Sistemas Automveis

Fuel systems SI engines

Mrio Alves (mjf@isep.ipp.pt)

11 de outubro de 2016 | 1
 Sistemas Automveis
Outline

Objective of fuel systems

Classification of fuel systems
Evolution technology, regulations
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position, fuel pump/pressure, ignition,
supercharging
Exhaust subsystem
exhaust, EGR, oxygen sensors heating
Other subsystems controlled by the engine ECU
Radiator fan, Variable valves timing control, A/C compressor control,
OBD/Check engine lamp
Sensors
Actuators
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 Sistemas Automveis
Main objective is to deliver fuel into the cylinders
at proper timings (optimizing power)
in correct amounts (for optimal A/F ratio, function of load, RPM,
engine temperature,)
in the right form (fuel atomization, for full combustion and lower
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emissions)
 Sistemas Automveis
Classification of fuel systems (CI and SI)

Operating ICE type single or multiple direct/indirect technology

principle injectors injection
Mechanical SI (single point) indirect Carburetor
Diesel (multi-point) direct or Injection Pump (in-line or
indirect rotary), few hundred bars

Electronic SI SPI indirect in the throttle body, few

bars
MPI indirect Fuel rail, few bars

direct Fuel rail, tens of bars

Diesel (multi-point) direct Fuel-rail or pump/unit-

injection, hundreds to
thousands of bars

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 Sistemas Automveis
Classification of fuel systems

Fuel system types

Mechanical (increasingly electronically assisted)
SI mostly used until the dawn of electronics (< 1960)
materialized by the Carburetor
CI still in use, but gradually changing to common rail
materialized by the Injection Pump (in the figure)

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http://what-when-how.com/automobile/distributor-type-injection-pump-automobile/
 Sistemas Automveis
Classification of fuel systems

Fuel system types

Electronic (ECU-based)
Single-Point Injection (SPI) Figure a)
Aka throttle-body injection
mostly used in low-cost small-sized SI engines
Multi-Point Injection (MPI)
Indirect (external) Figure b)
SI: injection is done upstream (the intake valves)
Diesel: injection is done in a pre-chamber
Direct (internal) Figure c)
pressure accumulator/common-rail systems (SI + most Diesel)
pump/unit-injector systems (few Diesel)

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http://www.intechopen.com/books/advances-in-internal-combustion-engines-and-fuel-
technologies/combustion-process-in-the-spark-ignition-engine-with-dual-injection-system
 Sistemas Automveis
Evolution fuel injection technology

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http://engineringcorner.blogspot.pt/2011/10/next-generation-engines.html
 Sistemas Automveis
Evolution European emission standards

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https://www.ngk.de/en/technology-in-detail/lambda-sensors/basic-exhaust-principles/euro-standards/
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Evolution emission reduction vs. technologies

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http://www.transportpolicy.net/index.php?title=EU:_Light-duty:_Emissions
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Carburetor-based fuel systems

Basic carburetor operation

air is drawn into the engine by the
pumping action of the pistons
(vacuum)
the air accelerates as it passes through
the venturi, causing a slight drop in
pressure.
this pressure drop pulls fuel from the
float bowl (through a nozzle) into the
throttle body
it then mixes with air in a fine mist,
which is distributed to the cylinders
through the intake manifolds
the choke valve enables the driver to
control (enrich) the mixture, at cold
start

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http://cf.ydcdn.net/1.0.1.42/images/main/carburetor.jpg
 Sistemas Automveis
Carburetor-based fuel systems

Main problems
Controlling fuel quantity accurately
dependent on vacuum (not on fuel injection
pressure/duration)
insensitive to air temperature, pressure,
humidity, engine temperature, RPM, throttle
position,
Controlling fuel quantity in real-time
delayed/reactive response
Even delivery of air/fuel mixture
across all cylinders (intake manifolds)
Hard cold-start
flooded carburetor
Fuel consumption
12-15 litres per 100 km was common
Pollution
high hydrocarbons in exhaust gases
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https://s3.amazonaws.com/lowres.cartoonstock.com/transport-carburator-carburettor-flooded-
car_problems-roadside_rescue-mtun1380_low.jpg
 Sistemas Automveis
Electronic fuel injection (EFI) systems

EFI emerged due to

stringent exhaust emission regulations
Increasing fossil fuel cost
evolution of analog/digital electronics
Basics
fuel pump compresses fuel
fuel accumulator (rail) stores fuel
electrically controlled injectors spray
the fuel
into intake manifold or
combustion chamber
ECU controls injection
timing/duration for optimal engine
control
reduced emissions
reduced fuel consumption
maximized performance
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http://www.gerrysap.com/efi.html
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EFI systems: Single-Point Injection (example)

Mono-Jetronic
(19881995)
one lambda sensor
mechanical fuel
pressure regulator
first generation
ignition system
first generation on-
board diagnosis

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http://www.jnc.cz/auto/monomotronic/Mono-Jetronic_blo ck_diagram.gif
 Sistemas Automveis
EFI systems: Multi-Point Injection (example 1)

D-Jetronic (19671976)
"Speed-Density" fuel injection, i.e. there is no Air Flow Meter (AFM)
air-mass flow is measured indirectly, by measuring intake air pressure (3),
temperature (not numbered), RPM (not in figure) and knowing cylinder
volume

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http://www.aficionadosalamecanica.net/images-inyeccion/d-jetronic.jpg
 Sistemas Automveis
EFI systems: Multi-Point Injection (example 2)

L-Jetronic (19741989)
L stands for Luft (air) flow meter (AFM)
first generation ignition
flap type AFM (11)

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http://www.jagweb.com/aj6eng/42efi/page1.php
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EFI systems: Multi-Point Injection (example 3)

Motronic (1987-1998)
integrates injection and
ignition (ECU controls both)
fuel pressure accumulator
(fuel rail)
more sensors proliferate
second generation ignition
system
intake air mass flow is
directly measured by air-
flow meter (12, flap type)

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http://www.autobinary.co.za/motronic%20(1).jpg
 Sistemas Automveis
EFI systems: Multi-Point Injection (example 4)

Gasoline Direct Injection

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http://www.gasitaly.com/f5direct
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EFI systems: Multi-Point Injection (example 5)

Toyota Computer-
Controlled System (TCCS)
1994 3VZ-E engine

11 de outubro de 2016 | 18
http://enginepartsdiagram.com/1994-toyota-pickup-electronic-
fuel-injection-system-efi-diagram/
 Sistemas Automveis
Fuel supply system example (E38/E39 base for BMW 7 Series 1995-2001)

11 de outubro de 2016 | 19

http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3
 Sistemas Automveis
Fuel supply system example (E38/E39 base for BMW 7 Series 1995-2001)

Emphasis on the fuel tank

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http://www.bimmerfest.com/forums/showthread.php?t=446032&page=3
 Sistemas Automveis
Engine control - fundamentals

Computer-controlled
closed loop
fault-tolerant
real-time
networked
Controls
fuel injection
ignition
ISC, EGR,
Composed of
inputs (sensors)
outputs (actuators)
controller (ECU)
network (e.g. CAN)
11 de outubro de 2016 | 21
https://autoelectricalsystems.wordpress.com/2015/12/05/engine-
management-system-for-petrol-engines/
 Sistemas Automveis
Engine control DGI computer architecture (example 1)

OEM = Renesas

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http://www.renesas.eu/applications/automotive/powertrain/gasoline_direct/index.jsp
 Sistemas Automveis
Engine control DGI computer architecture (example 2)

OEM = Infineon

11 de outubro de 2016 | 23
http://www.infineon.com/cms/en/applications/automotive/
powertrain/gasoline-direct-injection/
 Sistemas Automveis
Outline

Fuel systems classification

SI fuel systems evolution
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection

11 de outubro de 2016 | 24
 Sistemas Automveis
Fuel injection algorithm (1)

Base fuel volume

engine RPM
engine load
Corrections
exhaust oxygen
water temp.
accelerator pedal
air temperature
air pressure
knock
voltage

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (2)

Computation of fuel injection duration (volume/mass)

1. Baseline (target) fuel volume is computed according to engine load
engine load = air mass flow divided by engine speed
> air mass flow > injection duration
2. ECU selects closed- or open-loop mode based on throttle opening,
engine speed, vehicle speed, and fuel trim and air flow maps
closed-loop: normal engine operation (A/F 14,7)
open-loop: cold engine/strong accel/desaccelation (A/F < 14,7)
3. Corrections to the target fuel volume based on several parameters
(see flowchart) and an injector pulse width calculated
all these computations must be made in a few milliseconds
for an optimal (real-time) control of the engine

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (3)

Example fuel map (for computing the base fuel volume)

A/F ratio is optimized for best trade-off of power, fuel economy,
low emissions and knock prevention
lower load & RPM leaner mixture (A/F > 14,7)
higher load & RPM richer mixture (A/F < 14,7)
ECU interpolates between values

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (4)

Correction according to
coolant temperature
fuel vaporization gets poorer for
colder engine (specially < 80 C)
injection duration is increased
(A/F mix enrichened) for lower
temperatures

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (5)

Correction according to
intake air temperature
a change in air temperature
changes the air density
air density varies inversely
proportionally with air
temperature
> temperature < density
the colder the air, the denser it
becomes (more air mass for the
same air volume)
more fuel must be injected to
keep the same air/fuel ratio

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (6)

Correction according to
atmosferic pressure
air density varies proportionally
with air pressure
> pressure > density
air pressure varies inversely
proportionally with altitude
< altitude > pressure
lower altitude higher density
less pressure
more fuel must be injected to
keep the same air/fuel ratio

11 de outubro de 2016 | 30

http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (7)

Correction according to
accelerator pedal
fuel is denser than air
thus cannot move into the
cylinder as quickly during
engine acceleration
so, a momentary lean
condition may occur
to compensate for this, the
injection duration is
increased
extra injection pulses also
may be delivered
Injection duration is reduced
during deceleration to improve
fuel economy and emissions.

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http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (8)

Correction according to
charging system voltage
current through the injector solenoid
needle valve is pulled up
latency (dead time) between when
the current starts and the valve is
fully open
injector valve speed depends on
applied voltage
> voltage > current
< injector opening time
injector must be activated
earlier for lower voltages and
later for higher voltages
the actual opening period of
the injector remains the same
11 de outubro de 2016 | 32

http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Fuel injection algorithm (9)

Correction according to
oxygen in exhaust gases
ECU uses UO2 in a feedback
(closed) loop
to restrict A/F ratio to a narrow
range where catalyst is most
efficient (A/F = 14.7 1%)
UO2 > 0,5 V rich mix
reduce fuel injection
UO2 < 0,45 V lean mix
increase fuel injection

11 de outubro de 2016 | 33

http://www.stealth316.com/2-fuelinjection.htm
 Sistemas Automveis
Outline

Fuel systems classification

SI fuel systems evolution
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position

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 Sistemas Automveis
Idle speed and throttle control

Idle (or idling) state

an ICE is considered to be idle if the two following conditions apply
the throttle pedal/grip is not depressed
the engine is uncoupled to the drivetrain
(either in neutral or with the clutch activated)
Idle speed
is the rotational speed of the crankshaft at idle state
usually measured in revolutions (rotations) per minute (RPM)
Idle Speed Control (ISC) (aka Idle Air Control (IAC))
idle speed must be optimized so that
1. the engine runs smoothly (without vibrations)
2. the engine generates enough power to operate ancillary devices
alternator, A/C, water/oil pumps, power steering
3. fuel consumption is minimized (lowest RPM)
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Idle speed and throttle control

Typical idle RPM:

passenger-car = 600 1,000
buses/trucks = 500 600
motorcycles = 1000-1500
Idle Speed Control can be
purely mechanical
as in carburetor-based fuel systems
ECU-based, through the control of either
bypass ISC valve (in the intake manifold)
inputting air upstream and outputting air downstream the
throttle valve
throttle valve
Electronic Throttle Control (ETC), Throttle Actuator
Control (TAC) or Throttle-By-Wire
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 Sistemas Automveis
Idle speed and throttle control

Throttle (valve)
valve that controls the flow of intake air
by opening/closing of a rotating plaque (aka butterfly)
integrated in the throttle body

11 de outubro de 2016 | 37
http://www.acuravigorclub.com/Timely-Topics/Timely0604.htm
http://mazdarx7.ugocapeto.com/Graphics/airintake.jpg
 Sistemas Automveis
Idle speed and throttle control

Bypass ISC valve (aka idle air control (IAC) valve)

controls the flow of intake air
through a bypass to the throttle
inputting air upstream the throttle
outputting air downstream the throttle
operating principles
DC motor + worm drive
step (servo) motor
solenoid valve

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http://www.stealth316.com/2-isc-iac.htm
 Sistemas Automveis
Idle speed and throttle control

Throttle (valve)
its actuation can be
purely mechanically-controlled (driven by a cable or rod)
ECU-controlled (throttle-by-wire)

11 de outubro de 2016 | 39
http://www.croberts.com/Throttle-control-
system-defects.htm
 Sistemas Automveis
Idle speed and throttle control

Purely mechanically-controlled throttle

up to the nineties, throttle opening/closing was directly
(mechanically) driven by a cable connected to the drivers
accelerator pedal/grip
driver pressing the accelerator = throttle opened
driver not pressing the accelerator = throttle closed
idle state
ISC is purely mechanical, via the following mechanisms
manual adjustment of air bypass (screw)
manual adjustment of throttle
position (cable; stop screw)
automatic adjustment of air bypass
according to coolant temperature
(thermal valve)

11 de outubro de 2016 | 40
http://www.autozone.com/repairinfo/repairguide/repairGu
ideContent.jsp?pageId=0900c15280088325
 Sistemas Automveis
Idle speed and throttle control

ECU-controlled throttle
throttle-by-wire has been emerging since the nineties
BMW was the first vehicle manufacturer to offer electronic
throttle control in the 7-Series (1988)
accelerator cable gradually replaced by ECU + throttle actuator
either the driver is pressing the accelerator or not, the
throttle is ALWAYS controlled by the engines ECU
driver not pressing the accelerator = idle state

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http://www.aa1car.com/library/throttle-by-wire.htm
 Sistemas Automveis
Outline

Fuel systems classification

SI fuel systems evolution
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position, fuel
pump/pressure

11 de outubro de 2016 | 42
 Sistemas Automveis
Fuel pump/pressure control

Efficient fuel injection requires

enough fuel flow (g/s)
adequate fuel pressure (according to engine state)
Main components
fuel pump
mechanically-driven
by the crankshaft, through gears, chains or a toothed belt
(often the timing belt)
electrically-driven
controlled by the ignition switch or by the engine ECU
pressure regulator
mechanical (diaphragm-controlled, not used nowadays)
electrical (controlled by the engine ECU)
fuel rail (if applicable)
aka fuel accumulator or fuel distributor
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 Sistemas Automveis
Fuel pump/pressure control

Fuel systems can have 1 or 2 fuel pumps

1 pump fuel systems
low pressure (few bars)
used in ordinary SI engines (figure)
high pressure (hundreds of bars)
used in CI engines
in-line
distributor-type
common-rail

11 de outubro de 2016 | 44

http://12v.org/urs/engine_map/22618.phtml
 Sistemas Automveis
Fuel pump/pressure control

Fuel systems can have 1 or 2 fuel pumps

2 pumps
primary pump (low pressure)
few bars
secondary pump (high pressure)
hundreds of bars

used in
CI unit-injector
CI common rail
SI direct injection (fig.)
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http://www.motonic.co.kr/eng/02_product/product04.asp?leftMenu=4
 Sistemas Automveis
Fuel pump/pressure control

Pressure regulators are crucial for optimizing fuel

injection, and can be
purely mechanically-controlled
diaphragm-controlled, not used nowadays
guarantees a constant pressure differential between the
fuel pressure in the accumulator and the air depression in
the intake manifold
electrically-controlled
controlled by the engine ECU
enables an optimized control of the fuel pressure in the fuel
accumulator, according to engine/load conditions

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 Sistemas Automveis
Fuel pump/pressure control
1 bar = 14,7 PSI
(average air pressure at sea level
Mechanically-controlled fuel
pressure regulator
guarantees constant pressure differential
between
fuel pressure (in the rail) and
intake air depression (intake manifold)
operation
throttle opens (left figure)
1. intake air pressure increases
2. return valve closes
3. no fuel return to tank
4. fuel pressure increases in rail
throttle closes (right figure)
1. intake air pressure decreases
(vacuum)
2. return valve opens
3. fuel returns to tank
4. fuel pressure decreases in rail
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http://www.troublecodes.net/pcodes/p0300/
 Sistemas Automveis
Fuel pump/pressure control

Mechanically-controlled fuel pressure regulator

11 de outubro de 2016 | 48

http://www.rx7club.com/single-turbo-rx-7s-23/frp-fuel-pressure-regulator-vacuum-line-why-882703/
 Sistemas Automveis
Fuel pump/pressure control

ECU-controlled fuel pressure regulator (CI engine)

Pressure Control Valve (PCV)

11 de outubro de 2016 | 49

https://www.dieselnet.com/tech/diesel_fi_common-rail_control.php
 Sistemas Automveis
Fuel pump/pressure control

ECU-controlled fuel pressure regulator (SI GDI engine)

PCV is integrated with high-pressure fuel pump

11 de outubro de 2016 | 50
http://www.slideshare.net/GLADIADORVASCO/automotive-fuel-and-emissions-control-
systems-60582784
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Ignition

(ignition will be addressed in a separated module)

11 de outubro de 2016 | 51
https://autoelectricalsystems.wordpress.com/2015/12/05/engine-
management-system-for-petrol-engines/
 Sistemas Automveis
Outline

Fuel systems classification

SI fuel systems evolution
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position, fuel pump/pressure,
ignition, supercharging (forced air induction)

11 de outubro de 2016 | 52
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Supercharging

Supercharging = forced air induction

compress intake air increase air mass (flow)
power output is increased for a given displacement and engine
speed
Types
mechanically-driven supercharger
directly driven by crankshaft (belt)
exhaust-gas-driven turbocharger
driven by exhaust gases (turbine)
hybrid (mechanically-driven) twin-charger
supercharger + turbocharger
hybrid (electrically-driven) electric supercharger
electric motor/generator supporting the turbo/supercharger

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Supercharging turbocharger

waste gate allows exhaust air to bypass the turbine

(modulated by boost controller)
pop-off valve emergency pressure release (prevents
excessive air pressure into combustion chamber)
blow-off valve prevents back-pressure in the
compressor when throttle valve is abruptly shut

11 de outubro de 2016 | 54

http://atlanticz.ca/zclub/techtips/turbo/
 Sistemas Automveis
Supercharging supercharger

Driven by the crankshaft through belt + pulley

no turbo lag but requires some engine power

11 de outubro de 2016 | 55
http://www.diamondp.com/kb_results.asp?ID=8
http://www.americanmuscle.com/power-adders-for-s550-mustangs.html
 Sistemas Automveis
Supercharging twin-charger

< RPM supercharger

> RPM turbocharger

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http://prettymotors.com/twincharging-engine/
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Supercharging electric turbocharger

Series-hybrid turbocharger
turbine-motor/generator-compressor
< RPM
Battery motor compressor
> RPM
turbine generator battery
replacing the alternator?

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http://www.aeristech.co.uk/full-electric-turbocharger-technology/
 Sistemas Automveis
Supercharging electric supercharger

Drive is fully electrical

Particularly good for low RPM
when engine power is low
Tens of kW hundreds of A
powerful alternator

11 de outubro de 2016 | 58
http://www.aeristech.co.uk/full-electric-turbocharger-technology/
http://blog.caranddriver.com/blowing-your-way-to-savings-how-electric-superchargers-boost-mpg/
 Sistemas Automveis
Supercharging hybrid supercharging

< RPM supercharger

> RPM turbocharger

11 de outubro de 2016 | 59
http://www.autocar.co.uk/car-news/motoring/audi-reveals-
electric-turbocharger-technology
 Sistemas Automveis
Outline

Objective of fuel systems

Classification of fuel systems
Evolution technology, regulations
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position, fuel pump/pressure,
ignition, supercharging
Exhaust subsystem
exhaust, EGR, oxygen sensors heating

11 de outubro de 2016 | 60
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Exhaust system

Objectives
convey exhaust gases out of the engine
reduce exhaust heat, noise and pollutant emissions, affecting
engine power as little as possible
Main components
exhaust manifold to draw exhaust gases out of the cylinders
turbocharger (if applicable) to increase engine power
catalytic converter to reduce pollutant emissions
muffler(s)/silencer(s) to reduce noise
exhaust pipe(s) to link the above components in order to
convey and expel gases at a convenient point in the vehicle

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 Sistemas Automveis
Exhaust system

Exhaust system outlook SI engine

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http://hdabob.com/exhaust.htm
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Exhaust gas recirculation (EGR)

recirculates part of the exhaust gases into the intake

5-15% in SI engines
up to 50% in CI engines
EGR aim is to meet emissions standards
most ICE (SI and CI) must have EGR
some modern ICE do not need EGR
e.g. use selective catalytic reduction (SCR) to reduce NOx

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Exhaust gas recirculation (EGR)

EGR leads to
< oxygen admitted
< peak in-cylinder temperatures
< NOx emissions
< engine power
> particulate emissions (CI)
NOx reduction efficiency
< for > oxygen %
a given NOx reduction requires
< EGR at high loads
> EGR at low loads

11 de outubro de 2016 | 64

https://www.dieselnet.com/tech/engine_egr_performance.php
 Sistemas Automveis
Exhaust gas recirculation (EGR)

EGR system can be low or high-pressure and includes

ECU-controlled EGR valve
EGR cooler (specially for SI engines)

11 de outubro de 2016 | 65
http://www.ni.com/white-paper/13516/en/#
http://denso-europe.com/denso-develops-it-first-egr-cooler-for-gasoline-engines/
 Sistemas Automveis
Outline

Objective of fuel systems

Classification of fuel systems
Evolution technology, regulations
Carburetor-based fuel systems
Electronic Fuel Injection (EFI) systems
Engine control fundamentals
Air/fuel mixture and combustion control subsystems
Injection, idle speed and throttle position, fuel pump/pressure, ignition,
supercharging
Exhaust subsystem
exhaust, EGR, oxygen sensors heating
Other subsystems controlled by the engine ECU
Radiator fan, Variable valves timing control, A/C compressor control,
OBD/Check engine lamp
Sensors
Actuators

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 Sistemas Automveis
Engine control - sensors

(sensors will be addressed in a separated module)

IG/STA switch, neutral switch, A/C switch
THW, THA, MAP, TPS
Air Flow Meter
Knock, RPM,
Crankshaft/cam shaft position
Fuel pressure/temperature
Oxygen sensors (pre/post catalyzer)
Alternator output voltage

11 de outubro de 2016 | 67
 Sistemas Automveis
Engine control - actuators

(actuators will be addressed in a separated module)

Fuel pump
Radiator fan
igniters
Injectors
Throttle control
ISC
EGR control
Fuel pressure regulator
OBD/Check engine lamp
Oxygen sensors heating
Variable valves timing control
A/C compressor control
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