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Automotive Systems course (Module 03) - Fuel Systems in Spark Ignition Internal Combustion Engines

The document covers various fuel systems used in internal combustion engines, including carburetor-based and electronic fuel injection (EFI) systems. It discusses the evolution of fuel injection technologies, their classifications, and engine control fundamentals. The primary objectives outlined include optimizing fuel delivery for performance, emissions reduction, and adaptability to engine conditions.

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11 de outubro de 2016 | 1 SistemasAutomóveis Fuel systems – SI engines Mário Alves (mjf@isep.ipp.pt)
11 de outubro de 2016 | 2 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating • Other subsystems controlled by the engine ECU • Radiator fan, Variable valves timing control, A/C compressor control, OBD/Check engine lamp • Sensors • Actuators
11 de outubro de 2016 | 3 SistemasAutomóveis • Main objective is to deliver fuel into the cylinders • at proper timings (optimizing power) • in correct amounts (for optimal A/F ratio, function of load, RPM, engine temperature,…) • in the right form (fuel atomization, for full combustion and lower emissions)
11 de outubro de 2016 | 4 SistemasAutomóveis Classification of fuel systems (CI and SI) Operating principle ICE type single or multiple injectors direct/indirect injection technology Mechanical SI (single point) indirect Carburetor Diesel (multi-point) direct or indirect Injection Pump (in-line or rotary), few hundred bars Electronic SI SPI indirect in the throttle body, few bars MPI indirect Fuel rail, few bars direct Fuel rail, tens of bars Diesel (multi-point) direct Fuel-rail or pump/unit- injection, hundreds to thousands of bars
11 de outubro de 2016 | 5 SistemasAutomóveis Classification of fuel systems • Fuel system types • “Mechanical” (increasingly electronically assisted) • SI – mostly used until the dawn of “electronics” (< 1960) • materialized by the “Carburetor” • CI – still in use, but gradually changing to “common rail” • materialized by the “Injection Pump” (in the figure) http://what-when-how.com/automobile/distributor-type-injection-pump-automobile/
11 de outubro de 2016 | 6 SistemasAutomóveis Classification of fuel systems • Fuel system types • “Electronic” (ECU-based) • Single-Point Injection (SPI) – Figure a) • Aka “throttle-body injection” • mostly used in low-cost small-sized SI engines • Multi-Point Injection (MPI) • Indirect (external) – Figure b) • SI: injection is done upstream (the intake valves) • Diesel: injection is done in a pre-chamber • Direct (internal) – Figure c) • pressure accumulator/common-rail systems (SI + most Diesel) • pump/unit-injector systems (few Diesel) http://www.intechopen.com/books/advances-in-internal-combustion-engines-and-fuel- technologies/combustion-process-in-the-spark-ignition-engine-with-dual-injection-system
11 de outubro de 2016 | 7 SistemasAutomóveis Evolution – fuel injection technology http://engineringcorner.blogspot.pt/2011/10/next-generation-engines.html
11 de outubro de 2016 | 8 SistemasAutomóveis Evolution – European emission standards https://www.ngk.de/en/technology-in-detail/lambda-sensors/basic-exhaust-principles/euro-standards/
11 de outubro de 2016 | 9 SistemasAutomóveis Evolution – emission reduction vs. technologies http://www.transportpolicy.net/index.php?title=EU:_Light-duty:_Emissions
11 de outubro de 2016 | 10 SistemasAutomóveis Carburetor-based fuel systems • Basic carburetor operation • air is drawn into the engine by the pumping action of the pistons (vacuum) • the air accelerates as it passes through the venturi, causing a slight drop in pressure. • this pressure drop pulls fuel from the float bowl (through a nozzle) into the throttle body • it then mixes with air in a fine mist, which is distributed to the cylinders through the intake manifolds • the choke valve enables the driver to control (enrich) the mixture, at cold start http://cf.ydcdn.net/1.0.1.42/images/main/carburetor.jpg
11 de outubro de 2016 | 11 SistemasAutomóveis Carburetor-based fuel systems • Main problems • Controlling fuel quantity accurately • dependent on vacuum (not on fuel injection pressure/duration) • insensitive to air temperature, pressure, humidity, engine temperature, RPM, throttle position,… • Controlling fuel quantity in real-time • delayed/reactive response • Even delivery of air/fuel mixture • across all cylinders (intake manifolds) • Hard cold-start • flooded carburetor… • Fuel consumption • 12-15 litres per 100 km was common • Pollution • high hydrocarbons in exhaust gases https://s3.amazonaws.com/lowres.cartoonstock.com/transport-carburator-carburettor-flooded- car_problems-roadside_rescue-mtun1380_low.jpg
11 de outubro de 2016 | 12 SistemasAutomóveis Electronic fuel injection (EFI) systems • EFI emerged due to • stringent exhaust emission regulations • Increasing fossil fuel cost • evolution of analog/digital electronics • Basics • fuel pump compresses fuel • fuel accumulator (rail) stores fuel • electrically controlled injectors spray the fuel • into intake manifold or • combustion chamber • ECU controls injection timing/duration for optimal engine control • reduced emissions • reduced fuel consumption • maximized performance http://www.gerrysap.com/efi.html
11 de outubro de 2016 | 13 SistemasAutomóveis EFI systems: Single-Point Injection (example) • Mono-Jetronic (1988–1995) • one lambda sensor • mechanical fuel pressure regulator • first generation ignition system • first generation on- board diagnosis http://www.jnc.cz/auto/monomotronic/Mono-Jetronic_blo ck_diagram.gif
11 de outubro de 2016 | 14 SistemasAutomóveis EFI systems: Multi-Point Injection (example 1) • D-Jetronic (1967–1976) • "Speed-Density" fuel injection, i.e. there is no Air Flow Meter (AFM) • air-mass flow is measured indirectly, by measuring intake air pressure (3), temperature (not numbered), RPM (not in figure) and knowing cylinder volume http://www.aficionadosalamecanica.net/images-inyeccion/d-jetronic.jpg
11 de outubro de 2016 | 15 SistemasAutomóveis EFI systems: Multi-Point Injection (example 2) • L-Jetronic (1974–1989) • L stands for Luft (air) flow meter (AFM) • first generation ignition • flap type AFM (11) http://www.jagweb.com/aj6eng/42efi/page1.php
11 de outubro de 2016 | 16 SistemasAutomóveis EFI systems: Multi-Point Injection (example 3) • Motronic (1987-1998) • integrates injection and ignition (ECU controls both) • fuel pressure accumulator (fuel rail) • more sensors proliferate • second generation ignition system • intake air mass flow is “directly” measured by air- flow meter (12, flap type) http://www.autobinary.co.za/motronic%20(1).jpg
11 de outubro de 2016 | 17 SistemasAutomóveis EFI systems: Multi-Point Injection (example 4) • Gasoline Direct Injection http://www.gasitaly.com/f5direct
11 de outubro de 2016 | 18 SistemasAutomóveis EFI systems: Multi-Point Injection (example 5) • Toyota Computer- Controlled System (TCCS) • 1994 3VZ-E engine http://enginepartsdiagram.com/1994-toyota-pickup-electronic- fuel-injection-system-efi-diagram/
11 de outubro de 2016 | 19 SistemasAutomóveis Fuel supply system example (E38/E39 – base for BMW 7 Series 1995-2001) http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3
11 de outubro de 2016 | 20 SistemasAutomóveis Fuel supply system example (E38/E39 – base for BMW 7 Series 1995-2001) http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3 • Emphasis on the fuel tank
11 de outubro de 2016 | 21 SistemasAutomóveis Engine control - fundamentals • Computer-controlled • closed loop • fault-tolerant • real-time • networked • Controls • fuel injection • ignition • ISC, EGR, … • Composed of • inputs (sensors) • outputs (actuators) • controller (ECU) • network (e.g. CAN) https://autoelectricalsystems.wordpress.com/2015/12/05/engine- management-system-for-petrol-engines/
11 de outubro de 2016 | 22 SistemasAutomóveis Engine control – DGI computer architecture (example 1) • OEM = Renesas http://www.renesas.eu/applications/automotive/powertrain/gasoline_direct/index.jsp
11 de outubro de 2016 | 23 SistemasAutomóveis Engine control – DGI computer architecture (example 2) • OEM = Infineon http://www.infineon.com/cms/en/applications/automotive/ powertrain/gasoline-direct-injection/
11 de outubro de 2016 | 24 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection
11 de outubro de 2016 | 25 SistemasAutomóveis Fuel injection – algorithm (1) • Base fuel volume • engine RPM • engine load • Corrections • exhaust oxygen • water temp. • accelerator pedal • air temperature • air pressure • knock • voltage http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 26 SistemasAutomóveis Fuel injection – algorithm (2) • Computation of fuel injection duration (volume/mass) 1. Baseline (target) fuel volume is computed according to engine load • engine load = air mass flow divided by engine speed • > air mass flow  > injection duration 2. ECU selects closed- or open-loop mode based on throttle opening, engine speed, vehicle speed, and fuel trim and air flow maps • closed-loop: normal engine operation (A/F  14,7) • open-loop: cold engine/strong accel/desaccelation (A/F < 14,7) 3. Corrections to the target fuel volume based on several parameters (see flowchart) and an injector pulse width calculated • all these computations must be made in a few milliseconds • for an optimal (real-time) control of the engine http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 27 SistemasAutomóveis Fuel injection – algorithm (3) • Example “fuel map” (for computing the base fuel volume) • A/F ratio is optimized for best trade-off of power, fuel economy, low emissions and knock prevention • lower load & RPM  leaner mixture (A/F > 14,7) • higher load & RPM  richer mixture (A/F < 14,7) • ECU interpolates between values http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 28 SistemasAutomóveis Fuel injection – algorithm (4) • Correction according to coolant temperature • fuel vaporization gets poorer for colder engine (specially < 80 ºC) • injection duration is increased (A/F mix enrichened) for lower temperatures http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 29 SistemasAutomóveis Fuel injection – algorithm (5) • Correction according to intake air temperature • a change in air temperature changes the air density • air density varies inversely proportionally with air temperature • > temperature  < density • the colder the air, the denser it becomes (more air mass for the same air volume) • more fuel must be injected to keep the same air/fuel ratio http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 30 SistemasAutomóveis Fuel injection – algorithm (6) • Correction according to atmosferic pressure • air density varies proportionally with air pressure • > pressure  > density • air pressure varies inversely proportionally with altitude • < altitude  > pressure • lower altitude  higher density  less pressure • more fuel must be injected to keep the same air/fuel ratio http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 31 SistemasAutomóveis Fuel injection – algorithm (7) • Correction according to accelerator pedal • fuel is denser than air • thus cannot move into the cylinder as quickly during engine acceleration • so, a momentary lean condition may occur • to compensate for this, the injection duration is increased • extra injection pulses also may be delivered • Injection duration is reduced during deceleration to improve fuel economy and emissions. http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 32 SistemasAutomóveis Fuel injection – algorithm (8) • Correction according to charging system voltage • current through the injector solenoid  needle valve is pulled up • latency (dead time) between when the current starts and the valve is fully open • injector valve speed depends on applied voltage • > voltage  > current  < injector opening time • injector must be activated earlier for lower voltages and later for higher voltages • the actual opening period of the injector remains the same http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 33 SistemasAutomóveis Fuel injection – algorithm (9) • Correction according to oxygen in exhaust gases • ECU uses UO2 in a feedback (closed) loop • to restrict A/F ratio to a narrow range where catalyst is most efficient (A/F = 14.7  1%) • UO2 > 0,5 V  rich mix  reduce fuel injection • UO2 < 0,45 V  lean mix  increase fuel injection http://www.stealth316.com/2-fuelinjection.htm
11 de outubro de 2016 | 34 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position
11 de outubro de 2016 | 35 SistemasAutomóveis Idle speed and throttle control • Idle (or idling) state • an ICE is considered to be “idle” if the two following conditions apply • the throttle pedal/grip is not depressed • the engine is uncoupled to the drivetrain (either in neutral or with the clutch activated) • Idle speed • is the rotational speed of the crankshaft at idle state • usually measured in revolutions (rotations) per minute (RPM) • Idle Speed Control (ISC) (aka Idle Air Control (IAC)) • idle speed must be optimized so that 1. the engine runs smoothly (without vibrations) 2. the engine generates enough power to operate ancillary devices • alternator, A/C, water/oil pumps, power steering 3. fuel consumption is minimized (lowest RPM)
11 de outubro de 2016 | 36 SistemasAutomóveis Idle speed and throttle control • Typical idle RPM: • passenger-car = 600 – 1,000 • buses/trucks = 500 – 600 • motorcycles = 1000-1500 • Idle Speed Control can be • purely mechanical • as in carburetor-based fuel systems • ECU-based, through the control of either • bypass ISC valve (in the intake manifold) • inputting air upstream and outputting air downstream the throttle valve • throttle valve • Electronic Throttle Control (ETC), Throttle Actuator Control (TAC) or Throttle-By-Wire
11 de outubro de 2016 | 37 SistemasAutomóveis Idle speed and throttle control • Throttle (valve) • valve that controls the flow of intake air • by opening/closing of a rotating plaque (aka butterfly) • integrated in the throttle body http://mazdarx7.ugocapeto.com/Graphics/airintake.jpg http://www.acuravigorclub.com/Timely-Topics/Timely0604.htm
11 de outubro de 2016 | 38 SistemasAutomóveis Idle speed and throttle control • Bypass ISC valve (aka idle air control (IAC) valve) • controls the flow of intake air • through a bypass to the throttle • inputting air upstream the throttle • outputting air downstream the throttle • operating principles • DC motor + worm drive • step (servo) motor • solenoid valve http://www.stealth316.com/2-isc-iac.htm
11 de outubro de 2016 | 39 SistemasAutomóveis Idle speed and throttle control • Throttle (valve) • its actuation can be • purely mechanically-controlled (driven by a cable or rod) • ECU-controlled (throttle-by-wire) http://www.croberts.com/Throttle-control- system-defects.htm
11 de outubro de 2016 | 40 SistemasAutomóveis Idle speed and throttle control • Purely mechanically-controlled throttle • up to the nineties, throttle opening/closing was directly (mechanically) driven by a cable connected to the driver’s accelerator pedal/grip • driver pressing the accelerator = throttle opened • driver not pressing the accelerator = throttle closed  “idle” state • ISC is purely mechanical, via the following mechanisms • manual adjustment of air bypass (screw) • manual adjustment of throttle position (cable; stop screw) • automatic adjustment of air bypass according to coolant temperature (thermal valve) http://www.autozone.com/repairinfo/repairguide/repairGu ideContent.jsp?pageId=0900c15280088325
11 de outubro de 2016 | 41 SistemasAutomóveis Idle speed and throttle control • ECU-controlled throttle • throttle-by-wire has been emerging since the nineties • BMW was the first vehicle manufacturer to offer electronic throttle control in the 7-Series (1988) • accelerator cable gradually replaced by ECU + throttle actuator • either the driver is pressing the accelerator or not, the throttle is ALWAYS controlled by the engine’s ECU • driver not pressing the accelerator = “idle” state http://www.aa1car.com/library/throttle-by-wire.htm
11 de outubro de 2016 | 42 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure
11 de outubro de 2016 | 43 SistemasAutomóveis Fuel pump/pressure control • Efficient fuel injection requires • enough fuel flow (g/s) • adequate fuel pressure (according to engine state) • Main components • fuel pump • mechanically-driven • by the crankshaft, through gears, chains or a toothed belt (often the timing belt) • electrically-driven • controlled by the ignition switch or by the engine ECU • pressure regulator • mechanical (diaphragm-controlled, not used nowadays) • electrical (controlled by the engine ECU) • fuel rail (if applicable) • aka fuel accumulator or fuel distributor
11 de outubro de 2016 | 44 SistemasAutomóveis Fuel pump/pressure control • Fuel systems can have 1 or 2 fuel pumps • 1 pump fuel systems • low pressure (few bars) • used in ordinary SI engines (figure) • high pressure (hundreds of bars) • used in CI engines • in-line • distributor-type • common-rail http://12v.org/urs/engine_map/22618.phtml
11 de outubro de 2016 | 45 SistemasAutomóveis Fuel pump/pressure control • Fuel systems can have 1 or 2 fuel pumps • 2 pumps • primary pump (low pressure) • few bars • secondary pump (high pressure) • hundreds of bars • used in • CI unit-injector • CI common rail • SI direct injection (fig.) http://www.motonic.co.kr/eng/02_product/product04.asp?leftMenu=4
11 de outubro de 2016 | 46 SistemasAutomóveis Fuel pump/pressure control • Pressure regulators are crucial for optimizing fuel injection, and can be • purely mechanically-controlled • diaphragm-controlled, not used nowadays • guarantees a “constant” pressure differential between the fuel pressure in the accumulator and the air depression in the intake manifold • electrically-controlled • controlled by the engine ECU • enables an optimized control of the fuel pressure in the fuel accumulator, according to engine/load conditions
11 de outubro de 2016 | 47 SistemasAutomóveis Fuel pump/pressure control • Mechanically-controlled fuel pressure regulator • guarantees “constant” pressure differential between • fuel pressure (in the “rail”) and • intake air depression (intake manifold) • operation • throttle opens (left figure) 1. intake air pressure increases 2. return valve closes 3. no fuel return to tank 4. fuel pressure increases in “rail” • throttle closes (right figure) 1. intake air pressure decreases (vacuum) 2. return valve opens 3. fuel returns to tank 4. fuel pressure decreases in “rail” http://www.troublecodes.net/pcodes/p0300/ 1 bar = 14,7 PSI (average air pressure at sea level
11 de outubro de 2016 | 48 SistemasAutomóveis Fuel pump/pressure control • Mechanically-controlled fuel pressure regulator http://www.rx7club.com/single-turbo-rx-7s-23/frp-fuel-pressure-regulator-vacuum-line-why-882703/
11 de outubro de 2016 | 49 SistemasAutomóveis Fuel pump/pressure control • ECU-controlled fuel pressure regulator (CI engine) • Pressure Control Valve (PCV) https://www.dieselnet.com/tech/diesel_fi_common-rail_control.php
11 de outubro de 2016 | 50 SistemasAutomóveis Fuel pump/pressure control • ECU-controlled fuel pressure regulator (SI GDI engine) • PCV is integrated with high-pressure fuel pump http://www.slideshare.net/GLADIADORVASCO/automotive-fuel-and-emissions-control- systems-60582784
11 de outubro de 2016 | 51 SistemasAutomóveis Ignition • (ignition will be addressed in a separated module) https://autoelectricalsystems.wordpress.com/2015/12/05/engine- management-system-for-petrol-engines/
11 de outubro de 2016 | 52 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging (forced air induction)
11 de outubro de 2016 | 53 SistemasAutomóveis Supercharging • Supercharging = forced air induction • compress intake air  increase air mass (flow) • power output is increased for a given displacement and engine speed • Types • mechanically-driven –supercharger • directly driven by crankshaft (belt) • exhaust-gas-driven – turbocharger • driven by exhaust gases (turbine) • hybrid (mechanically-driven) – twin-charger • supercharger + turbocharger • hybrid (electrically-driven) – electric supercharger • electric motor/generator supporting the turbo/supercharger
11 de outubro de 2016 | 54 SistemasAutomóveis Supercharging – turbocharger • waste gate  allows exhaust air to bypass the turbine (modulated by boost controller) • pop-off valve  emergency pressure release (prevents excessive air pressure into combustion chamber) • blow-off valve  prevents back-pressure in the compressor when throttle valve is abruptly shut http://atlanticz.ca/zclub/techtips/turbo/
11 de outubro de 2016 | 55 SistemasAutomóveis Supercharging – supercharger http://www.diamondp.com/kb_results.asp?ID=8 • Driven by the crankshaft through belt + pulley • no turbo lag but requires some engine power http://www.americanmuscle.com/power-adders-for-s550-mustangs.html
11 de outubro de 2016 | 56 SistemasAutomóveis Supercharging – twin-charger • < RPM  supercharger • > RPM  turbocharger http://prettymotors.com/twincharging-engine/
11 de outubro de 2016 | 57 SistemasAutomóveis Supercharging – electric turbocharger • Series-hybrid turbocharger • turbine-motor/generator-compressor • < RPM • Battery  motor  compressor • > RPM • turbine  generator  battery • replacing the alternator? http://www.aeristech.co.uk/full-electric-turbocharger-technology/
11 de outubro de 2016 | 58 SistemasAutomóveis Supercharging – electric supercharger • Drive is fully electrical • Particularly good for low RPM • when engine power is low • Tens of kW  hundreds of A •  powerful alternator http://www.aeristech.co.uk/full-electric-turbocharger-technology/ http://blog.caranddriver.com/blowing-your-way-to-savings-how-electric-superchargers-boost-mpg/
11 de outubro de 2016 | 59 SistemasAutomóveis Supercharging – hybrid supercharging • < RPM  supercharger • > RPM  turbocharger http://www.autocar.co.uk/car-news/motoring/audi-reveals- electric-turbocharger-technology
11 de outubro de 2016 | 60 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating
11 de outubro de 2016 | 61 SistemasAutomóveis Exhaust system • Objectives • convey exhaust gases out of the engine • reduce exhaust heat, noise and pollutant emissions, affecting engine power as little as possible • Main components • exhaust manifold  to draw exhaust gases out of the cylinders • turbocharger (if applicable)  to increase engine power • catalytic converter  to reduce pollutant emissions • muffler(s)/silencer(s)  to reduce noise • exhaust pipe(s)  to link the above components in order to convey and expel gases at a convenient point in the vehicle
11 de outubro de 2016 | 62 SistemasAutomóveis Exhaust system • Exhaust system outlook – SI engine http://hdabob.com/exhaust.htm
11 de outubro de 2016 | 63 SistemasAutomóveis Exhaust gas recirculation (EGR) • recirculates part of the exhaust gases into the intake • 5-15% in SI engines • up to 50% in CI engines • EGR aim is to meet emissions standards • most ICE (SI and CI) must have EGR • some modern ICE do not need EGR • e.g. use selective catalytic reduction (SCR) to reduce NOx
11 de outubro de 2016 | 64 SistemasAutomóveis Exhaust gas recirculation (EGR) • EGR leads to • < oxygen admitted • < peak in-cylinder temperatures • < NOx emissions  • < engine power  • > particulate emissions (CI)  • NOx reduction efficiency • < for > oxygen % • a given NOx reduction requires • < EGR at high loads • > EGR at low loads https://www.dieselnet.com/tech/engine_egr_performance.php
11 de outubro de 2016 | 65 SistemasAutomóveis Exhaust gas recirculation (EGR) • EGR system can be low or high-pressure and includes • ECU-controlled EGR valve • EGR cooler (specially for SI engines) http://denso-europe.com/denso-develops-it-first-egr-cooler-for-gasoline-engines/ http://www.ni.com/white-paper/13516/en/#
11 de outubro de 2016 | 66 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating • Other subsystems controlled by the engine ECU • Radiator fan, Variable valves timing control, A/C compressor control, OBD/Check engine lamp • Sensors • Actuators
11 de outubro de 2016 | 67 SistemasAutomóveis Engine control - sensors • (sensors will be addressed in a separated module) • IG/STA switch, neutral switch, A/C switch • THW, THA, MAP, TPS • Air Flow Meter • Knock, RPM, • Crankshaft/cam shaft position • Fuel pressure/temperature • Oxygen sensors (pre/post catalyzer) • Alternator output voltage
11 de outubro de 2016 | 68 SistemasAutomóveis Engine control - actuators • (actuators will be addressed in a separated module) • Fuel pump • Radiator fan • igniters • Injectors • Throttle control • ISC • EGR control • Fuel pressure regulator • OBD/Check engine lamp • Oxygen sensors heating • Variable valves timing control • A/C compressor control

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Automotive Systems course (Module 03) - Fuel Systems in Spark Ignition Internal Combustion Engines

  • 1.
    11 de outubrode 2016 | 1 SistemasAutomóveis Fuel systems – SI engines Mário Alves (mjf@isep.ipp.pt)
  • 2.
    11 de outubrode 2016 | 2 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating • Other subsystems controlled by the engine ECU • Radiator fan, Variable valves timing control, A/C compressor control, OBD/Check engine lamp • Sensors • Actuators
  • 3.
    11 de outubrode 2016 | 3 SistemasAutomóveis • Main objective is to deliver fuel into the cylinders • at proper timings (optimizing power) • in correct amounts (for optimal A/F ratio, function of load, RPM, engine temperature,…) • in the right form (fuel atomization, for full combustion and lower emissions)
  • 4.
    11 de outubrode 2016 | 4 SistemasAutomóveis Classification of fuel systems (CI and SI) Operating principle ICE type single or multiple injectors direct/indirect injection technology Mechanical SI (single point) indirect Carburetor Diesel (multi-point) direct or indirect Injection Pump (in-line or rotary), few hundred bars Electronic SI SPI indirect in the throttle body, few bars MPI indirect Fuel rail, few bars direct Fuel rail, tens of bars Diesel (multi-point) direct Fuel-rail or pump/unit- injection, hundreds to thousands of bars
  • 5.
    11 de outubrode 2016 | 5 SistemasAutomóveis Classification of fuel systems • Fuel system types • “Mechanical” (increasingly electronically assisted) • SI – mostly used until the dawn of “electronics” (< 1960) • materialized by the “Carburetor” • CI – still in use, but gradually changing to “common rail” • materialized by the “Injection Pump” (in the figure) http://what-when-how.com/automobile/distributor-type-injection-pump-automobile/
  • 6.
    11 de outubrode 2016 | 6 SistemasAutomóveis Classification of fuel systems • Fuel system types • “Electronic” (ECU-based) • Single-Point Injection (SPI) – Figure a) • Aka “throttle-body injection” • mostly used in low-cost small-sized SI engines • Multi-Point Injection (MPI) • Indirect (external) – Figure b) • SI: injection is done upstream (the intake valves) • Diesel: injection is done in a pre-chamber • Direct (internal) – Figure c) • pressure accumulator/common-rail systems (SI + most Diesel) • pump/unit-injector systems (few Diesel) http://www.intechopen.com/books/advances-in-internal-combustion-engines-and-fuel- technologies/combustion-process-in-the-spark-ignition-engine-with-dual-injection-system
  • 7.
    11 de outubrode 2016 | 7 SistemasAutomóveis Evolution – fuel injection technology http://engineringcorner.blogspot.pt/2011/10/next-generation-engines.html
  • 8.
    11 de outubrode 2016 | 8 SistemasAutomóveis Evolution – European emission standards https://www.ngk.de/en/technology-in-detail/lambda-sensors/basic-exhaust-principles/euro-standards/
  • 9.
    11 de outubrode 2016 | 9 SistemasAutomóveis Evolution – emission reduction vs. technologies http://www.transportpolicy.net/index.php?title=EU:_Light-duty:_Emissions
  • 10.
    11 de outubrode 2016 | 10 SistemasAutomóveis Carburetor-based fuel systems • Basic carburetor operation • air is drawn into the engine by the pumping action of the pistons (vacuum) • the air accelerates as it passes through the venturi, causing a slight drop in pressure. • this pressure drop pulls fuel from the float bowl (through a nozzle) into the throttle body • it then mixes with air in a fine mist, which is distributed to the cylinders through the intake manifolds • the choke valve enables the driver to control (enrich) the mixture, at cold start http://cf.ydcdn.net/1.0.1.42/images/main/carburetor.jpg
  • 11.
    11 de outubrode 2016 | 11 SistemasAutomóveis Carburetor-based fuel systems • Main problems • Controlling fuel quantity accurately • dependent on vacuum (not on fuel injection pressure/duration) • insensitive to air temperature, pressure, humidity, engine temperature, RPM, throttle position,… • Controlling fuel quantity in real-time • delayed/reactive response • Even delivery of air/fuel mixture • across all cylinders (intake manifolds) • Hard cold-start • flooded carburetor… • Fuel consumption • 12-15 litres per 100 km was common • Pollution • high hydrocarbons in exhaust gases https://s3.amazonaws.com/lowres.cartoonstock.com/transport-carburator-carburettor-flooded- car_problems-roadside_rescue-mtun1380_low.jpg
  • 12.
    11 de outubrode 2016 | 12 SistemasAutomóveis Electronic fuel injection (EFI) systems • EFI emerged due to • stringent exhaust emission regulations • Increasing fossil fuel cost • evolution of analog/digital electronics • Basics • fuel pump compresses fuel • fuel accumulator (rail) stores fuel • electrically controlled injectors spray the fuel • into intake manifold or • combustion chamber • ECU controls injection timing/duration for optimal engine control • reduced emissions • reduced fuel consumption • maximized performance http://www.gerrysap.com/efi.html
  • 13.
    11 de outubrode 2016 | 13 SistemasAutomóveis EFI systems: Single-Point Injection (example) • Mono-Jetronic (1988–1995) • one lambda sensor • mechanical fuel pressure regulator • first generation ignition system • first generation on- board diagnosis http://www.jnc.cz/auto/monomotronic/Mono-Jetronic_blo ck_diagram.gif
  • 14.
    11 de outubrode 2016 | 14 SistemasAutomóveis EFI systems: Multi-Point Injection (example 1) • D-Jetronic (1967–1976) • "Speed-Density" fuel injection, i.e. there is no Air Flow Meter (AFM) • air-mass flow is measured indirectly, by measuring intake air pressure (3), temperature (not numbered), RPM (not in figure) and knowing cylinder volume http://www.aficionadosalamecanica.net/images-inyeccion/d-jetronic.jpg
  • 15.
    11 de outubrode 2016 | 15 SistemasAutomóveis EFI systems: Multi-Point Injection (example 2) • L-Jetronic (1974–1989) • L stands for Luft (air) flow meter (AFM) • first generation ignition • flap type AFM (11) http://www.jagweb.com/aj6eng/42efi/page1.php
  • 16.
    11 de outubrode 2016 | 16 SistemasAutomóveis EFI systems: Multi-Point Injection (example 3) • Motronic (1987-1998) • integrates injection and ignition (ECU controls both) • fuel pressure accumulator (fuel rail) • more sensors proliferate • second generation ignition system • intake air mass flow is “directly” measured by air- flow meter (12, flap type) http://www.autobinary.co.za/motronic%20(1).jpg
  • 17.
    11 de outubrode 2016 | 17 SistemasAutomóveis EFI systems: Multi-Point Injection (example 4) • Gasoline Direct Injection http://www.gasitaly.com/f5direct
  • 18.
    11 de outubrode 2016 | 18 SistemasAutomóveis EFI systems: Multi-Point Injection (example 5) • Toyota Computer- Controlled System (TCCS) • 1994 3VZ-E engine http://enginepartsdiagram.com/1994-toyota-pickup-electronic- fuel-injection-system-efi-diagram/
  • 19.
    11 de outubrode 2016 | 19 SistemasAutomóveis Fuel supply system example (E38/E39 – base for BMW 7 Series 1995-2001) http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3
  • 20.
    11 de outubrode 2016 | 20 SistemasAutomóveis Fuel supply system example (E38/E39 – base for BMW 7 Series 1995-2001) http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3 • Emphasis on the fuel tank
  • 21.
    11 de outubrode 2016 | 21 SistemasAutomóveis Engine control - fundamentals • Computer-controlled • closed loop • fault-tolerant • real-time • networked • Controls • fuel injection • ignition • ISC, EGR, … • Composed of • inputs (sensors) • outputs (actuators) • controller (ECU) • network (e.g. CAN) https://autoelectricalsystems.wordpress.com/2015/12/05/engine- management-system-for-petrol-engines/
  • 22.
    11 de outubrode 2016 | 22 SistemasAutomóveis Engine control – DGI computer architecture (example 1) • OEM = Renesas http://www.renesas.eu/applications/automotive/powertrain/gasoline_direct/index.jsp
  • 23.
    11 de outubrode 2016 | 23 SistemasAutomóveis Engine control – DGI computer architecture (example 2) • OEM = Infineon http://www.infineon.com/cms/en/applications/automotive/ powertrain/gasoline-direct-injection/
  • 24.
    11 de outubrode 2016 | 24 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection
  • 25.
    11 de outubrode 2016 | 25 SistemasAutomóveis Fuel injection – algorithm (1) • Base fuel volume • engine RPM • engine load • Corrections • exhaust oxygen • water temp. • accelerator pedal • air temperature • air pressure • knock • voltage http://www.stealth316.com/2-fuelinjection.htm
  • 26.
    11 de outubrode 2016 | 26 SistemasAutomóveis Fuel injection – algorithm (2) • Computation of fuel injection duration (volume/mass) 1. Baseline (target) fuel volume is computed according to engine load • engine load = air mass flow divided by engine speed • > air mass flow  > injection duration 2. ECU selects closed- or open-loop mode based on throttle opening, engine speed, vehicle speed, and fuel trim and air flow maps • closed-loop: normal engine operation (A/F  14,7) • open-loop: cold engine/strong accel/desaccelation (A/F < 14,7) 3. Corrections to the target fuel volume based on several parameters (see flowchart) and an injector pulse width calculated • all these computations must be made in a few milliseconds • for an optimal (real-time) control of the engine http://www.stealth316.com/2-fuelinjection.htm
  • 27.
    11 de outubrode 2016 | 27 SistemasAutomóveis Fuel injection – algorithm (3) • Example “fuel map” (for computing the base fuel volume) • A/F ratio is optimized for best trade-off of power, fuel economy, low emissions and knock prevention • lower load & RPM  leaner mixture (A/F > 14,7) • higher load & RPM  richer mixture (A/F < 14,7) • ECU interpolates between values http://www.stealth316.com/2-fuelinjection.htm
  • 28.
    11 de outubrode 2016 | 28 SistemasAutomóveis Fuel injection – algorithm (4) • Correction according to coolant temperature • fuel vaporization gets poorer for colder engine (specially < 80 ºC) • injection duration is increased (A/F mix enrichened) for lower temperatures http://www.stealth316.com/2-fuelinjection.htm
  • 29.
    11 de outubrode 2016 | 29 SistemasAutomóveis Fuel injection – algorithm (5) • Correction according to intake air temperature • a change in air temperature changes the air density • air density varies inversely proportionally with air temperature • > temperature  < density • the colder the air, the denser it becomes (more air mass for the same air volume) • more fuel must be injected to keep the same air/fuel ratio http://www.stealth316.com/2-fuelinjection.htm
  • 30.
    11 de outubrode 2016 | 30 SistemasAutomóveis Fuel injection – algorithm (6) • Correction according to atmosferic pressure • air density varies proportionally with air pressure • > pressure  > density • air pressure varies inversely proportionally with altitude • < altitude  > pressure • lower altitude  higher density  less pressure • more fuel must be injected to keep the same air/fuel ratio http://www.stealth316.com/2-fuelinjection.htm
  • 31.
    11 de outubrode 2016 | 31 SistemasAutomóveis Fuel injection – algorithm (7) • Correction according to accelerator pedal • fuel is denser than air • thus cannot move into the cylinder as quickly during engine acceleration • so, a momentary lean condition may occur • to compensate for this, the injection duration is increased • extra injection pulses also may be delivered • Injection duration is reduced during deceleration to improve fuel economy and emissions. http://www.stealth316.com/2-fuelinjection.htm
  • 32.
    11 de outubrode 2016 | 32 SistemasAutomóveis Fuel injection – algorithm (8) • Correction according to charging system voltage • current through the injector solenoid  needle valve is pulled up • latency (dead time) between when the current starts and the valve is fully open • injector valve speed depends on applied voltage • > voltage  > current  < injector opening time • injector must be activated earlier for lower voltages and later for higher voltages • the actual opening period of the injector remains the same http://www.stealth316.com/2-fuelinjection.htm
  • 33.
    11 de outubrode 2016 | 33 SistemasAutomóveis Fuel injection – algorithm (9) • Correction according to oxygen in exhaust gases • ECU uses UO2 in a feedback (closed) loop • to restrict A/F ratio to a narrow range where catalyst is most efficient (A/F = 14.7  1%) • UO2 > 0,5 V  rich mix  reduce fuel injection • UO2 < 0,45 V  lean mix  increase fuel injection http://www.stealth316.com/2-fuelinjection.htm
  • 34.
    11 de outubrode 2016 | 34 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position
  • 35.
    11 de outubrode 2016 | 35 SistemasAutomóveis Idle speed and throttle control • Idle (or idling) state • an ICE is considered to be “idle” if the two following conditions apply • the throttle pedal/grip is not depressed • the engine is uncoupled to the drivetrain (either in neutral or with the clutch activated) • Idle speed • is the rotational speed of the crankshaft at idle state • usually measured in revolutions (rotations) per minute (RPM) • Idle Speed Control (ISC) (aka Idle Air Control (IAC)) • idle speed must be optimized so that 1. the engine runs smoothly (without vibrations) 2. the engine generates enough power to operate ancillary devices • alternator, A/C, water/oil pumps, power steering 3. fuel consumption is minimized (lowest RPM)
  • 36.
    11 de outubrode 2016 | 36 SistemasAutomóveis Idle speed and throttle control • Typical idle RPM: • passenger-car = 600 – 1,000 • buses/trucks = 500 – 600 • motorcycles = 1000-1500 • Idle Speed Control can be • purely mechanical • as in carburetor-based fuel systems • ECU-based, through the control of either • bypass ISC valve (in the intake manifold) • inputting air upstream and outputting air downstream the throttle valve • throttle valve • Electronic Throttle Control (ETC), Throttle Actuator Control (TAC) or Throttle-By-Wire
  • 37.
    11 de outubrode 2016 | 37 SistemasAutomóveis Idle speed and throttle control • Throttle (valve) • valve that controls the flow of intake air • by opening/closing of a rotating plaque (aka butterfly) • integrated in the throttle body http://mazdarx7.ugocapeto.com/Graphics/airintake.jpg http://www.acuravigorclub.com/Timely-Topics/Timely0604.htm
  • 38.
    11 de outubrode 2016 | 38 SistemasAutomóveis Idle speed and throttle control • Bypass ISC valve (aka idle air control (IAC) valve) • controls the flow of intake air • through a bypass to the throttle • inputting air upstream the throttle • outputting air downstream the throttle • operating principles • DC motor + worm drive • step (servo) motor • solenoid valve http://www.stealth316.com/2-isc-iac.htm
  • 39.
    11 de outubrode 2016 | 39 SistemasAutomóveis Idle speed and throttle control • Throttle (valve) • its actuation can be • purely mechanically-controlled (driven by a cable or rod) • ECU-controlled (throttle-by-wire) http://www.croberts.com/Throttle-control- system-defects.htm
  • 40.
    11 de outubrode 2016 | 40 SistemasAutomóveis Idle speed and throttle control • Purely mechanically-controlled throttle • up to the nineties, throttle opening/closing was directly (mechanically) driven by a cable connected to the driver’s accelerator pedal/grip • driver pressing the accelerator = throttle opened • driver not pressing the accelerator = throttle closed  “idle” state • ISC is purely mechanical, via the following mechanisms • manual adjustment of air bypass (screw) • manual adjustment of throttle position (cable; stop screw) • automatic adjustment of air bypass according to coolant temperature (thermal valve) http://www.autozone.com/repairinfo/repairguide/repairGu ideContent.jsp?pageId=0900c15280088325
  • 41.
    11 de outubrode 2016 | 41 SistemasAutomóveis Idle speed and throttle control • ECU-controlled throttle • throttle-by-wire has been emerging since the nineties • BMW was the first vehicle manufacturer to offer electronic throttle control in the 7-Series (1988) • accelerator cable gradually replaced by ECU + throttle actuator • either the driver is pressing the accelerator or not, the throttle is ALWAYS controlled by the engine’s ECU • driver not pressing the accelerator = “idle” state http://www.aa1car.com/library/throttle-by-wire.htm
  • 42.
    11 de outubrode 2016 | 42 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure
  • 43.
    11 de outubrode 2016 | 43 SistemasAutomóveis Fuel pump/pressure control • Efficient fuel injection requires • enough fuel flow (g/s) • adequate fuel pressure (according to engine state) • Main components • fuel pump • mechanically-driven • by the crankshaft, through gears, chains or a toothed belt (often the timing belt) • electrically-driven • controlled by the ignition switch or by the engine ECU • pressure regulator • mechanical (diaphragm-controlled, not used nowadays) • electrical (controlled by the engine ECU) • fuel rail (if applicable) • aka fuel accumulator or fuel distributor
  • 44.
    11 de outubrode 2016 | 44 SistemasAutomóveis Fuel pump/pressure control • Fuel systems can have 1 or 2 fuel pumps • 1 pump fuel systems • low pressure (few bars) • used in ordinary SI engines (figure) • high pressure (hundreds of bars) • used in CI engines • in-line • distributor-type • common-rail http://12v.org/urs/engine_map/22618.phtml
  • 45.
    11 de outubrode 2016 | 45 SistemasAutomóveis Fuel pump/pressure control • Fuel systems can have 1 or 2 fuel pumps • 2 pumps • primary pump (low pressure) • few bars • secondary pump (high pressure) • hundreds of bars • used in • CI unit-injector • CI common rail • SI direct injection (fig.) http://www.motonic.co.kr/eng/02_product/product04.asp?leftMenu=4
  • 46.
    11 de outubrode 2016 | 46 SistemasAutomóveis Fuel pump/pressure control • Pressure regulators are crucial for optimizing fuel injection, and can be • purely mechanically-controlled • diaphragm-controlled, not used nowadays • guarantees a “constant” pressure differential between the fuel pressure in the accumulator and the air depression in the intake manifold • electrically-controlled • controlled by the engine ECU • enables an optimized control of the fuel pressure in the fuel accumulator, according to engine/load conditions
  • 47.
    11 de outubrode 2016 | 47 SistemasAutomóveis Fuel pump/pressure control • Mechanically-controlled fuel pressure regulator • guarantees “constant” pressure differential between • fuel pressure (in the “rail”) and • intake air depression (intake manifold) • operation • throttle opens (left figure) 1. intake air pressure increases 2. return valve closes 3. no fuel return to tank 4. fuel pressure increases in “rail” • throttle closes (right figure) 1. intake air pressure decreases (vacuum) 2. return valve opens 3. fuel returns to tank 4. fuel pressure decreases in “rail” http://www.troublecodes.net/pcodes/p0300/ 1 bar = 14,7 PSI (average air pressure at sea level
  • 48.
    11 de outubrode 2016 | 48 SistemasAutomóveis Fuel pump/pressure control • Mechanically-controlled fuel pressure regulator http://www.rx7club.com/single-turbo-rx-7s-23/frp-fuel-pressure-regulator-vacuum-line-why-882703/
  • 49.
    11 de outubrode 2016 | 49 SistemasAutomóveis Fuel pump/pressure control • ECU-controlled fuel pressure regulator (CI engine) • Pressure Control Valve (PCV) https://www.dieselnet.com/tech/diesel_fi_common-rail_control.php
  • 50.
    11 de outubrode 2016 | 50 SistemasAutomóveis Fuel pump/pressure control • ECU-controlled fuel pressure regulator (SI GDI engine) • PCV is integrated with high-pressure fuel pump http://www.slideshare.net/GLADIADORVASCO/automotive-fuel-and-emissions-control- systems-60582784
  • 51.
    11 de outubrode 2016 | 51 SistemasAutomóveis Ignition • (ignition will be addressed in a separated module) https://autoelectricalsystems.wordpress.com/2015/12/05/engine- management-system-for-petrol-engines/
  • 52.
    11 de outubrode 2016 | 52 SistemasAutomóveis Outline • Fuel systems classification • SI fuel systems evolution • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging (forced air induction)
  • 53.
    11 de outubrode 2016 | 53 SistemasAutomóveis Supercharging • Supercharging = forced air induction • compress intake air  increase air mass (flow) • power output is increased for a given displacement and engine speed • Types • mechanically-driven –supercharger • directly driven by crankshaft (belt) • exhaust-gas-driven – turbocharger • driven by exhaust gases (turbine) • hybrid (mechanically-driven) – twin-charger • supercharger + turbocharger • hybrid (electrically-driven) – electric supercharger • electric motor/generator supporting the turbo/supercharger
  • 54.
    11 de outubrode 2016 | 54 SistemasAutomóveis Supercharging – turbocharger • waste gate  allows exhaust air to bypass the turbine (modulated by boost controller) • pop-off valve  emergency pressure release (prevents excessive air pressure into combustion chamber) • blow-off valve  prevents back-pressure in the compressor when throttle valve is abruptly shut http://atlanticz.ca/zclub/techtips/turbo/
  • 55.
    11 de outubrode 2016 | 55 SistemasAutomóveis Supercharging – supercharger http://www.diamondp.com/kb_results.asp?ID=8 • Driven by the crankshaft through belt + pulley • no turbo lag but requires some engine power http://www.americanmuscle.com/power-adders-for-s550-mustangs.html
  • 56.
    11 de outubrode 2016 | 56 SistemasAutomóveis Supercharging – twin-charger • < RPM  supercharger • > RPM  turbocharger http://prettymotors.com/twincharging-engine/
  • 57.
    11 de outubrode 2016 | 57 SistemasAutomóveis Supercharging – electric turbocharger • Series-hybrid turbocharger • turbine-motor/generator-compressor • < RPM • Battery  motor  compressor • > RPM • turbine  generator  battery • replacing the alternator? http://www.aeristech.co.uk/full-electric-turbocharger-technology/
  • 58.
    11 de outubrode 2016 | 58 SistemasAutomóveis Supercharging – electric supercharger • Drive is fully electrical • Particularly good for low RPM • when engine power is low • Tens of kW  hundreds of A •  powerful alternator http://www.aeristech.co.uk/full-electric-turbocharger-technology/ http://blog.caranddriver.com/blowing-your-way-to-savings-how-electric-superchargers-boost-mpg/
  • 59.
    11 de outubrode 2016 | 59 SistemasAutomóveis Supercharging – hybrid supercharging • < RPM  supercharger • > RPM  turbocharger http://www.autocar.co.uk/car-news/motoring/audi-reveals- electric-turbocharger-technology
  • 60.
    11 de outubrode 2016 | 60 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating
  • 61.
    11 de outubrode 2016 | 61 SistemasAutomóveis Exhaust system • Objectives • convey exhaust gases out of the engine • reduce exhaust heat, noise and pollutant emissions, affecting engine power as little as possible • Main components • exhaust manifold  to draw exhaust gases out of the cylinders • turbocharger (if applicable)  to increase engine power • catalytic converter  to reduce pollutant emissions • muffler(s)/silencer(s)  to reduce noise • exhaust pipe(s)  to link the above components in order to convey and expel gases at a convenient point in the vehicle
  • 62.
    11 de outubrode 2016 | 62 SistemasAutomóveis Exhaust system • Exhaust system outlook – SI engine http://hdabob.com/exhaust.htm
  • 63.
    11 de outubrode 2016 | 63 SistemasAutomóveis Exhaust gas recirculation (EGR) • recirculates part of the exhaust gases into the intake • 5-15% in SI engines • up to 50% in CI engines • EGR aim is to meet emissions standards • most ICE (SI and CI) must have EGR • some modern ICE do not need EGR • e.g. use selective catalytic reduction (SCR) to reduce NOx
  • 64.
    11 de outubrode 2016 | 64 SistemasAutomóveis Exhaust gas recirculation (EGR) • EGR leads to • < oxygen admitted • < peak in-cylinder temperatures • < NOx emissions  • < engine power  • > particulate emissions (CI)  • NOx reduction efficiency • < for > oxygen % • a given NOx reduction requires • < EGR at high loads • > EGR at low loads https://www.dieselnet.com/tech/engine_egr_performance.php
  • 65.
    11 de outubrode 2016 | 65 SistemasAutomóveis Exhaust gas recirculation (EGR) • EGR system can be low or high-pressure and includes • ECU-controlled EGR valve • EGR cooler (specially for SI engines) http://denso-europe.com/denso-develops-it-first-egr-cooler-for-gasoline-engines/ http://www.ni.com/white-paper/13516/en/#
  • 66.
    11 de outubrode 2016 | 66 SistemasAutomóveis Outline • Objective of fuel systems • Classification of fuel systems • Evolution – technology, regulations • Carburetor-based fuel systems • Electronic Fuel Injection (EFI) systems • Engine control – fundamentals • Air/fuel mixture and combustion control subsystems • Injection, idle speed and throttle position, fuel pump/pressure, ignition, supercharging • Exhaust subsystem • exhaust, EGR, oxygen sensors heating • Other subsystems controlled by the engine ECU • Radiator fan, Variable valves timing control, A/C compressor control, OBD/Check engine lamp • Sensors • Actuators
  • 67.
    11 de outubrode 2016 | 67 SistemasAutomóveis Engine control - sensors • (sensors will be addressed in a separated module) • IG/STA switch, neutral switch, A/C switch • THW, THA, MAP, TPS • Air Flow Meter • Knock, RPM, • Crankshaft/cam shaft position • Fuel pressure/temperature • Oxygen sensors (pre/post catalyzer) • Alternator output voltage
  • 68.
    11 de outubrode 2016 | 68 SistemasAutomóveis Engine control - actuators • (actuators will be addressed in a separated module) • Fuel pump • Radiator fan • igniters • Injectors • Throttle control • ISC • EGR control • Fuel pressure regulator • OBD/Check engine lamp • Oxygen sensors heating • Variable valves timing control • A/C compressor control