Upload
vggalileo
View
217
Download
0
Embed Size (px)
Citation preview
8/3/2019 GDI - The Future is Already Here.
1/5
UNDERSTANDING GDI GASOLINE DIRECT INJECTION.
The future of Gasoline Engines lies in the Gasoline Direct Injection (GDI).Couple the consumer demands for Cheaper Prices
,
Better Performance and GreaterFuel Economy together with World Wide legislation on Exhaust Emission Outputs
and you can see the vehicle manufacturers have a very tough task ahead of them in
the next decade.
To meet these demands, the Vehicle Manufacturers are switching to Direct Fuel
Injection, be it Diesel or Gasoline Fuel, Direct Injection is their only way forward.Direct Injection is the Future for the Gasoline Engine and the Future is already here.The abbreviation GDI (with a capitalised letter "I") is a registered trademark of
Mitsubishi Motors. Other companies have developed other names for what is
Gasoline Direct Injection (GDI) engines but have had to change their brand name of
their system, VW/Audi have branded their system
(Fuel Stratified Injection) Alfa Romeo JTS,
Renault HPI and so on, the fact is they are all
Gasoline Fuel fired directly into the combustion chamber.On a direct injection engine, a very
fine mist of Fuel is
injected directly in to the combustion chamber at a
pressure of between 50 120 Bar, depending on the type
of system. During idle and light throttle, the metered fuel
is injected at microscopic milli second (mS) durations at
a pressure of approximately 50 bar.This design enables the engine to operate a stratified charge combustion, described
by most of the vehicle manufacturers as an Ultra Lean Burnmode, giving a muchimproved fuel efficiency, great engine torque and reduced exhaust emission levels at
low load.
http://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Lean_burnhttp://en.wikipedia.org/wiki/Fuel_efficiencyhttp://en.wikipedia.org/wiki/Fuel_efficiencyhttp://en.wikipedia.org/wiki/Fuel_efficiencyhttp://en.wikipedia.org/wiki/Lean_burn8/3/2019 GDI - The Future is Already Here.
2/5
To achieve these pressures, the gasoline is pressurized by a
high-pressure pump that is a combination of mechanically
driven and electronically controlled and mounted on the engine.
This pump compresses the fuel to the pressure level required in the
fuel rail.
As the vehicle accelerates and the load increases, in a normal simultaneous gasoline
injection engine, the injector will open for longer mS periods to allow more fuel in to
the manifold to meet the demands of the engine.With the sequential firing GDI systems, the injector only opens to a maximum of
5mS.As the fuel requirement increases, the injector remains at 5mS and the pumppressure increases to meet the demand, allowing the injector to open and close
quickly and efficiently. No more Duty Cycle as we have known it.These engines use a very high specification
injector,Hitachi, Bosch, Denso and Siemensbeing the major suppliers.This design of injector requires a greater
current supply to open them against the
50 bar fuel pressure, some having a very
low resistance of 0.7 OHMS, which allows
them to operate under extreme conditions.With these type of GDI systems, the ECU would supply a Fast On voltage of up to
90v for approximately 150 S, them drop down to a Peak Current for 350 S ,
dropping down again to the Hold Current for another 3500 S before the injectoris closed by the Fast Turn Off that aides the energy dissipation of the injector.
BOSCH DENSOBOSCH DENSOBOSCH DENSOBOSCH DENSO
This graph shows the
Driver ControlUsed in an ASNU GDI
Adapter Box,
show the speed and
efficiency in which
the injector operates in
opening and
closing in a five mS pulse
width.
8/3/2019 GDI - The Future is Already Here.
3/5
The FUEL QUANTITY and FUEL SPRAY and DISTRIBUTION and ATOMISATION
from these injectors is far more critical than ever before for the engines correctrunning, performance, fuel economy and exhaust emissions.During a StratifiedCombustion Mode, the Air/Fuel ration on some system can be as fine as 65:1,
this means that the FUEL represents approximately 1.5% of the total mass
during the combustion stroke.This style of injector can have varying types of spray patterns, depending on
the engine requirements, but all of them will be atomising a much smaller fuel
droplet size. To explain the difference, a conventional injector would have a fuel
droplet size, as an example, of 165 micron, some GDI injectors would produce a
fuel droplet of say, only 65 micron.
Although the spray pattern shape may look the same, the size of the droplet is
much finer and the higher the pressure, the finer the droplet size. Smaller fuel
droplets will burn quicker and a give cleaner, more efficient combustion stroke,
improving performance, economy and reduce exhaust emissions.Even the slightest loss of the fuel delivery will have an adverse effect on the
engines Drivability, Power Output, Fuel Economy and Exhaust Emissions.Carbon can build up on the tip of the injector
and interfere with the distribution and
atomisation of the fuel.
The GDI systems operate in SEQUENTIAL
mode,firing each injector in turn as opposed to theconventionalSIMULTANEOUSmodeas used in most conventional manifold injectionsystems.
8/3/2019 GDI - The Future is Already Here.
4/5
Sealing the injector against compression loss is critical, the Mitsubishi
injectors use a copper compression washer, this must be replaced every time
the injector is removed.
The Bosch injectors use a Teflon seal thatalso needs replacing every time the injector
is removed. Special tools are required to
replace these seals.
The major problem for repair workshops is the diagnosing problems with the
injectors, ASNU M.D Phil Ellisdon, claims that less than 5% of workshops,
including main dealerships, have the training or equipment to diagnose
problems with manifold injection systems, when it comes to GDI, then its less
that 1%.Removing the injectors is a very time consuming task, when Phil Ellisdon asks
workshops what they do when they have injector problems, often the reply
from main dealerships is to replace them with new.
At over 150.00 each, plus over 4 hours labourmeans a very large invoice, but Ellisdon asks, do
you check them first? What happens if you put
the new ones in and the engine still has a problem?
Fitting new injectors on a GDI engine without testing
the injectors is a bit like Russian Roulete.To assist these workshops in their diagnosis, ASNU
have developed a GDI Adapter Box, a system built
and designed to Test & Service all GDI Injectors.ASNU have been working with GDI injectors all over
the world since 1997, when Mitsubishi first
introduced their GDI Injection on their Charisma,
8/3/2019 GDI - The Future is Already Here.
5/5
ASNU service over 60,000 injectors per month around the world, Phil Ellisdon
said that as soon as the Charisma came out, ASNU saw the problems with
carbon on the tips, all of a sudden the phone started ringing from various
parts of the world, asking about the problems with these new injectors.
Fortunately for ASNU Shell Fuels had one of thefirst one in the market and found carbon build up
on the injectors, after only 1500 miles.
Shell already having an ASNU sent Phil Ellisdon a
set for him to decide best how they should be tested
and serviced, the rest as they say, is history.Now 10 years later, GDI injectors have advanced,
Bosch now have 5 generations of GDI injectors,
soon there will be a PiePiePiePiezozozozo gasoline injector, already
being used in the Diesel Common Rail injectors.Gasoline Direction Injection is the future and
the Future is already here.