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Fundamental Behaviour of Valves Used in Diesel Fuel Injection Equipment

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Fundamental Behaviour of Valves Used in Diesel Fuel Injection Equipment School of Engineering and Mathematical Sciences Fundamental Behaviour of Valves Used in Diesel Fuel Injection Equipment Michael James McLorn Thesis submitted for the degree of Doctor of Philosophy April 2013 2 I hereby declare that the work presented in this thesis is my own work, was developed in a joint effort, or has been built upon existing knowledge as stated and acknowledged in the text accordingly. Date Michael James McLorn 3 Disclaimer The views and findings are those of the author and are not necessarily endorsed by Delphi Diesel Systems, the company providing the facilities and finance for this research. 4 ABSTRACT Engine manufacturers have acknowledged that in order to meet future strict emission regulations, greater optimisation of the combustion process is necessary. They are also aware that in a direct injection diesel engine, the Fuel Injection Equipment (FIE) plays the most critical role in the combustion efficiency and the formation of exhaust pollutants. In fact, the engine torque curve, fuel consumption, smoke, noise and exhaust emissions are all determined by the quantity and manner in which the fuel is injected into the engine cylinder. In modern high speed diesel engine applications, it is the inwardly-opening needle valve which fulfils this purpose. Its location, being situated within the tip of a fuel injector nozzle, ensures that the needle valve is the ultimate link between the FIE and the combustion process. This arguably makes this valve the single most important component within the whole fuel injection system, or in other words, the most important piece of the puzzle. This thesis details a series of experimental projects which were carried out to study the internal flow inside some common types of valves found within diesel FIE. Although primarily focusing on the needle valve design, both ball and cone check valves were also considered. The typical approach of visualising the internal flow structure involved the use of enlarged transparent models and a refractive index matched working fluid. Laser Light sheet illumination and Particle Image Velocimetry techniques were adopted to provide qualitative and quantitative analysis of the internal flow structure within the aforementioned types of valves. In the case of the needle valve, two reported flow phenomena, the ‘flow transition’ and the ‘flow overshoot’ were confirmed to occur within the nozzle sac, whilst a third previously unknown flow structure, the ‘reverse overshoot’ was exposed. PIV analysis has quantified flow structures within the injection holes and these have been associated with vortical structures known to exist within the emerging spray plumes. Additional observations were made of the growth of the separated region and the influence of hole entry cavitation on the bulk flow within the injection hole. In the case of an un-sprung ball check valve, a novel design of lift stop was put forward and found during steady-state flow to improve the operational performance and neutralise some undesirable behaviour. This effect was especially apparent at the full lift condition. It is anticipated that knowledge gained and described within this thesis will have commercial value to assist with design optimisation of future FIE components and for the validation of simulation data, in particular with regard analysis of the flow within the injection hole. 5 6 ACKNOWLEDGEMENTS Firstly I would like to give thanks to my academic supervisor at City University. Throughout the 5 year duration of this PhD, Professor Manolis Gavaises provided me with direction yet freedom whilst offering meaningful advice and guidance when sought. Secondly I would like to thank the significant input from the Advanced Engineering Group at Delphi Diesel Systems technical centre in Gillingham, Kent. In no particular order, Dr Celia Soteriou, Mark Winterbourn, Satish Sankhalpara, Abdul Aziz, Daniel Bush, Dr Larry Yu and Marion Balin. This is not a conclusive list so I would like to extend thanks to the dozens of other colleagues who let me ‘pick their brains’ on regular occasions. I wish also to thank the City University faculty staff who contributed to the projects discussed within this thesis, in particular Dr Nicholas Mitroglou. Finally I would like to give thanks to Delphi Diesel Systems for the financial support in funding this PhD, the use of their excellent research facilities and for providing access to unpublished internal reports and papers. 7 8 TABLE OF CONTENTS ABSTRACT ................................................................................................................ 5 ACKNOWLEDGEMENTS ............................................................................................. 7 LIST OF FIGURES ..................................................................................................... 14 LIST OF TABLES ....................................................................................................... 16 LIST OF EQUATIONS ................................................................................................ 16 NOMENCLATURE .................................................................................................... 17 Abbreviations ........................................................................................................................ 17 Non-Dimensional Numbers ................................................................................................. 19 Symbols ................................................................................................................................. 19 1. CHAPTER 1 INTRODUCTION .............................................................................. 21 1.1. Development of the Diesel Engine ........................................................................ 21 1.2. Fuel Injection ............................................................................................................. 23 1.2.1. Indirect Injection ............................................................................................... 23 1.2.2. Direct Injection .................................................................................................. 24 1.2.3. Evolution of the Fuel Injection Equipment .................................................... 26 1.2.4. Multiple Injection Strategy ............................................................................... 27 1.2.5. Injection Rate Shaping .................................................................................... 28 1.2.6. Recent & Future FIE Trends ........................................................................... 29 1.3. Combustion ............................................................................................................... 30 1.3.1. Main Combustion Products ............................................................................. 32 1.3.2. Lesser combustion products ........................................................................... 33 1.3.3. Fuel Distribution ................................................................................................ 35 1.4. Fuel Quality ............................................................................................................... 36 1.4.1. Calibration Oil ................................................................................................... 36 1.5. Emission Standards ................................................................................................. 37 1.5.1. European Exhaust Emission Standards ....................................................... 37 1.5.2. Worldwide Exhaust Emission Standards ...................................................... 39 1.5.3. Exhaust After-Treatment ................................................................................. 40 1.5.4. FIE After-Treatment Approaches ................................................................... 42 1.6. Modern Fuel Injection Strategies ........................................................................... 43 1.6.1. High Pressure Rotary Pumps ......................................................................... 43 1.6.2. Electronic Unit Injectors ................................................................................... 45 1.6.3. Common Rail Systems .................................................................................... 47 Table of Contents 1.6.4. Hybrid FIE systems........................................................................................... 51 1.6.5. Summary of FIE systems ................................................................................. 53 1.6.6. Future Trends for FIE ....................................................................................... 54 1.7. Multi-hole LD Nozzles .............................................................................................. 56 1.7.1. Nozzle Design ................................................................................................... 56 1.7.2. Nozzle Manufacture .......................................................................................... 58 2. CHAPTER 2 – EXPERIMENTAL TEST FACILITIES ................................................63 2.1. High Pressure Rig ..................................................................................................... 63 2.2. Low Pressure Rig ...................................................................................................... 64 2.3. Spray Visualisation Rig ...........................................................................................
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