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A 500-hour test cycle has been used to evaluate the durability of a prototype high pressure common rail injection system operating up to 1800 bar with E10 gasoline. Some aspects of the original diesel based hardware design were optimized in order to accommodate an opposed-piston, two-stroke engine application and also to mitigate the impacts of exposure to gasoline. Overall system performance was maintained throughout testing as fueling rate and rail pressure targets were continuously achieved and no physical damage was observed in the low-pressure components. Injectors showed no deviation in their flow characteristics after exposure to gasoline and high resolution imaging of the nozzle spray holes and pilot valve assemblies did not indicate the presence of cavitation damage. The high pressure pump did not exhibit any performance degradation during gasoline testing and teardown analysis after 500 hours showed no evidence of cavitation erosion.

Delphi Diesel Systems (DDS) - Heavy Duty Business is developing a new range of Ultra High Pressure Common Rail Fuel Injectors with the functionality to allow the combustion heat release to be heavily adapted during operation. This allows the injector performance to be simultaneously optimised across a broad range of engine conditions, removing the constraints of having to select a single rate shape type for all operating conditions. This new technology range builds on the performance of Delphi's 2700 bar Fuel Systems of F2E, F2P and F2R, whilst adding in new levels of injector control, beyond what is available in the current market. In addition to this new functionality, Delphi's new Heavy Duty Injector range also demonstrates greatly reduced leakage and improved accuracy of fuel control. This paper reviews the benefits and possibilities of this new injector technology.