NEW COMMON RAIL SYSTEM SUITED FOR RETROFIT AND NEW OFF-ROAD ENGINES Marco Ganser Stelios Stylianou

Common Rail System schematic diagram Legend: Engine Injectors Fuel tank Filter H-Pressure pump Common Rail LP Return LP Return Line ECU Battery (12 or 24 Volt) Throttle Speed sensor Pressure sensor Further Sensors

Legend:

Engine

Injectors

Fuel tank

Filter

H-Pressure pump

Common Rail

LP Return

LP Return Line

ECU

Battery (12 or 24 Volt)

Throttle

Speed sensor

Pressure sensor

Further Sensors

Project Deutz-Ganser CRS on TBD 628 8 cylinder engine Source: CIMAC Paper # 233 (2004)

Engine performance TBD 628: series versus CR Redesign Source: CIMAC Paper # 233 (2004) Series max Power = 1840 kW CR max Power = 2120 kW

Fuel consumption TBD 628: series versus CR Redesign Source: CIMAC Paper # 233 (2004)

Smoke emissions TBD 628: series versus CR Redesign Smoke emissions; NOx according to IMO Source: CIMAC Paper # 233 (2004)

Common Rail System for 2MW TBD 628 engine (Ganser gen. 1) 8 cylinder inline engine with 12.5 Liters/cylinder 250 kW/cylinder Engine speed 1000 RPM, injection duration 5 ms Two rails are bulky, heavy and costly Source: CIMAC Paper # 233 (2004)

8 cylinder inline engine with 12.5 Liters/cylinder

250 kW/cylinder

Engine speed 1000 RPM, injection duration 5 ms

Two rails are bulky, heavy and costly

CR System for 2 to 5 MW engine: new generation Is there (are there) an arrangement that: does not need rails has a continuous rising injection pressure at the nozzle has a uniform fuelling for all injectors and running conditions is simple and practical to make The question is:

Is there (are there) an arrangement that:

does not need rails

has a continuous rising injection pressure at the nozzle

has a uniform fuelling for all injectors and running conditions

is simple and practical to make

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

AMESim model of 8 cylinder configuration Shows: injection sac and accumulator pressure histories Accumulator volume can be as small as the maximum injection quantity New Ganser CRS with WDD and HP pump (2 MW engine) 15 times Source: CIMAC Paper # 70 (2007)

AMESim model of 8 cylinder configuration

Shows: injection sac and accumulator pressure histories

Accumulator volume can be as small as the maximum injection quantity

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

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

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.

New, compact injector with accumulator Features: Long life compact hydraulic control in front accumulator in right part zero leakage various sizes available This example suited for DEUTZ TBD 628: NO CHANGES NEEDED TO CYLINDER HEAD LITTLE CHANGE for HP Pump drive

Features:

Long life

compact hydraulic control in front

accumulator in right part

zero leakage

various sizes available

This example suited for DEUTZ TBD 628:

NO CHANGES NEEDED TO CYLINDER HEAD

LITTLE CHANGE for HP Pump drive

Common Rail Pump for 1-3 MW Diesel engines fuel delivery 12 l/min. @ 2500 RPM. pressure 0 - 1600 bar dimensions L40 x W15 x H28 cm weight 35 kg

fuel delivery 12 l/min. @ 2500 RPM.

pressure 0 - 1600 bar

dimensions L40 x W15 x H28 cm

weight 35 kg

Smallest overall HP volume Accumulator in injectors <= 50% of competitors Injection pressure at the nozzle 20% higher than competitors at the same pump outlet pressure Very simple because there are no rail(s) Advantages of the WDD System

Smallest overall HP volume

Accumulator in injectors <= 50% of competitors

Injection pressure at the nozzle 20% higher than competitors at the same pump outlet pressure

Very simple because there are no rail(s)

A realized locomotive project Components of 40 injectors for 7FDL locomotive engine The same components as assembled injectors, ready for shipment

A realized locomotive project ……..

CR System for 2 to 5 MW engine: new generation We offer the new Ganser CRS state-of-the-art Common Rail Systems with: individual injector’s accumulator no rails exceptionally low HP volume due to new WDD-system highest effective injection pressure highest performance and installation flexibility We also supply conventional high efficiency systems with rails, should a conventional solution be preferred.

We offer the new Ganser CRS state-of-the-art Common Rail Systems with:

individual injector’s accumulator

no rails

exceptionally low HP volume due to new WDD-system

highest effective injection pressure

highest performance and installation flexibility

We also supply conventional high efficiency systems with rails, should a

conventional solution be preferred.

ISO certification and internet Ganser CRS AG is ISO – certified since 2004 Visit our homepage: www.ganser-crs.ch

Information about Ganser CRS AG Formed on 17th August 2003, 30 years of experience with CR Purpose: delivery and sale of CRS in the Off-Road domain Ganser CRS AG is a subsidiary of Ganser-Hydromag AG Actual Team: 3 ETH engineers, 1 HR und finances, 1 TS engineer, 2 designers, 2 technicians

Formed on 17th August 2003, 30 years of experience with CR

Purpose: delivery and sale of CRS in the Off-Road domain

Ganser CRS AG is a subsidiary of Ganser-Hydromag AG

Actual Team: 3 ETH engineers, 1 HR und finances, 1 TS engineer, 2 designers, 2 technicians