Heui PPT 9-2010

Hydraulically Actuated Electronic Unit Injector (HEUI) ( ) Systems y
For
Gus Wrights Students
What is HEUI?
H E U I
Title, Edition
Author(s)
Hydraulically actuated
Electronic
Unit
Injector
2008 Pearson Education, Upper Saddle River, NJ 07458. All Rights Reserved.
Uses Hydraulics to Pressurize Fuel

OIL
Hydraulic Amplifier Piston
1th 8
Diameter
Plunger Fuel Under Pressure
P ess i ed engine oil not a camshaft is used Pressurized sed to inject f fuel. el
3
Title, Edition
Author(s)
HEUI Advantage
Electronic Control Injection Timing Injection Quantity
Pressurized Fuel to Injection Nozzle
Intensified Oil Pressure Injection Pressure Injection Rate

Camshaft Controls
1. How much fuel - how far the plunger moves. 2. Injection Rate - Rotational speed of cam 3. Injection Timing - When the plunger moves
Pumping Plunger
Camshaft
HEUI System
Author(s)
Conventional System
P Pressurizes i fuel f l independently i d d tl of f engine i speed. d

4
Title, Edition
HEUI Common Rail
HEUI pressurizes fuel independently of engine speed = Lower emissions,
improved power and fuel economy !

Plunger velocities of camshaft actuated fuel systems are low at slow engine speeds.
Poor pressurization and atomization are the results. results Timing and rate control are fixed in camshaft geometry
Title, Edition
Author(s)
HEUI Advantage Superior Atomization
High pressurization improves atomization and distribution especially at low speed and high load conditions.
6
Title, Edition
Author(s)
HEUI Advantages g Higher g Pressurization
Higher Hi h pressurization i ti of f fuel f l 22,000 30,000 psi (2010 G2 injectors). I Improves atomization, t i ti mixing and distribution of fuel in the combustion chamber. chamber Promotes shorter ignition delay and burn time. B tt t Better tolerance l f for EGR
Title, Edition
Author(s)
HEUI - Hydraulically actuated Electronic Unit Injection

Pressurized engine oil provides injection force.
Uses pressurized engine oil as the actuation force for injecting fuel
Title, Edition
Author(s)
HEUI Advantages Injection Rate Shaping
Capable of pilot injection. injection (For quieter engine operations and lower emissions) Varying V i oil il pressure enables bl control of injection rate over all speed and load conditions. Latest injector capable of many different injection shape profiles
Title, Edition
Author(s)
Digital Control Valve Cam-less Diesel

High Pressure Oil Sturman Digital Control Valve Drive Piston Oil Return Electrical Supply
Title, Edition
Author(s)
Use hydraulic system pressure to actuate valves. Variable valve timing. Compression-less starting. Internal braking Improved fuel efficiency and power.
10
HEUI System Components

HEUI Injectors Low-pressure p oil system y High-pressure oil system Electronic control system
Title, Edition
Author(s)
11
Typical System Components
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Author(s)
12
HEUI Injectors -Types Types
HI-300A Powerstroke T-444E International HI450A -3126 Cat

Title, Edition
Author(s)
HI-300B Powerstroke T-444E International HI450B -3126 Cat
G2 6.0L Powerstroke VT 365/275, DTs International
2nd Generation HI-300 Cat C-7
13
First & Second Generation
Title, Edition
Author(s)
14
First Generation HEUI Injectors HEUI A & B
HEUI A injector is identified by black coloured solenoid and d does not th have split-shot lit h t capabilities biliti (1993-1997). (1993 1997) The Th white hit coloured solenoid does (1997 2001). 2008 Pearson Education, Upper Saddle River, NJ 07458.
Title, Edition
Author(s)
15
All Rights Reserved.
Internal View
Solenoid Poppet Valve Intensifier Piston Oil Inlet Plunger Fuel Inlet Pressure Chamber
Nozzle Valve Fuel Annulus
Title, Edition
Author(s)
16
HEUI A & B Internal Construction
High pressure oil inlet 450 -3,300 psi
Fuel Pressure 30-80 psi
Title, Edition
Author(s)
17
Oil & Fuel Galleries

Injector Tube Cylinder Head
High-Pressure Oil Supply Injector j O-Rings g Low-Pressure Fuel Supply
Pass through cylinder head or jumper tube.

18
Title, Edition
Author(s)
Oil & Fuel Galleries

High g Pressure Oil Pump (Hidden behind reservoir) High Pressure Oil Rail Fuel Rail Injectors Oil Reservoir
Plugs on cylinder head indicate the ends of fuel and oil passageways to supply the injectors
Title, Edition
Author(s)
19
Oil Flow Schematic
Engine oil is pressurized by a high pressure pump. pump

20
Title, Edition
Author(s)
Accumulator Mounted On Pump

High Pressure Oil Pump Oil Accumulator
Injection Control Pressure Regulator
Accumulator needed for oil supply during servicing and prolonged cranking cranking. CAT 3126B
21
Title, Edition
Author(s)
Stages of Injection Major Components

Solenoid Poppet Valve Seat Oil Discharge Port Poppet Valve
Amplifier Piston
Oil Inlet
Fuel Pressure Chamber
Nozzle
Title, Edition
Author(s)
22
Fill Cycle
Energizing the solenoid lifts the poppet valve and admits oil into the injector. The cavity above the amplifier piston begins to fill
23
Title, Edition
Author(s)
Injection
Pressurized oil pushes down on the amplifier/intensifier piston. The surface ratio at the top of the amplifier piston compared to the bottom is approximately 7:1. Pressure multiplication of fuel beneath the piston takes place because of the high ratio
A Amplifier lifi Piston Pi - top Amplifier Piston bottom
Title, Edition
Author(s)
24
Poppet Valve
Poppet valve and amplifier piston

25
Title, Edition
Author(s)
Amplifier Piston
T Top Acted A t d upon by b oil il
The ratio of the top to the bottom of th amplifier the lifi achieves hi th the pressure multiplication required to inject fuel. Amplifier p ratio vary y between models of injectors typically 7:1 An injector operating with 3,300psi of oil pressure develops 23 23,000psi 000psi of injection pressure
Bottom Acting on fuel Split Shot Injector Amplifier Piston
Title, Edition
Author(s)
26
End of Injection j
Oil vent
De-energizing the solenoid allows the lower poppet valve to return to i seat and its d open the h upper poppet seat to open. Oil vents out the upper pp vent port p on the injector. The amplifier piston retracts and injection ends
Amplifier piston
Title, Edition
Author(s) 2008 Pearson Education, Upper Saddle River, NJ 07458. All Rights Reserved.
27
Pilot - Split Shot Injectors

The amplifier piston has an annular groove and is connected to holes in the bottom of the injector
Groove cross-drilled G d ill d to holes in bottom
Holes drilled in bottom
Title, Edition
Author(s)
28
Pilot Split p Shot Injection j
Pilot, also called split shot injection takes place 8 -10 10 degrees before the main injection
Title, Edition
Author(s)
29
Pilot Split p Shot Injection j
Pressurized fuel is vented from the annular groove of the amplifier piston as the groove uncovers a spill port next to the plunger barrel. Injection begins then abruptly ends with a small quantity of fuel injected (pilot). The main injection begins after the groove passes the spill port
Title, Edition
Author(s)
30
G2 Injector
Oil Inlet
Injector Coils
The second generation HEUI injector (G2) was developed for International engines g used also by Ford
Fuel Inlet
Title, Edition
Author(s)
31
G2 Injection Control Valve
Control valve uses two digital like solenoids for faster response and improved rate shaping capabilities. (Three injection events in one cycle) Hydraulically balanced, proprietary materials, uses residual magentism to 2008 Pearson Education, Upper Saddle River, NJ 07458. Title, Edition All Rights Reserved. Author(s) open. 32
G2 Injector High Pressure Oil Supply

Oil Manifold
Pressurized engine g oil is supplied pp by y a heavy y cast iron oil manifold located above the injectors
33
Title, Edition
Author(s)
AWA Fittings g
AWA Fittings
Injection Control Pressure Sensor
Branch Tube
AWA valves dampen hydraulic pulsations g injector j cackle. causing

34
Title, Edition
Author(s)
G2 Injector O Rings
O O rings seal fuel and oil pressure to the injector

35
Title, Edition
Author(s)
G2 Injector Fuel Supply
Fuel is supplied to the injectors through a fuel gallery ll cast into the h cylinder l d head h d
36
Title, Edition
Author(s)
Two Piston Oil Pump DT DTs s

High Pressure Oil Line To Oil Manifold
Injection Pressure Regulator
Title, Edition
Author(s)
Oil and fuel pump share drive. drive

37
G2 Injection j Digital g Valve
The G2 injector uses two coils to move a spool valve. The injector also uses an amplifier/intensifier piston which operates similarly to other HEUI injectors The digital g valve overcomes the technological g barriers of switching g very y highg pressure fluid at extreme speeds with reduced coil response time.
38
Title, Edition
Author(s)
Fill Cycle
When the spool valve is closed, oil above the amplifier/intensifier piston is vented ented to the atmosphere. tmo phe e No current is applied to either coil No injection takes place
Title, Edition
Author(s)
39
Main Injection Step 1
A triggering force of 20-amps @ 48volts of current is applied to the coils for only 800 microseconds. The spool valve rapidly moves a maximum of .017 to admit pressurized oil into the cavity above the amplifier piston.
Title, Edition
Author(s)
40
Main Injection Step 2
Current to the coil stops. Residual magnetism g initiates spool p valve movement but hydraulic forces continue to open the valve. The amplifier/intensifier piston is forced downwards with oil pressure up to 3,100-psi Injection occurs. An intensifier surface area of ratio of 7.1:1 creates 22,000psi injection p j pressure. p
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Author(s)
41
E d of End fI Injection j i
Current pulsed to the spool valve initiates valve closure. Hydraulic forces close the valve Oil above the amplifier piston vents to the atmosphere beneath the valve cover. Injection ends A mechanical relief valve will open at 4,000-psi of oil pressure (maximum theoretical injection pressure of 28,000 psi)
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Author(s)
42
Metering, Timing & Rate Control
All HEUI engines have injection rate controlled by injection pressure. (Idle i.e. i e 582-psi 6.0L 6 0L Powerstroke)
43
Title, Edition
Author(s)
This HEUI injector for Cat C-7 uses a specialized internal valve which provides four different shapes of injection q , ramped, p , pilot p injection j and post p combustion square, injection. Variable pressure is controlled by oil pressure
44
Title, Edition
Author(s)
The fast acting digital valve (coils + spool valve) allows for electronic rate shaping of the injection event
Title, Edition
Author(s)
45
Pulse width + injection pressure determine the mass or injection quantity. Wh th When the injection i j ti signal i l is i applied li d to t the th solenoids l id determines d t i injection i j ti timing. ti i
Title, Edition
Author(s)
46
High Pressure Oil Systems
A high-pressure oil pump in the valley of the V-8 Powerstroke pressurizes oil for injection
47
Title, Edition
Author(s)
The 6.0L has the high pressure pump at the rear of the engine
Title, Edition
Author(s)
48
Title, Edition
Author(s)
49
High Pressure Oil Systems - ICP
An injection control pressure sensor (ICP) measures oil pressure to the oil manifolds supplying pressurized oil to the injectors
50
Title, Edition
Author(s)
High g Pressure Oil Systems y -ICPR

PWM Electrical Signal
P Pressurized i d Oil In I
To Oil Sump
An injection control pressure regulator (ICPR) uses a PWM signal from the ECM to electronically regulate oil pressure from the pump. The longer the pulse width, the higher the system pressure. Without a signal all oil flows through the valve to the oil sump
Title, Edition
Author(s) 2008 Pearson Education, Upper Saddle River, NJ 07458. All Rights Reserved.
51
ICPR Operation
To Injectors Oil From High-Pressure Pump
PWM Signal From ECM
Drain To Oil Sump

Normally open allowing oil to flow to sump. Closes with increase pulse width. width
52
Title, Edition
Author(s)
ICP ICPR Closed Loop

ECM
Injector Drive M d l Module
ICPR ICP
A closed loop feedback circuit is formed between the ICP and ICPR. The injection pressure is adjusted based on look look-up up tables in the ECM and the values reported by the ICP
Title, Edition
Author(s)
53
High Pressure Oil Systems -ICPR
The PWM signal to the ICPR is reported in duty cycle %. It is an important impo tant piece of diagnostic information info mation to diagnose aerated ae ated oil, oil worn pumps and leaking injector O-rings
Title, Edition
Author(s)
54
Engine g Control
ECM IDM
High voltage, 110-volts DC on earlier HEUI system required the use of a injector drive module to handle the high current flows to the i j injectors
Title, Edition
Author(s)
55
CAT C7 & C9 HEUI
Hydraulically y y balanced nozzle vale. Balanced with oil not fuel.

56
Title, Edition
Author(s)
CAT C-7 & C-9 HEUI
Internal ICPR Variable displacement p pump p p for lower parasitic loss and drive torque.
57
Title, Edition
Author(s)
HEUI Codes
Sensed voltage Hi Open Sensed voltage Low Shorted to ground
Title, Edition
Author(s)
58
Oil Quality & HEUI
HEUI engines are sensitive to oil quality oil needs high levels of antifoaming g additives to prevent p oil aeration. Over extending oil changes, improper oil will lead to loss of power, and high fuel consumption. C-7 Cat engines have an electrical connector which needs adjustment between 15w-40 and 10w-30 oils.
Title, Edition
Author(s)
59

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Hydraulically Actuated Electronic Unit Injector (HEUI) ( ) Systems y

Gus Wrights Students

Uses Hydraulics to Pressurize Fuel

Plunger Fuel Under Pressure

Intensified Oil Pressure Injection Pressure Injection Rate

P Pressurizes i fuel f l independently i d d tl of f engine i speed. d

HEUI Common Rail

HEUI pressurizes fuel independently of engine speed = Lower emissions,

improved power and fuel economy !

HEUI Advantage Superior Atomization

HEUI Advantages g Higher g Pressurization

HEUI - Hydraulically actuated Electronic Unit Injection

HEUI Advantages Injection Rate Shaping

Digital Control Valve Cam-less Diesel

HEUI System Components

Typical System Components

HEUI Injectors -Types Types

HI-300A Powerstroke T-444E International HI450A -3126 Cat

HI-300B Powerstroke T-444E International HI450B -3126 Cat

G2 6.0L Powerstroke VT 365/275, DTs International

2nd Generation HI-300 Cat C-7

First & Second Generation

First Generation HEUI Injectors HEUI A & B

All Rights Reserved.

Nozzle Valve Fuel Annulus

HEUI A & B Internal Construction

High pressure oil inlet 450 -3,300 psi

Fuel Pressure 30-80 psi

Oil & Fuel Galleries

High-Pressure Oil Supply Injector j O-Rings g Low-Pressure Fuel Supply

Pass through cylinder head or jumper tube.

Oil & Fuel Galleries

Oil Flow Schematic

Engine oil is pressurized by a high pressure pump. pump

Accumulator Mounted On Pump

Injection Control Pressure Regulator

Stages of Injection Major Components

Fuel Pressure Chamber

A Amplifier lifi Piston Pi - top Amplifier Piston bottom

Poppet valve and amplifier piston

Pilot - Split Shot Injectors

Groove cross-drilled G d ill d to holes in bottom

Holes drilled in bottom

Pilot Split p Shot Injection j

Pilot Split p Shot Injection j

G2 Injection Control Valve

G2 Injector High Pressure Oil Supply

Injection Control Pressure Sensor

AWA valves dampen hydraulic pulsations g injector j cackle. causing

O O rings seal fuel and oil pressure to the injector

G2 Injector Fuel Supply

Two Piston Oil Pump DT DTs s

Injection Pressure Regulator

Oil and fuel pump share drive. drive

G2 Injection j Digital g Valve

Main Injection Step 1

Main Injection Step 2

Metering, Timing & Rate Control

Metering, Timing & Rate Control