Search Results

Cyclic variability in internal combustion engines (ICEs) arises from multiple concurrent sources, many of which remain to be fully understood and controlled. This variability can, in turn, affect the behavior of the engine resulting in undesirable deviations from the expected operating conditions and performance. Shot-to-shot variation during the fuel injection process is strongly suspected of being a source of cyclic variability. This study focuses on the shot-to-shot variability of injector needle motion and its influence on the internal nozzle flow behavior using diesel fuel. High-speed x-ray imaging techniques have been used to extract high-resolution injector geometry images of the sac, orifices, and needle tip that allowed the true dynamics of the needle motion to emerge. These measurements showed high repeatability in the needle lift profile across multiple injection events, while the needle radial displacement was characterized by a much higher degree of randomness.

This study is a continuation of previous work assessing the robustness of a Cummins XPI common rail injection system operating with gasoline-like fuel. All the hardware from the original study was retained except for the high pressure pump head and check valves which were replaced due to cavitation damage. An additional 400 hour NATO cycle was run on the refurbished fuel system to achieve a total exposure time of 800 hours and detect any other significant failure modes. As in the initial investigation, fuel system parameters including pressures, temperatures and flow rates were logged on a test bench to monitor performance over time. Fuel and lubricant samples were taken every 50 hours to assess fuel consistency, metallic wear, and interaction between fuel and oil. High fidelity driving torque and flow measurements were made to compare overall system performance when operating with both diesel and light distillate fuel.