A two stage diesel injector with direct-driven needle and hub

Currently, the leading manufacturers of diesel internal combustion engines have to solve complex and often inconsistent problems. One of these problems deals with the implementation of multiple injections to improve the environmental and performance characteristics of the engine. COMMON RAIL-type direct injection battery systems with electrohydraulic or piezoelectric injectors are considered to be the most advanced systems at the moment. They can inject up to nine portions of fuel per cycle, with portion volumes varying by two orders of magnitude. The pilot injection volume may be less than 1 cubic millimeter, while the main portion volume may exceed 100 cubic millimeters. Since the fuel is injected through similar holes, the flow-rate is determined by injection duration or pressure. The problem is to choose appropriate diameters of holes, which is not an easy task. If the diameter of a hole is relatively large, measuring small volumes is difficult. Electronic injector valves are not able to do this due to electromagnetic transient processes limiting their functionality. If the diameter of a hole is relatively small, the required fuel volume can be provided by increasing the main injection time, which contradicts the optimal eco-friendly injection, or by increasing the pressure. The injection pressure increase is also limited by leaks and manufacturing capabilities. In this paper, a fuel injector with two kinds of holes of a new type with directly driven needle and hub is investigated for the COMMON RAIL-type fuel system of a diesel engine. The conducted research proved its advantages over other injectors. Injector specifications are calculated.

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