1.

ELECTRONIC INJECTION SYSTEMS

In carburettor engine, uniformity of mixture strength is difficult to realize in each cylinder of a multicylinder engine Fig 10.1 maldistribution

Injection system instead of carburetion

To have uniform distribution of fuel in multi cylinder engine To improve breathing capacity ie Volumetric efficiency To reduce or eliminate detonation To prevent fuel loss during scavenging in case of two stroke engine

Types of Injection Systems - Classification

Gasoline direct injection into the cylinder GDI i. ii. Manifold injection Port Injection a. Continuous and b. Timed

The above fuel injection systems can be grouped under

Single - point or Throttle body injection system and Multi point or Port injection

Single - point or Throttle body injection system

One or two injectors mounted inside throttle body assembly Fuel spray directed at one point or at the center of the intake manifold

Multi point or Port injection

One injector for each cylinder

Fuel is injected in more than one location commonly used

a.

Continuous fuel injection system

Rotary pump injects fuel through a nozzle located in the manifold immediately down stream of the throttle plate at a gauge pressure of 0.75 to 1.5 bar In a super charged engine, fuel is injected at the entrance of the supercharger The timing and duration of the injection is determined by the Electronic Control Unit (ECU) depending on the load and speed

b.

Timed fuel injection system

Fuel pump injects fuel through nozzle in the manifold or the cylinder head port at about 6.5 bar or into combustion chamber at about 16 to 35 bar Injects fuel usually during early part of suction stroke Direct in cylinder injection is superior always desirable and better compared to the manifold injection but causes oil dilution Both low and high volatile fuels can be used with high volumetric efficiency

Components of Injection system Objectives

Meter Atomize Uniformly distribute the fuel throughout the air mass in the cylider Must maintain the required A/F ratio as per the load speed requirement of the engine Pumping element from fuel tank to injector through pipes and filter Metering Element Measures and supplies fuel at the rate determined by load and speed conditions of engine Mixing Element Atomize the fuel and mixes it with air to form a homogenous mixture Metering Control Adjust the metering in accordance with load and speed conditions of the engine Mixing Control adjusts the fuel air ratio as demanded by the load and speed conditions of the engine

Distributing Element Divides the metered fuel equally among the cylinders Timing Control - Fixes the start and stop of the fuel air mixing process Ambient control Compenstas for changes in T and P of either air or fuel that may affect the various elements of the system

2.

ELECTRONIC FUEL INJECTION SYSTEM

Modern gasoline injection sytem use engine sensors, a computer and solinoid operated fuel injectors to meter and inject the right amount of fuel These systems called electronic fuel injection (EFI) use elctrical and electronic devices to monitor and control engine operation An electronic control unit (ECU) receives elctrical signals in the form of current or voltage from various sensors It then uses the stored data to give necessary commands to the injectors, ignition system and other engine related devices As a result the vehicle gives better milage

Typical Sensors for an EFI system

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Exhaust Gas or Oxygen Sensor calculates the air fuel ratio changes in proportion Engine Temperature Sensor senses the engine coolent temperature adjust the mixture strength to rich side for cold starting Air flow sensor Monitors mass or volume of air flowing into the intake manifold for adjusting the quantity of fuel Air Inlet Temperature Sensor Cheks the temperature of the ambient air entering the engine for fine tuning the mixture strength Throttle Position Sensor Senses the movement of the throttle plate so that the mixture flow can be adjusted for engine speed and acceleration Manifold Pressure Sensor Monitors vacuum in the engine intake manifold so that the mixture strength can be adjusted with changes in engine load Camshaft Possition Sensor Senses the rotation of the camshaft / crank shaft for speed and timing of injection Knock Sensor Microphone type sensor that detects ping or preignition noise so that the engine timing can be retarded

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Merits of EFI System

Improvement in volumetric efficiency due to less resistance in intake manifold eliminates pressure loss in carburettor and manifold heating Manifold wetting is eleminated fuel being injected into or close to the cylinder

Atomization is independent of cranking speed and hence starting will be easier Better atomization and vaporisation will make the engine less knock prone Ice formation of on throttle plate is completely eliminated Less volatile fuel can be used since distribution of fuel is independent of vaporisation Variation of air fuel ratio almost negligible during turing travelling in grades and in uneven roads etc Position of the injection unit is not so critical and thereby the height of the engine may be less

Demerits of EFI System

High maintenance cost Difficulty in servicing Possibility of malfunction of some sensors

Multi Point Fuel Injection (MPFI) System

a. b. Port injection Throttle body injection

a.

Port injection
Injector placed on the side of the intake manifold fig 10.3 - sprays fuel into the air inside the intake manifold Fig 10.4 MPFI system each cylinder will have an injector

b.

Throttle body injection

Fig 10.5 - Injector placed slightly above the throat of the throttle body

Injector spray the fuel into the air near the throat of the throttle body

Timed / Continuous Injection System (for both a & b)

In the timed injection system fuel is sprayed from injector in pulses In continuous injection system fuel is sprayed

continuously from the injectors

MPFI System : Classified as D-MPFI and L-MPFI D-MPFI System

Fig 10.6 manifold fuel injection system First vacuum is sensed followed by volume of air by its density

As air enters into the intake manifold, the manifold pressure sensor detects the intake manifold vacuum and sends the information to ECU The speed sensor also sends information about the rpm of the engine to the ECU The ECU in turn sends commands to the injector to regulate the amount of fuel supply for injection When the injector sprays fuel in the intake manifold the fuel mixes with air and the mixture enters the cylinder

L-MPFI System

Fig 10.7 port fuel injection system also called air mass metering or air flow metering In this type the fuel metering is regulated by the engine speed and the amount of Air that actually enters the engine

a.

Functional Divisions of MPFI System

Electronic Control system

b. c.

Fuel System Air Induction System

a.

MPFI - Electronic Control System

Fig 10.8 Sensors that monitor : intake air temperature, air flow, oxygen, water temperature, the starter signals, throttle position, engine speed sensors sends information signals to ECU The ECU in turn sends commands to the injector to regulate the amount of fuel supply for injection

b.

MPFI Fuel System

Fig 10.9 At the time of starting the cold start injector is operated by the cold start injector time switch The cold start injector injects fuel into the air intake chamber, thus enriching the air-fuel mixture

The pressure regulator regulates the pressure of the fuel The injectors receive signals from the ECU and inject the fuel into the intake manifold

c.

MPFI Air Induction System

Fig 10.10 Air cleaner, air flow meter, throttle body and air valve supply a proper amount of air to the air intake chamber / intake manifold The quantity of air supplied is just what is necessary for complete combustion

Electronic Control System

It mainly consists a. ECU which determines the duration of operation of the injectors b. Cold start injector - to control its operation c. Starter timing switch Circuit opening relay to control fuel pump operation Resistor to stabilize the injector operation

a.

Electronic Control Unit (ECU)

ECU in the electric control system receives signals from the sensors and determines the opening time for the injectors which also controls the injection volume

b.

Cold Start Injector

Fig 10.11 Cold start injector serves the purpose of supplying more fuel at the time of starting a type of solenoid valve

c.

Timing switch
Duration of injection time is controlled by a timing switch The main injector also supplies fuel at the same time

When the engine is hot, the cold start injector will stop injection

Air Valve
The position of air valve - Fig 10.11 for cold engine When T is low the air valve opens completely As the temperature rises, the air valve closes gradually During normal operating T, air valve closes completely

Injection Timing
According to the firing order, the injection of fuel takes place inside the inlet manifold at various timings The ECU calculates the approximate injection timing for each cylinder and the air fuel mixture is made available at each suction stroke To meet the operating conditions, the injection valve is kept open for a longer time by ECU

3.

GROUP GASOLINE INJECTION SYSTEM

Fig 10.12 shows a block diagram with sensors & ECU for a group injection system

In an engine having group injection system, the injectors are not activated individually, but are activated in groups In six cylinder engine there are two groups each group having 3 injector The timing of injectors is decided by engine speed sensor Based on the signals from the speed sensor, the ECU activates one group of injectors Subsequently the ECU activates other group of injectors Fig 10.13 Injector grouping for six cylinder engine

Injectors for cylinders 1, 3 and 5 open at the same time and inject the fuel into the intake manifold After these injectors close, the injectors for the cylinders 2, 4 and 6 open and inject fuel

Fig 10.14 shows port injection using electronic group fuel injection system for an eight cylinder engine Eight injectors are divided into two groups having four each

4.

ELECTRONIC DIESEL INJECTION SYSTEM

For an engine to operate at high efficiency and low emission levels the parameters to be precisely controlled with injection pump are Timing Rate of injection End of injection Quantity of injected fuel

Precise control can be achieved by means of EFI system

Injection timing Fuel injection quantity Injection rate during various stages of Injection Injection pressure during Injection Nozzle operating speed and Pilot Injection timing and its quantity

The following are easy to obtain with EFI systems

Very high Injection pressure Sharp start and stop of Injection Cylinder cut off Diagnostic capability Turbocharger control and Two stage injection

Electronic Diesel Injection Control There are various versions of electronically controlled
diesel fuel injection systems a. b. c. Electronically controlled Injection pumps (Inline and Distributor type) Electronically controlled unit Injectors Common rail fuel injection system

a.

Electronically controlled diesel fuel injection systems may use the following as inputs o o o o o o o o Engine Speed Crank shaft position Accelerator pedal position Intake air temperature Lubricating oil Temperature Ambient air Temperature Turbocharger boost Temperature Intake air mass flow rate

Electronically Controlled Unit Injectors

Fig 10.15 shows schematic layout of entire system

Unit injectors can be combination of high pressure pumps and injectors in one unit do not have high pressure pipe lines and hence the injection lag is low

The main high pressure pump is situated above injector A simplified cross section of the unit injector and phases of injection are shown in Fig 10.16 The fuel pushed down by the injector just by passes the injection nozzle till the solenoid controlled spill valve closes the spill port The closure of the spill port iniates the injection process The injection stops when the solenoid valve opens the spill port The ECU generates the pulses to operate the solenoid controlled spill valve

Electronically Controlled Injection Pumps (Inline and Distributor Type)

In the case of the electronically controlled there will be a control sleeve which can be moved up and down by an actuator which is controlled by the ECU The ECU determines the amount of fuel based different parameters Fig 10.17 shows schematic block diagram of an electronically controlled inline fuel injection system

ECU determines correct quantity of the fuel to be injected based on the inputs and the data in the look up table

ECU can also regulate the fuel quantity depending on other conditions like braking ECU also protects the engine against over heating by regulating the maximum quantity of fuel delivered

Common Rail Fuel Injection System

The common rail fuel injection system is finding increasing use in diesel engines as it has the potential to drastically cut emissions and fuel consumption This system provides control of many important parameters linked to the injected system It has a wide range of applications: some important features are: Very high injection pressures of the order of 1500 bar Complete control over start, and end of injection Injection pressure is independent of engine speed Ability to have pilot, main and post injection Variable injection pressure

Fig 10.18 shows a typical layout of the common rail fuel injection system

Fig 10.18. Sensors of a Common Rail Injection System, together with Various System Components

1.

ELECTRONIC INJECTION SYSTEMS

Injection system instead of carburetion Types of Injection Systems - Classification Components of Injection system

2. ELECTRONIC FUEL INJECTION SYSTEM

Typical Sensors for an EFI system

Merits of EFI System Demerits of EFI System Multi Point Fuel Injection (MPFI) System Timed / Continuous Injection System (for both a & b) MPFI System : Classified as D-MPFI and L-MPFI Functional Divisions of MPFI System Electronic Control System Electronic Control Unit (ECU)

3. 4.

GROUP GASOLINE INJECTION SYSTEM ELECTRONIC DIESEL INJECTION SYSTEM

Electronic Diesel Injection Control Electronically Controlled Unit Injectors Electronically Controlled Injection Pumps (Inline and Common Rail Fuel Injection System