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We developed a novel method for reducing the engine noise associated with the high-pressure fuel system in gasoline direct-injection (DI) engines. We focused on the level of noise at idle running speed, because at the idle state, engine noise is the only noise source to the driver. The dominant vibration source of the high-pressure fuel system was fuel pulsation from the high-pressure fuel pump and activation noise of the solenoid-drive injector. To reduce the noise of the idling engine, we focused on the vibration transmission path from the high-pressure fuel system to the cylinder head, which results in noise radiation from the engine block. Next, we focused on the radiation noise associated with the pressurization event of the high-pressure fuel pump. To reduce the vibration transmission from the high-pressure fuel system to the cylinder head, the fuel rail and the injector were isolated from the cylinder head by avoiding metal-to-metal contact.

We investigated the size of fuel spray droplets from nozzles for direct injection gasoline (DIG) engines. Our findings showed that the droplet size can be predicted by referencing the geometry of the nozzle. In a DIG engine, which is used as part of a system to reduce fuel consumption, the injector nozzle causes the fuel to spray directly into the combustion chamber. It is important that this fuel spray avoid adhesion to the chamber wall, so multi-hole injection nozzles are used to obtain spray shape adaptability. It is also important that spray droplets be finely atomized to achieve fast vaporization. We have developed a method to predict the atomization level of nozzles for fine atomization nozzle design. The multi-hole nozzle used in a typical DIG injector has a thin fuel passage upstream of the orifice hole. This thin passage affects the droplet size, and predicting the droplet size is quite difficult if using only the orifice diameter.