This application is based on and claims the priority under 35 USC 119 of German Patent Application 10 2012 011 149.5, filed on Jun. 5, 2012, the entire disclosure of which is incorporated herein by reference.
The invention relates to a fuel injection system and method for diesel engines using compression ignition, wherein fuel injection nozzles carry out a controlled injection of fuel into a combustion chamber formed by a piston in a cylinder with controllable inlet and exhaust valves.
In a conventional diesel engine, diesel fuel is injected into the combustion chamber in the cylinder, for example from a fuel injection nozzle located approximately centrally above the combustion chamber in the head of the engine. As the air charge in the cylinder is compressed during the compression up-stroke of the piston, the compression causes the air to be heated to a high temperature, which is sufficiently high to cause spontaneous compression-induced ignition of the injected fuel. However, due to the high temperature during the combustion in such diesel engines, various nitrogen oxide NOx compounds are produced as combustion byproducts, and are emitted in the exhaust gas. The higher the combustion temperature, the higher the proportion of nitrogen oxide NOx emissions will be. Such NOx emissions are undesirable as they include poisonous compounds and contribute to pollution of the atmosphere. In order to reduce or limit the formation and thus the emission of NOx, it is desirable to carry out the combustion with a lean air/fuel mixture, i.e. by providing excess air beyond the minimum air ratio needed for combustion of the fuel. Nonetheless, even if an excess quantity of air is provided in relation to the injected fuel quantity overall, due to the formation of a heterogenous mixture in the case of diesel combustion, as a result certain zones will arise in the combustion chamber in which the combustion progresses stoichiometrically, i.e. in the exact air/fuel ratio for stoichiometric combustion, without excess air. For this reason, a constant pressure combustion with excess air in principle results in higher NOx emissions than a constant volume combustion process with formation of a homogenous air/fuel mixture.
In order to limit the formation of NOx combustion byproducts in the case of a diesel combustion, it is thus necessary to try to achieve a homogenous air/fuel mixture and a corresponding homogenous combustion. Simultaneously, it is also necessary that fuel in liquid form must be injected into the combustion chamber during the combustion, in order to further obtain or maintain the advantages of the diesel combustion process. According to the present state of the art, the above two goals or objects are directly in conflict with one another, because in conventional fuel injection systems, the injection of diesel fuel very early during the compression stroke causes a detonation-like combustion known as “diesel knock”, which can lead to mechanical damage of the engine.
In view of the above, it is an object of the invention to further develop and modify a fuel injection system of the above described general type, which provides a combination of components and/or features to achieve a lean air/fuel mixture with a thorough vaporization of the injected diesel fuel for forming a relatively homogenous air/fuel mixture, and ensures a reliable ignition injection of diesel fuel, in order to reduce or limit the a formation of NOx emissions. It is a further object of the invention to enable the injection of distinct fuel quantities at distinct time points within the engine cycle and at distinct locations within the combustion chamber, in order to improve the homogenous combustion and reduce or limit the formation of NOx emissions. Another object of the invention is to provide a supplemental fuel injection nozzle in addition to the (e.g. conventional) primary fuel injection nozzle, by which combination of nozzles the improvements being strived for can be achieved. The invention further aims to provide both a system or apparatus as well as a method with respective combinations of features for achieving the desired goals. The invention further aims to avoid or overcome the disadvantages of the prior art, and to achieve additional advantages, as apparent from the present specification. The attainment of these objects is, however, not a required limitation of the claimed invention.
The above objects have been achieved according to the invention in a fuel injection system for a diesel engine with compression ignition, having a combustion chamber formed in a cylinder bounded by a piston moving in the cylinder, and with controllable inlet and exhaust valves, as well as a primary fuel injection is nozzle. According to the invention, an additional supplemental fuel injection nozzle is provided. The supplemental injection nozzle is controllable independently of the primary injection nozzle. The supplemental injection nozzle is preferably arranged in an upper wall or boundary area of the combustion chamber, for example especially in an upper area of the cylinder near the cylinder head, or in a portion of the cylinder head bounding the upper end of the cylinder. The supplemental injection nozzle has a fixed or adjustable fuel injection angle so as to inject a supplemental quantity of diesel fuel into or onto a boundary area and especially preferably a hot vaporizing surface of the combustion chamber that has a prevailing component temperature above the boiling temperature of the diesel fuel. To carry out the combustion process, first a supplemental quantity of diesel fuel is injected via the supplemental injection nozzle onto the hot vaporizing surface, to vaporize the fuel and produce a homogenous lean air/fuel mixture below a self-ignition limit. After the conditions of temperature and pressure within the combustion chamber have changed due to further compression by the piston's further up-stroke, then the primary combustion quantity of diesel fuel is injected via the primary fuel injection nozzle in order to initiate the compression-induced combustion.
In further preferred embodiments of the invention, the injection angle of the supplemental injection nozzle is oriented so as to direct the injected supplemental quantity of diesel fuel into contact with one or more hot vaporizing surfaces within the combustion chamber, for example an exhaust valve, an area on the crown or top surface of the piston, or an area of the flame ring in the top area of the cylinder adjoining the cylinder head. The “injection angle” refers to the orientation of the central axis of the injection spray pattern, e.g. the central axis of the injection spray cone, or refers to the angular width of the spray pattern sufficient to impinge fuel onto the stated surfaces. Through the contact of the diesel fuel with such a hot vaporizing surface, this causes a reliable vaporization of the fuel and thus the formation of a homogenous mixture of the vaporized fuel with the air present in the combustion chamber. The supplemental quantity of fuel is limited, however, so that there is an extreme excess air quantity in the resulting homogenous mixture. Due to the prevailing extreme air excess as well as the relatively low temperature level in the combustion chamber at the time of the supplemental injection, this lean homogenous air/fuel mixture does not self-ignite. Thereby, the NOx components formed during the subsequent combustion can be reduced.
Furthermore, the non-ignitable homogenous air/fuel mixture present in the combustion chamber can reduce the temperature level in the combustion chamber. Particularly, the supplemental injected fuel serves to cool the particular “hot spot” within the combustion chamber at which the supplemental injected fuel is directed, e.g. the exhaust valve, the flame ring area, or the top surface of the piston. As further alternatives, the supplemental injected fuel may be directed at any combination of two or more of these areas, for example especially at the flame ring area and the exhaust valve, or at the flame ring area and the piston top surface, or at the exhaust valve and the piston top surface. This cooling can help to avoid the occurrence of detonation or diesel knock, for example.
Then, following the supplemental injection, the normal primary injection of fuel necessary for ignition and combustion is carried out, for example in a conventional manner. The primary injected fuel mixes into the homogenous lean air/fuel mixture already established in the combustion chamber by the supplemental injected fuel. The compression up-stroke of the piston has continued in the meantime between the supplemental fuel injection and the primary fuel injection, thereby increasing the temperature and the pressure in the combustion chamber, which then leads to the smooth homogenous ignition and combustion of the resultant air/fuel mixture including both the supplemental injected fuel and the primary injected fuel.
In order to ensure an optimized vaporization of the supplemental injected fuel, the selected vaporization surface at the time of the first injection, i.e. the supplemental injection via the supplemental injection nozzle, shall have a temperature in a range from 200° C. to 500° C., and especially preferably in a range from 200° C. to 350° C. The target injection area is thus selected appropriately based on the operating temperatures at different areas within the combustion chamber.
Furthermore, to suitably control the supplemental injection, the supplemental injection nozzle preferably has an adjustable spray angle and/or an adjustable injection angle and/or an adjustable nozzle orifice diameter. Furthermore, a plurality of such supplemental injection nozzles can be arranged at different locations and/or with different injection angles.
As discussed above, the supplemental fuel injection via the one or more supplemental injection nozzles is preferably carried out after closing the inlet valve and before the beginning of the main or primary fuel injection via the primary fuel injection nozzle. In particular preferred embodiments, the supplemental fuel injection shall take place between 10° CA aBDC and 40° CA aBDC, and especially between 17° CA aBDC and 23° CA aBDC in typical diesel engines operating according to a typical diesel cycle, or between 80° CA bBDC and 40° CA aBDC in diesel engines operating according to a Miller cycle or an Atkinson cycle. After the supplemental injection, the primary fuel injection for the ignition is carried out via the primary injection nozzle at a time point between 20° CA bTDC and 0° CA bTDC. As is conventionally known in the above expressions, “CA” means “crankshaft angle”, “a” means “after”, “b” means “before”, “BDC” means “bottom dead center” and “TDC” means “top dead center” regarding the travel of the piston as linked to the rotation angle of the crankshaft. Thus, for example, “aBDC” means “after bottom dead center” and “bTDC” means “before top dead center”.
In order that the invention may be clearly understood, it will now be explained in further detail in connection with example embodiments thereof, with reference to the accompanying drawings, wherein:
An air inlet opening or passage 110 and an exhaust outlet opening or passage 109 are provided in the cylinder head 114. The inlet passage 110 and exhaust passage 109 are respectively equipped with a controlled inlet valve 105 and a controlled outlet valve 103, whereby the respective passages are opened and closed in a controlled manner during the operating cycle of the piston 113 in the cylinder 115. Such valves and the control arrangement for controlling the valves can be according to any conventional known teachings in addition to the teachings herein.
Further, a primary fuel injection nozzle 107 is fitted in the cylinder head 114, for example arranged approximately centrally axially at the top of the combustion chamber 117 in the cylinder 115. The primary injection nozzle 107 is thus oriented axially downwardly to inject the primary fuel 123 for combustion into the combustion chamber 117 as will be described below in connection with
According to the invention, the engine is further equipped with at least one supplemental fuel injection nozzle 101, which is arranged to inject supplemental fuel at particular beneficial locations in the combustion chamber. In the illustrated embodiments, the supplemental fuel injection nozzle 101 is arranged in the sidewall of the cylinder 115 near the top of the combustion chamber 117, for example at or near the top dead center (TDC) position of the piston 113. In the example embodiment of
The supplemental injection nozzle 101 has its nozzle body oriented substantially at 90° relative to the axis of the primary injection nozzle 107, and sprays or injects the supplemental fuel charge laterally into the combustion chamber 117. The injection angle of the nozzle orifice, i.e. the direction of the central axis of the fuel injection pattern of the nozzle 101, or the angular range of the spray pattern, is either fixed or adjustable so as to direct the supplemental fuel injection spray at particular locations within the combustion chamber, as follows. In the embodiment according to
A representative sequence of a combustion process in the engine with the fuel injection system according to the invention will now be described.
Namely, instead of just a single vaporizing surface, it is alternatively possible to inject respective sprays of supplemental fuel from one or more supplemental injection nozzle(s) 101 onto all three of the exhaust valve 103, the flame ring area 119 and the surface of the piston 113, or any selected combination of two of these vaporizing surfaces. This can be achieved by adjusting the injection angle of an adjustable nozzle 101, or providing a plurality of nozzles 101, or providing a single nozzle 101 that has an injection spray pattern directed at more than one target vaporizing surface. The selected target location(s) at which the supplemental fuel is directed, e.g. the exhaust valve 103, the wall of the flame ring 119, and/or the top surface of the piston 113, are considered to be vaporizing surfaces because they are typically heated to a temperature of about 230° C. during the operation of the diesel engine. As a result of this elevated temperature, the injected supplemental fuel completely vaporizes when striking and/or approaching the respective vaporizing surface. This vaporized fuel mixes into the air charge in the combustion chamber 117 and produces a homogenous lean air/fuel mixture with an excess air ratio or proportion of about 3.2 times the minimum necessary air quantity for combustion of the diesel fuel. At this time, the piston position is approximately 20° CA aBDC (after bottom dead center) as shown in
Thereafter, when the piston 113 has traveled farther upwardly to the position shown in
The primary injection nozzle 107 and the supplemental injection nozzle 101, as well as the valves 103 and 105, can be controlled by a control arrangement (not shown) that is adapted, configured, arranged and connected to the controlled components so as to achieve the control as described herein. The control arrangement may include one or more cooperating conventionally known valve and/or injector controllers, which may have any known construction and operation, e.g. with electronic, electric, electro-mechanical, mechanical, pneumatic, and/or hydraulic components, controlled by mechanical linkages, hardware, firmware and/or software, so as to carry out the control according to the invention as disclosed herein.
When adding the supplemental fuel injection according to the invention, the quantity of fuel injected for the primary injection can be maintained the same as without a supplemental fuel injection, or can be adjusted as desired. If the primary injection quantity is maintained the same as it would be without the supplemental injection, then adding the supplemental injection results in an increased fuel charge and thus greater power produced during the combustion and output during the power stroke of the piston. If the air quantity remains the same, then the air/fuel mixture will be richer as discussed above. Alternatively, the primary fuel injection quantity can be reduced as desired, so that the total fuel quantity (primary plus supplemental) is less than, equal to or greater than the normal fuel quantity that would have been injected by the primary injector without the inventive modification. This preferably results in a rich final air/fuel mixture as mentioned above. The extent or proportion of enrichment, e.g. the air/fuel ratio, can be adjusted as desired by adjusting the quantity of fuel for the supplemental injection and/or the quantity of fuel for the primary injection.
It should be understood that a “lean combustion mixture” generally refers to an air/fuel mixture in which the air quantity or proportion is greater than the air proportion that is minimally necessary for combustion of the fuel. Particularly, a lean combustion mixture exists if the air proportion amounts to about 1.5 to 5 times the minimum necessary air proportion for combustion. On the other hand, a “rich combustion mixture” exists if the air proportion in the mixture is smaller than the air proportion that is minimally necessary for combustion of the fuel. Particularly, a rich combustion mixture exists when the air proportion is below 1.5 times the minimum necessary air proportion. For diesel fuel combustion, the necessary air proportion is about 14.2 kg of air per 1 kg of diesel fuel.
References to directions such as “top” refer to the orientation of a cylinder according to
Although the invention has been described with reference to specific example embodiments, it will be appreciated that it is intended to cover all modifications and equivalents within the scope of the appended claims. It should also be understood that the present disclosure includes all possible combinations of any individual features recited in any of the appended claims. The abstract of the disclosure does not define or limit the claimed invention, but rather merely abstracts certain features disclosed in the application.
Number | Date | Country | Kind |
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10 2012 011 149.5 | Jun 2012 | DE | national |