PAVAI COLLEGE OF TECHNOLOGY

NAMAKKAL.

ADVANCE IN I.C ENGINE

The Common
Rail Direct Injection (CRDI)-Diesel Engine

SUBMITTED BY

S.SELVAKUMAR[PRE FINAL-MECH] N.PRAKASH[PRE FINAL-MECH]

E-mail id: sskkumar050@gmail.com E-mail id: prakashmech987@gmail.com

 one to achieve electronic controlled diesel injection due to
The Common
need of higher injection pressure unlike gasoline port
Rail Direct Injection (CRDI)-
injection.
Diesel Engine
CONVENTIONAL DIESEL SYSTEM:
ABSTRACT:
In the
To meet the emissions requirements, and to
conventional diesel system the fuel is pressurized by using
obtain further improvement in fuel economy, the
the inline jerk type pump. The maximum pressure achieved
automobile research centers are booming towards a newer
by this pump is about 210 bar. The mechanical injector
engine technology with the use of electronics.
used for the injection of the fuel is operating in a range of

pressure i.e NOP , NCP. (Nozzle Opening Pressure, Nozzle

This paper deals with a solution for achieving the
Closing Pressure). Mechanical metering of fuel quantity to
euro norms by use of “Electronic controlled Common Rail
be injected in the cylinder. Fuel injection timing
Direct Injection of diesel” in the CI engines. The CRDI
mechanically controlled by fuel injection pump and
system, which is controlled by Electronic Control Unit
variable with engine speed.
(ECU), is used to reduce pollution and to improve fuel
DRAWBACKS OF CONVENTIONAL DIESEL
economy.
SYSTEM:

 Noisy engine operation.

CRDI uses the Fuel Injection Equipment with the
 Fuel injection pressure varies during the
capability of operating at high pressures will be required to
injection process.
achieve the ultra low emissions challenges and low noise
 High fuel consumption at low engine
demands. This paper clearly deals with the importance of
speeds(due to imperfect A/F ratio).
various sensors like Acceleration pedal sensor, crankshaft
 High emissions at low engine speeds(due to
speed sensor, rail pressure sensor), electronic injector, high
imperfect A/F ratio)
pressure pump and accumulator, etc. The CRDI system
 Mechanical control of exhaust gas
enables the diesel vehicles to meet the stringent emission
recirculation in to intake manifold.
levels required by EURO-3 and beyond.

INTRODUCTION:  Poor air fuel mixture causes particulate

Fast increasing population of emissions.

automotive vehicles has given rise to a serious problem of COMMON RAIL INJECTION SYSTEM:
environmental pollution; many manufacturers’ tries to A common
overcome this problem. One of the important techniques is rail engine is designed to supply constant fuel pressure to
the fuel injection technique in diesel engines. It is not easier
electronically controlled injectors through a shared fuel The injectors, inject fuel into the combustion chamber

reservoir. This means that the fuel supply is not dependent when the solenoid valve is actuated. Because the injection

on the engine speeds. A common rail system is built by : pressure is independent of engine speed and load, the actual

 A high pressure pump with pressure start of injection, the injection pressure, and the duration of

regulator and inlet metering valve. injection can be freely chosen from a wide range.

 A rail which contains a pressurized reserve

of fuel.

 Injectors which inject precise amounts of

fuel into the cylinder as required.

 A Diesel Control Unit – the ‘brain’ of the

system, which precisely controls injector

flow and timing as well as rail pressure

while continuously monitoring the operating

Features of CRDI system:
conditions of the engine.

Block Diagram of CRDI system:

 Injection pressure, independent of

speed.
RAIL PR. SENSOR

HIGH PR.
COMMON RAIL (ACCUMULATOR)
 High pressure injection.
PUMP

 Reduced NOx emissions and engine

PRESSURE
FUEL TO REGULATOR
INJECTORS noise.

SIGNAL TO
INJECTORS
 Modular system, easily adapted to
ELECTRONIC DIESEL
INJECTOR
different engine types.
EDU
 Compact design.

ELECTRONIC CONTROL UNIT

 Full electronic control and interface

with other vehicle functions.

RPS APS CSS
Electronic Control Unit (ECU):

The ECM uses digital electronic

technology the input section provides an interface to the

Operating Principle:
sensors generating sensors supply voltages and converting
A feed pump delivers the fuel through a filter unit
analogue sensors signals into digital signals. The 8-BIT
to the high pressure pump. The high pressure pump
MICROPROCESSORS then calculate output values as
delivers fuel to the high pressure accumulator (the Rail).
results of input variables together with programmed

operational curves stored in memory, following a sequence

of programmed instructions to obtain the required output

values. Digital signal from Microprocessor is converted

into analogue by D/A converter. Microprocessor output

values converted into power signals by output stage and

used to control the position of the actuators

Block Diagram of ECU:

A/D CONVERTER

The advantage of the system derives from its

D/A CONVERTER

OUTPUT
SENSOR TO FUEL
ACTUATOR
injectors and advanced control of the injection process. The
INPUTS INPUT MICRO PROCESSOR OUTPUT AND
PUMP injectors have a balanced valve-independent of pressure

allowing the use of an ultra–compact, fast–acting solenoid

ROM RAM that enables precision in injection quantity and timing.

At the same time, a self – regulating

accelerometer pilot control (APC) function accurately

CRDI sensors:
monitors each injector to ensure an optimized combustion
The Common Rail Direct Injection system has an
throughout the engine life. The atomization by the fuel
Electronic Control Unit which gets the input from the
injectors is excellent, which promotes thorough combustion
following important sensors.
at all engine speeds.
1. Acceleration pedal sensor
High Pressure Accumulator (Rail):
2. Crankshaft speed sensor

3. Rail pressure sensor

The Acceleration sensor sends the signal input to

the ECU, according to acceleration pedal movement. The

crank shaft sensor access the speed of the engine and it is

supplied to the control unit. The Electronic control access

the pressure in the rail or high pressure accumulator by the

The high pressure Accumulator (Common Rail)
Rail pressure sensor.
is used to store the fuel at high pressure. When the nozzle
Electronic Diesel Injector:
actuator opens it supplies the high pressure fuel to the
injector. A pressure sensor is placed in the CR to monitor NOx & PM: From the Automotive research

the pressure in the rail to the ECU. centers it is claimed that a reduction of 25% in NOx and

1. Spherical type 65% in particulates from present acceptable levels. It

2. Cylindrical type achieves EURO 3 and US 98 legislation norms and beyond.

Advantages of CRDI system:

• Compact Design:

The compact design of the injector

outline enables the DCR system to be used on 2

or 4 valve per cylinder engines.

• Modular System:

With one electronically driven injector

per engine cylinder, the system is modular and

can be used on 3, 4, 5, and 6 cylinder engines.

• Independent Injection Pressure:

High Pressure Pump:
The injection pressure is
A common-rail injection system
independent of the engine speed and load, so
separates the two functions – generating pressure and
enabling high injection pressures at low
injecting – by first storing the fuel under high pressure in a

central container (rail), then delivering it to the individual speed if required.

injection valves (injectors) only on demand.

• Lower NOx & CO2Emissions:
Pressure Regulator:
Injection sequences which include
The pressure regulator monitors the high pressure
periods both pre and post the main injection can
in the rail by delivering the excess fuel to the tank after the
be utilized to reduce emissions particularly NOx,
signal received from the Electronic Control unit.
enabling the system to meet the stringent

Diesel feed pump & Filters: emissions levels required by EURO-3 and

The Diesel Feed Pump is used to pump the fuel beyond.

from the tank to the High Pressure Supply Pump through

• Noise Reduction & NOx Control:
the fuel filters which separate the dirt particles from the
The inclusion of pilot injection results
fuel.
in a significant reduction in noise.
Emissions:
 • Full Electronic Control:

Common Rail offers all the benefits of

full electronic-control fuel metering and timing,

as well as the option to interface with other

vehicle functions.

CONCLUSION:

Common Rail marks a fundamental change in

diesel technology and is happening now. More and more

vehicles are being introduced with Common Rail systems.

It is calculated that by 2009, 85% of new diesel vehicles

will incorporate Common Rail injection systems and 5

million such systems will already be on the road. So CRDI

is the best advanced technology for the diesel engine.