexity.

Common rail

Common-rail direct fuel injection is a direct fuel injection system for diesel engines.

Gasoline direct injection Internal air-fuel mixture system for internal combustion engines running on petrol

Gasoline direct injection (GDI), is a form of fuel injection employed in modern two-stroke and four-stroke gasoline engines. The gasoline is highly pressurized, and injected via a common rail fuel line directly into the combustion chamber of each cylinder, as opposed to conventional multipoint fuel injection that injects fuel into the intake tract or cylinder port. Directly injecting fuel into the combustion chamber requires high-pressure injection, whereas low pressure is used injecting into the intake tract or cylinder port.

Injection pump Injection pump

An Injection Pump is the device that pumps diesel into the cylinders of a diesel engine. Traditionally, the injection pump is driven indirectly from the crankshaft by gears, chains or a toothed belt that also drives the camshaft. It rotates at half crankshaft speed in a conventional four-stroke diesel engine. Its timing is such that the fuel is injected only very slightly before top dead centre of that cylinder's compression stroke. It is also common for the pump belt on gasoline engines to be driven directly from the camshaft. In some systems injection pressures can be as high as 220 bar (3190PSI).

A throttle is the mechanism by which fluid flow is managed by the constriction or obstruction.

Unit pump

The Unit Pump system is a modular high-pressure diesel injection system, which is closely related to the Unit Injector system UI, and is designed for use in commercial vehicle diesel engines.

Electronic Diesel Control

Electronic Diesel Control is a diesel engine fuel injection control system for the precise metering and delivery of fuel into the combustion chamber of modern diesel engines used in trucks and cars.

Two-stroke diesel engine

A two-stroke diesel engine is a Diesel engine that works in two strokes. It was invented by Hugo Güldner in 1899. Charles F. Kettering and colleagues, working at the General Motors Research Corporation and GM's subsidiary Winton Engine Corporation during the 1930s, advanced the art and science of two-stroke diesel technology to yield engines with much higher power-to-weight ratios and output range than contemporary four-stroke diesels. The first mobile application of two-stroke diesel power was with the diesel streamliners of the mid-1930s and continued development work resulted in improved two-stroke diesels for locomotive and marine applications in the late 1930s. This work laid the foundation for the dieselisation of railroads in the 1940s and 1950s.

MultiAir

MultiAir is a hydraulically-actuated variable valve timing and variable valve lift engine technology enabling "cylinder by cylinder, stroke by stroke" control of intake air directly via a gasoline engine's inlet valves. Developed by Fiat Powertrain Technologies, the technology bypasses a primary engine inefficiency: pumping losses caused by restriction of the intake passage by the throttle plate, used to regulate air feeding the cylinders.

Internal combustion engines come in a wide variety of types, but have certain family resemblances, and thus share many common types of components.

An anti-dribble valve is a component of a fuel injection system used for diesel engines. Its main function is to provide precise timing of fuel injection, particularly at the end of the injection time. If fuel was allowed to 'dribble' after the main phase of injection, this fuel would be too late for good combustion and so would be only partially burned as visible exhaust soot.

The EMD 1010 or EMD 265 is a line of four-stroke diesel engines manufactured by Electro-Motive Diesel. The precursor to the 1010 was introduced around 1998 as the 265H or H-Engine. The H-engine was initially designed for use as a 6,300 hp (4,700 kW) 16 cylinder, the EMD SD90MAC; however, the early engines were found to be unreliable, and unsuccessful in the market, with the proven EMD 710 2-stroke design being preferred. The EMD four-stroke engine was resurrected in 2015 to meet EPA Tier 4 emissions regulations.

4 VD 14,5/12-1 SRW Industrial diesel engine made by the VEB IFA Motorenwerke Nordhausen

The 4 VD 14,5/12-1 SRW is an inline four-cylinder diesel engine produced ca. 1 million times by the VEB IFA Motorenwerke Nordhausen from 1967 to 1990. The engine was one of the standard modular engines for agricultural and industrial use in the Comecon-countries.

References

  1. EMD Part Number 40112933 (new); 40112941 (remanufactured)