Project Report (Brief Summary)\

DATE: 06-04-2013

Fuel System Optimization for Achieving BS IV Norm in 1.5L Diesel Engine

September-2012
I studied about various types of fuel injection pump available in diesel engine system and studied about various components in Diesel Pump Compact (DPC) and their functions

October-December-2012
Visited the pump assembly section and saw how the pump is assembled. After assembly section I have been placed in pump validation section where I have observed the endurance and durability test by performing 200hrs pump test continuously in AVL validation test bed. After that I have been placed in pump testing section where I observed various kinds of test been performed in different kinds of fuel injection pump. After that I tested series of DPC fuel injection pump under No Load, Part Load and Full Load conditions and plotted the graph and had emission test and plotted the graph and found out the pump which has given better in both performance and emission by carefully comparing with the graph plotted in series of test.

January-2013
I took best of 5 DPC fuel injection pump and had a test with 5 1.5L diesel engine

Engine Spec Bore x Stroke = 73x88.9mm CR = 23:1 Fly up = 4400 + or 50 rpm Max Power = 38ps @ 4000rpm Max Torque = 8.15kgm @ 2250rpm Engine Idle speed = 800 + or 50rpm Injection Timing = 19 + or 1.25 deg After series of test in eddy current dynamometer I found out that the emission characteristics was reduced but it still didnt attain Bharat Stage IV qualification. So I tested with various types of Turbochargers and had series of test along with different Nozzle Operating Pressure, Nozzle angle, Injection pipe diameter and Glow plug angle.

February-2013
After performing series of test with turbochargers and other fuel system equipments mention above and comparing with the previous records I found out that the emissions like Hydrocarbon and Carbon Monoxide was significantly reduced but the NOx and Particulate matter was far above the required range.

March-2013
Since PM and NOx emission was far above the required range. I have tested various types of EGR and made some changes in intake and exhaust manifold and retested with EGR Waste gate valve and after series of test I found out that the NOx emission was reduced. But PM was still above the required limit.

Since the PM emission was above the limit I started testing with exhaust system like catalytic convertor where I chose close couple catalytic convertor and under body catalytic convertor and the test was conducted and found that PM also got reduced in the BS IV limit. Finally the engine was placed in vehicle and the EUDC cycle test was conducted in Chassis Dynamometer with CVS sampling system and found that the emission was well under the limit. After testing the engine is taken to ARAI for Certification test.

Ranjit. R Supervisor No.1101109006 Reg