This document provides information about common rail diesel injection systems. It discusses the components of a common rail system including the high pressure fuel pump, fuel rail, injectors, and engine control unit. It explains how these components work together under electronic control to precisely inject fuel into the engine cylinders. The document also covers the construction, working, advantages and disadvantages of common rail systems compared to conventional diesel injection systems. It provides details on piezoelectric injectors and the optimization of these injectors. Overall, the document presents an overview of common rail diesel injection technology.

1. VISHWAKARMA INSTITUTE OF TECHNOLOGY
COMMON RAIL DISEL INJECTION SYSTEM
Guidance:- Prof. Dr. D. B. Hulwan Sir
Subject:- Hybrid And Electric Vehicles
1
Sr No Name of Student Roll No. Gr. No.
1 Neha Deshpande 59 11920077
2 Shubham Deshtwad 61 11810380
3 Prajwal Dhore 63 11810226
4 Vaishnavi Dudhade 68 11920078
5 Furqan Gadwal 70 11920194

2. INTRODUCTION
 CRDI stands for Common Rail Direct Injection.
 The common rail system prototype was developed in the 1960s by Robert
Huber of Switzerland.
 CRDI means direct injection of the fuel into the cylinder of diesel engine
via a single, common line, called common rail which is connected to all
the fuel injectors.
2

3. OPERATING PRINCIPLE
The solenoid or piezoelectric valves make possible fine
electronic control over the fuel injection time and quantity.
The higher pressure that the common rail technology
provides better fuel atomisation.
The engine electronic control unit can inject a small of
diesel just before the main injection event by using sensor.
3

4. COMPONENTS OF CRDI
High Pressure Fuel Pump
Fuel Tank
Fuel Filter
Common Fuel Rail
Injectors
Engine Control Unit
4

5. IMPORTANT COPMPONENTS
ECU Fuel Injector
Fuel Filter High Pressure Pump
5

6. CONSTRUCTION
6

7. WORKING
7

8. MANUFACTURING PROCESS
3D Model
Manufacturing Drawings
Assembly in Solid works
Procurement Of Parts
Injector Body Machining on CNC
Testing and Quality Control of Individual Parts
Assembly
Testing of final Assembly
8

9. ADVANCED CONTROL FUNCTIONS
Injector Quantity Adjustment
Pressure Wave Correction
Fuel Mean Value Adaption
Fuel Balance Control
Zero Fuel Calibration
Combustion Signal Based Control
9

10. TRENDS IN DIESEL COMMON RAIL INJECTION
SYSTEM: INJECTORS
Piezo-Injector with Coaxial-
Vario-Nozzle
Hydraulically Amplified
Diesel Injector
10

11. DESIGN OPTIMIZATION OF PIEZO-ELECTRIC
OPERATED FUEL INJECTORS
• Effect of spring characteristics on fuel injectors.
• Material used is ‘Hard drawn steel wire C’-High Carbon steel.
• Optimized spring design:
For engine speed:1200 rpm
Compression ratio:18
Thickness:0.8mm
Outerdiameter:4.8mm
Length:5.6mm
11

12. ADVANTAGES OF PIEZOELECTRIC OPERATED
FUEL INJECTOR OVER SOLENOID OPERATED:
More fuel can be sprayed in one cycle than solenoid operated in
which max 3 time per stroke can be achieved.
Very high responsiveness of actuator & hence precise & accurate
injection control.
High combustion efficiency.
It provides feedback of minute fluctuations to ECU.
LIMITATIONS:
Expensive, hence not used in all vehicles.
Limited load bearing capacity of piezoelectric material due to more
dynamic loads.
12

13. MANUFACTURERS OF CRDI FUEL INJECTORS:
1. Bosch-Solenoid & Piezoelectric operated.
2. Delphi-Solenoid & Piezoelectric operated.
3. Denso-Solenoid & Piezoelectric operated.
4. Siemens-Piezoelectric operated.
CARS USING PIEZO-ELECTRIC OPERATED FUEL
INJECTORS:
1. Ford Figo.
2. Ford Fiesta.
3. Renault Duster.
4. Toyota Etios.
5. Most high performance cars.
13

14. ADVANTAGES
Enhances the power and performance of
engine.
Air mixes very uniformly with fuel.
Reduces noise and vibrations drastically.
Minimum wastage of fuel.
Maximum torque and power output.
14

15. DISADVANTAGES
CRDi system is very complex and needs good kind
of skilled engineering work.
Can’t be used in all kinds of engines.
Cost of the spare parts is very high.
It demands very costly maintenance.
15

16. CONCLUSION
Crdi engines no doubt costlier engines ,but saving
in the fuel can neutralize the cost of technology in
long run.
If one is buying a car with the CRDi engine , he or she
must keep in mind the that for what purpose he or she is
buying the car as it requires high maintenance cost.
16

17. REFERENCES
https://carbiketech.com/wp-
content/uploads/2014/07/ECU-Crankit-01.jpeg
Ganesan- Internal Combustion Engine Book
https://www.youtube.com/watch?v=5AQ07-LF5JA
17

18. THANK YOU
18