Scribd Logo
Upload

Welcome to Scribd!

  • 41 views

    8th Session Injector Construction and Operation

    Uploaded by

    Вячеслав Глушак
    The injector injects fuel from the common rail into the engine cylinder. It is comprised of a nozzle, two-way valve (TWV), orifice, and command piston. The TWV controls injection timing by regulating pressure in the control chamber. When the TWV opens, pressure drops in the control chamber, lifting the nozzle and starting injection. When the TWV closes, pressure rises in the control chamber again, closing the nozzle and ending injection. Some injectors have correction resistors or QR codes to improve precision of injection quantities.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    8th Session Injector Construction and Operation

    Uploaded by

    Вячеслав Глушак
    41 views4 pages
    The injector injects fuel from the common rail into the engine cylinder. It is comprised of a nozzle, two-way valve (TWV), orifice, and command piston. The TWV controls injection timing by regulating pressure in the control chamber. When the TWV opens, pressure drops in the control chamber, lifting the nozzle and starting injection. When the TWV closes, pressure rises in the control chamber again, closing the nozzle and ending injection. Some injectors have correction resistors or QR codes to improve precision of injection quantities.

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The injector injects fuel from the common rail into the engine cylinder. It is comprised of a nozzle, two-way valve (TWV), orifice, and command piston. The TWV controls injection timing by regulating pressure in the control chamber. When the TWV opens, pressure drops in the control chamber, lifting the nozzle and starting injection. When the TWV closes, pressure rises in the control chamber again, closing the nozzle and ending injection. Some injectors have correction resistors or QR codes to improve precision of injection quantities.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    41 views4 pages

    8th Session Injector Construction and Operation

    Uploaded by

    Вячеслав Глушак
    The injector injects fuel from the common rail into the engine cylinder. It is comprised of a nozzle, two-way valve (TWV), orifice, and command piston. The TWV controls injection timing by regulating pressure in the control chamber. When the TWV opens, pressure drops in the control chamber, lifting the nozzle and starting injection. When the TWV closes, pressure rises in the control chamber again, closing the nozzle and ending injection. Some injectors have correction resistors or QR codes to improve precision of injection quantities.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 4

    "Fundamentals of the Common Rail System"

    8th Session:INJECTOR CONSTRUCTION AND OPERATION


    In the last session the rail was discussed. The rail receives constant, high-pressure fuel from the supply
    pump, and provides fuel at a common pressure to each injector. This session will describe the injectors
    installed in each engine cylinder. Injectors function as the final step in the fuel injection system.

    1 OUTLINE
    • The injector injects high pressure fuel from the rail into the engine combustion chamber at the optimal
    injection timing, injection quantity, injection rate, and atomization in accordance with signals from the
    engine ECU.
    • Injection control is performed by the TWV (Two-Way Valve) and orifice opening and closing. The TWV
    controls the beginning and completion of injection by governing the pressure of the control chamber.
    • The command piston transfers pressure from the control chamber to the nozzle needle, which opens and
    closes the nozzle.
    When the nozzle needle valve is open, the nozzle atomizes the fuel and injects it.

    TWV (Two-Way Valve)

    Rail Pressure Sensor

    Orifice

    Engine
    ECU
    Control Chamber

    Rail
    Command Piston

    Nozzle Needle
    Supply Pump

    Nozzle

    <Injector>

    9 SERVICE TECH Vol.480 05-10


    "Fundamentals of the Common Rail System"

    2 CONSTRUCTION AND OPERATION


    1 Injector Construction
    • The injector is comprised of a nozzle similar to the conventional (nozzle body and nozzle needle), a TWV
    (Two-Way Valve) that controls the injection quantity, an orifice that controls the injection rate, and a command
    piston.
    • The latest type of injector is designed to withstand high pressure, causing an increase in sealability and
    resistance to high pressure wear. Further, high-speed operability has increased, enabling higher precision
    injection control and multiple injections.

    To Fuel Tank
    Connector

    TWV (Two-Way Valve)

    From Rail

    Command Piston

    Nozzle Spring

    Pressure Pin

    Nozzle Body
    Nozzle
    Nozzle Needle
    Leak Path
    Seat
    Orifice

    Reference
    In order to reduce exhaust gas and lower running noise, one injection is divided into a maximum of five separate
    injections.

    Ex: Five Injection Pattern

    Main Injection

    Injection Quantity
    Pilot Pre After Post
    Injection Injection Injection Injection

    Time

    SERVICE TECH Vol.480 05-10


    10
    "Fundamentals of the Common Rail System"

    2 Injector Operation
    The injector controls injection according to fuel pressure in the control chamber. The fuel pressure within the
    control chamber is governed by using the TWV to regulate fuel leakage from the control chamber. The
    following explains injector operation in detail. (For the sake of simplicity the nozzle needle has been included
    with the nozzle portion in the diagram below.)

    Non-injection
    When the TWV is not energized, the TWV keeps the control chamber leak path shut, causing both the fuel
    pressure in the control chamber and the fuel pressure exerted on the bottom of the nozzle are the same as rail
    pressure. The diameter of the control chamber command piston is larger than the diameter of the lower portion
    of the nozzle. As a result, the nozzle is pushed down and no injection occurs.

    Injection
    When the TWV is energized the valve lifts, opening a leak path for fuel to escape from the control chamber.
    When the leak path opens fuel leaks from the control chamber, decreasing control chamber pressure. As a
    result, the force pushing up on the nozzle becomes greater than the force exerted on the control chamber
    command piston. This lifts the nozzle, and injection begins. Excess fuel is returned to the fuel tank via the path
    displayed in the illustration below.

    Injection Complete
    When the TWV is de-energized the valve lowers, closing the leak path from the control chamber.
    When the leak path closes, the pressure in the control chamber returns to rail pressure. This closes the nozzle
    and stops injection.

    Solenoid Leak Path


    To Fuel Tank

    TWV
    Actuation Actuation Actuation
    Current Current Current

    TWV

    Rail
    Outlet Orifice

    Control Chamber Control Chamber Control Chamber


    Inlet Orifice
    Pressure Pressure Pressure

    Command Piston
    Injection Rate Injection Rate Injection Rate
    Nozzle

    Non-Injection Injection Injection Complete

    11 SERVICE TECH Vol.480 05-10


    "Fundamentals of the Common Rail System"

    3 OTHER COMPONENTS
    1 Injector with Correction Resistor
    The injector with correction resistor has a resistor built into the
    connector portion used to reduce the injection quantity variation Correction
    between cylinders. The engine ECU calculates the proper correction Resistor Terminal
    injection quantity by measuring the variation in resistance between
    injectors and reflecting this quantity in the output signal. Solenoid Terminal

    2 Injectors with QR Codes


    QR (Quick Response) codes are employed to improve injection quantity precision.
    Injection correction data is reflected in the QR codes, and the data from the QR codes is written to the engine
    ECU. Using QR codes drastically increases injection quantity correction points, causing improved injection
    quantity precision.

    • Correction Points Derived from QR Code


    Pressure
    Parameters
    QR Code

    10EA01EB
    13EA01EB Injection
    0300 0000
    Quantity
    0000 BC Q

    ID Code
    Actuation Pulse Width TQ

    Reference Handling Injectors with QR Codes


    The engine ECU performs corrections by recognizing the capabilities of each individual injector with QR codes.
    In light of this, when replacing an injector(s) or the engine ECU, it is necessary to register the ID code
    information into the engine ECU.

    • When replacing injectors


    "No correction resistance, electrical recognition impossible"
    It is necessary to register the ID code
    information of replaced injectors to the
    engine ECU. Spare Injector

    • When replacing the engine ECU


    It is necessary to re-register the ID code of Engine
    every injector installed in the vehicle to the ECU
    engine ECU.
    ∗ Necessary to register
    ID code to engine ECU

    SERVICE TECH Vol.480 05-10


    12

    You might also like