The document discusses the Common Rail System (CRS) for diesel engines, outlining its technological advancements, benefits, and applications. Key drivers for the development include emission regulations, fuel economy, and engine reliability. The CRS offers flexibility in injection timing and pressure, enhancing engine performance and compliance with emission standards.

1. COMMON RAIL SYSTEM (CRS)
FOR DIESEL ENGINES
By : Dr.K.C.VORA
SR. ASST. DIRECTOR
ENGINE DEVELOPMENT LABORATORY
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2. CONTENTS
Introduction
System types & Generation
Common Rail & emission strategy
System Validation & tests
Project milestones
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3. INTRODUCTION
TECHNOLOGY DRIVERS
• Emission regulations (Exhaust gas and
Noise)
• Further fuel economy improvements
• Further improvements in
- Reliability
- Durability of engine/vehicles
• Competitive costs and prices
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4. Cam driven FIE
Pressure generation and injection are coupled
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5. ENGINE DEVELOPMENT LABORATORY
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6. Common Rail & EDC FIP
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7. ENGINE DEVELOPMENT LABORATORY
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8. TECHNOLOGY DRIVERS-EMISSION
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9. TECHNOLOGY DEMANDS ON FIE
• High pressure potential (> 2000 bars)
• Realisation of the “ideal” rate of injection via pressure modulation
alone
• Capability of realising staged (boot) as well as pilot injection
where pilot is separated from the main injection
• Flexibility of selecting start of injection as well as end of injection
• Moderate initial rise of main injection
• Sharp cut off of the injection end
• Flexibility of selecting peak injection pressure
• Provide option to automatically change rate shape according to
engine speed and load
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10. Common Rail System
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11. Common Rail System
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12. Common Rail System
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13. Common Rail System
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14. Common Rail System
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15. ENGINE DEVELOPMENT LABORATORY
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16. ENGINE DEVELOPMENT LABORATORY
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17. Common Rail System
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18. ENGINE DEVELOPMENT LABORATORY
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19. ELECTRONIC DIESEL CONTROL
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20. CRS- ELECTRONIC CONTROL UNIT (ECU)
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21. CRS- ELECTRONIC CONTROL UNIT (ECU)
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22. CRS- ELECTRONIC CONTROL UNIT (ECU)
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23. CRS- ELECTRONIC CONTROL UNIT (ECU)
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24. CRS- ELECTRONIC CONTROL UNIT (ECU)
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25. CRS- ELECTRONIC CONTROL UNIT (ECU)
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26. CRS- ELECTRONIC CONTROL UNIT (ECU)
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27. CRS- ELECTRONIC CONTROL UNIT (ECU)
150mm from ECU
4 Plane screwing points
< 60 C
Away from water splash
Away from battery
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28. EDC Sensors
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29. EDC Sensors
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30. Orientation on CRS Component - Common
Rail
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31. Orientation on CRS Component - Common
Rail
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32. Common Rail System
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33. CRS ADVANTAGES
• Separation of pressure generation and injection allowing flexibility
in controlling both the injection rates and timing.
• Fuel pressure does not depend on the engine speed and load
conditions
(This feature differentiates the common rail from conventional
injection systems)
• High injection pressures and good spray preparations are possible
even at low engine speeds and loads.
• Capability to deliver stable, small pilot injections can be used for
decreased NOx emissions and noise.
• Option for post injections may be used together with such emission
control technologies as particulate filters, lean NOx catalysts, or NOx
adsorbers.
• Fuel pump operates with low drive torque.
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34. CONTENTS
Introduction completed.
System types & Generation
Common Rail & emission strategy
System Validation & tests
Project milestones
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35. SYSTEM TYPES
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36. SYSTEM TYPES
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37. Common Rail System – 1600bar
With CP1H, Gear pump (feed), Metering unit, Injector, Rail,
ECU
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38. Common Rail System – 1600bar
With CP1H, Gear pump (feed), Metering unit, Injector, Rail,
ECU
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39. COMMON RAIL SYSTEM-
COMMERCIAL VEHICLE (CRSN)
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40. CRS System for off highway applications- Basic
system
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41. CRS System for off highway applications- Basic
system
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42. System Components : CRS
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43. System Management
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44. Theory 1: Introduction to Common Rail
System
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45. Common Rail System & emission
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46. Common Rail System & emission
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47. Theory 1: Introduction to Common Rail System
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48. ENGINE DEVELOPMENT LABORATORY
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49. Common Rail System
Load Collective measurements
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50. Theory 1: Introduction to Common Rail System
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51. Project mile stones
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52. ENGINE DEVELOPMENT LABORATORY
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53. Common Rail System & Diagnosis
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54. ENGINE DEVELOPMENT LABORATORY
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55. Common Rail System & Fuel
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56. CONCLUSION
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57. ENGINE DEVELOPMENT LABORATORY
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