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Increasing decentralization of production combined with just-in-time delivery of products and components calls for a flexible and reliable transportation system. So far, trucks offer the most versatile and efficient solution to those problems. In consideration of increasingly strict emission standards and customer demands for more engine power and less fuel consumption, further selective developments and optimization of DI-diesel engines are necessary. One step in this direction is the application of 4 valves per cylinder in heavy-duty diesel engines to improve mixture formation of fuel and air to get a cleaner combustion and a higher power output. For visualizing the combustion processes inside the engine, an optically accessible heavy-duty DI-diesel engine was used. This engine is a slightly modified conventional heavy-duty MAN engine based on the D0824 LFL 06 series.

A central point for the further development of direct injection engines is the optimization of the mixture formation process, because all subsequent processes as ignition, combustion and pollutant formation are mainly influenced by the local air/fuel-ratio inside the cylinder. Especially for passenger car engines the interaction between the spray and the combustion chamber walls is an important issue for mixture formation. For that reason this interaction was object of the investigation described. The investigations were carried out in a heatable high pressure high temperature chamber under typical diesel engines conditions of 450°C temperature and 50 bar pressure. A passenger car common rail system was used as injection system equipped with a 6 hole nozzle with common rail specific seat geometry, mini-sac hole geometry and double needle guide.

The transport of goods is mainly realised by the use of heavy-duty vehicles equipped with diesel engines as a drive assembly. Considering the high flexibility and reliability as well as the growing interest in saving environmental resources, a further optimisation of DI-diesel engines regarding fuel consumption and exhaust emissions is necessary. Current discussions on the application of different injection systems for passenger cars (distributor pump, common-rail, …) are also of great significance with regard to heavy-duty vehicles. Optical measurement techniques are a valuable tool to evaluate the quality and the potential of modern DI-diesel injection systems. In this work a conventional heavy-duty engine (MAN) was modified to carry out optical investigations inside the combustion bowl, concerning spray propagation and flame luminosity for different injection nozzles. With respect to the current discussions, it was equipped with a modern common-rail system.