Fuel Injector Selection in Diesel Engine for BS6 Upgradation 2022-01-0441

For meeting the stringent BS VI emissions in a 3-cylinder diesel engine the Exhaust after treatment system (EATS) was upgraded from a single brick DOC (diesel oxidation catalyst) to 2 brick DOC+sDPF (Diesel Particulate Filter) configuration. To meet the demands of emission regulation and sDPF requirements, changes were also required in the Fuel injection system. Major changes were done to the fuel injector and fuel pump.

This paper primarily discusses the Fuel injector change from 1.1 to 2.2 family with changes in nozzle geometry, Nozzle tip protrusion (NTP), and injector cone angle and the effects on the emission and performance parameters. The various design values of NTP, cone angle, and Sac values are tested in an actual engine to meet the required power, torque and verified to meet NOx, HC, PM values as required by the new BS (Bharat Stage) VI regulation. Other boundary conditions are also checked - BSFC (Brake Specific Fuel Consumption), temperature, etc. The design change that was needed for the injector up-gradation - Cylinder head interface and injector clamp are also described in detail.

The paper also discusses the durability tests done for validating the new injector on parameters like nozzle coking, nozzle tip temperature, and various endurance tests reports are discussed. The finalized design has been validated on both engine testbed and vehicle successfully.