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Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
Common Rail System for retrofit and new off-road engines
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Common Rail System for retrofit and new off-road engines

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Presented by: Marco Ganser at the 2009 Railways and Harbours Conference in Cape Town.

Presented by: Marco Ganser at the 2009 Railways and Harbours Conference in Cape Town.

Published in: Business, Technology
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  • 1. NEW COMMON RAIL SYSTEM SUITED FOR RETROFIT AND NEW OFF-ROAD ENGINES Marco Ganser Stelios Stylianou
  • 2. Common Rail System schematic diagram <ul><li>Legend:  </li></ul><ul><ul><li>Engine </li></ul></ul><ul><ul><li>Injectors </li></ul></ul><ul><ul><li>Fuel tank </li></ul></ul><ul><ul><li>Filter </li></ul></ul><ul><ul><li>H-Pressure pump </li></ul></ul><ul><ul><li>Common Rail </li></ul></ul><ul><ul><li>LP Return </li></ul></ul><ul><ul><li>LP Return Line </li></ul></ul><ul><ul><li>ECU </li></ul></ul><ul><ul><li>Battery (12 or 24 Volt) </li></ul></ul><ul><ul><li>Throttle </li></ul></ul><ul><ul><li>Speed sensor </li></ul></ul><ul><ul><li>Pressure sensor </li></ul></ul><ul><ul><li>Further Sensors </li></ul></ul>
  • 3. Project Deutz-Ganser CRS on TBD 628 8 cylinder engine Source: CIMAC Paper # 233 (2004)
  • 4. Engine performance TBD 628: series versus CR Redesign Source: CIMAC Paper # 233 (2004) Series max Power = 1840 kW CR max Power = 2120 kW
  • 5. Fuel consumption TBD 628: series versus CR Redesign Source: CIMAC Paper # 233 (2004)
  • 6. Smoke emissions TBD 628: series versus CR Redesign Smoke emissions; NOx according to IMO Source: CIMAC Paper # 233 (2004)
  • 7. Common Rail System for 2MW TBD 628 engine (Ganser gen. 1) <ul><li>8 cylinder inline engine with 12.5 Liters/cylinder </li></ul><ul><li>250 kW/cylinder </li></ul><ul><li>Engine speed 1000 RPM, injection duration 5 ms </li></ul><ul><li>Two rails are bulky, heavy and costly </li></ul>Source: CIMAC Paper # 233 (2004)
  • 8. CR System for 2 to 5 MW engine: new generation <ul><li>Is there (are there) an arrangement that: </li></ul><ul><li>does not need rails </li></ul><ul><li>has a continuous rising injection pressure at the nozzle </li></ul><ul><li>has a uniform fuelling for all injectors and running conditions </li></ul><ul><li>is simple and practical to make </li></ul>The question is:
  • 9. New Ganser CRS with WDD and HP pump (2 MW engine) HP pump HP fuel lines WDD injectors Source: ASME ICEF Paper # 1521 (2006) WDD = Wave dynamics and dampening system
  • 10. <ul><li>AMESim model of 8 cylinder configuration </li></ul><ul><li>Shows: injection sac and accumulator pressure histories </li></ul><ul><li>Accumulator volume can be as small as the maximum injection quantity </li></ul>New Ganser CRS with WDD and HP pump (2 MW engine) 15 times Source: CIMAC Paper # 70 (2007)
  • 11. Advantages of the WDD System [1] Comparison competitor (System 2) vs. Ganser CRS (System 3) Pressure histories in accumulator during injection Injection pressure of System 3 with WDD is 280 bar or 20% higher and fully utilizes the pressure level generated by the HP pump [1] ASME-ICEF 2006, Paper # 1521
  • 12. Ganser CRS with WDD and HP pump (design stage) The Injectors have individual accumulators The WDD system allows unidirectional pressure wave propagation to enhance the injection rate shape
  • 13. Ganser CRS with WDD and HP pipes (Realized HW) The WDD system allows the use of either a CR HP pump or of the single jerk pumps available on an existing engine 6 cylinder inline system for 250-300 kW/cyl.
  • 14. New, compact injector with accumulator <ul><li>Features: </li></ul><ul><li>Long life </li></ul><ul><li>compact hydraulic control in front </li></ul><ul><li>accumulator in right part </li></ul><ul><li>zero leakage </li></ul><ul><li>various sizes available </li></ul><ul><li>This example suited for DEUTZ TBD 628: </li></ul><ul><li>NO CHANGES NEEDED TO CYLINDER HEAD </li></ul><ul><li>LITTLE CHANGE for HP Pump drive </li></ul>
  • 15. Common Rail Pump for 1-3 MW Diesel engines <ul><li>fuel delivery 12 l/min. @ 2500 RPM. </li></ul><ul><li>pressure 0 - 1600 bar </li></ul><ul><li>dimensions L40 x W15 x H28 cm </li></ul><ul><li>weight 35 kg </li></ul>
  • 16. <ul><li>Smallest overall HP volume </li></ul><ul><li>Accumulator in injectors <= 50% of competitors </li></ul><ul><li>Injection pressure at the nozzle 20% higher than competitors at the same pump outlet pressure </li></ul><ul><li>Very simple because there are no rail(s) </li></ul>Advantages of the WDD System
  • 17. A realized locomotive project Components of 40 injectors for 7FDL locomotive engine The same components as assembled injectors, ready for shipment
  • 18. A realized locomotive project ……..
  • 19. CR System for 2 to 5 MW engine: new generation <ul><li>We offer the new Ganser CRS state-of-the-art Common Rail Systems with: </li></ul><ul><li>individual injector’s accumulator </li></ul><ul><li>no rails </li></ul><ul><li>exceptionally low HP volume due to new WDD-system </li></ul><ul><li>highest effective injection pressure </li></ul><ul><li>highest performance and installation flexibility </li></ul><ul><li>We also supply conventional high efficiency systems with rails, should a </li></ul><ul><li>conventional solution be preferred. </li></ul>
  • 20. ISO certification and internet Ganser CRS AG is ISO – certified since 2004 Visit our homepage: www.ganser-crs.ch
  • 21. Information about Ganser CRS AG <ul><li>Formed on 17th August 2003, 30 years of experience with CR </li></ul><ul><li>Purpose: delivery and sale of CRS in the Off-Road domain </li></ul><ul><li>Ganser CRS AG is a subsidiary of Ganser-Hydromag AG </li></ul><ul><li>Actual Team: 3 ETH engineers, 1 HR und finances, 1 TS engineer, 2 designers, 2 technicians </li></ul>

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