The conventional internal combustion engines continue to
dominate many fields like transportation, agriculture and power
generation. Moreover, apprehension over oil price restriction has
created an unprecedented demand for fuel economy. Diesel engine is
mostly preferred for its higher thermal efficiency, high-torque and
outstanding longevity. In recent days with flooded technologies,
Uniqueness and the Differentiation of Product play vital role for a
successful business in Auto Industry. However, there is always
demand for low cost solutions and the product should be easily
acceptable the end-user. The present development study is related
to the Challenges of Design and Development of Internal Combustion
Engine to meet the stringent Emission and Performance requirements
(BS-IV and upgradable for BS-VI) with Diesel Fuel and more
particularly to achieve the targets with conventional Fuel
Injection Systems (Non-electronic Fuel Injectors, In-Line Fuel
Injection Pump-Governed Electronically) with required sub-systems.
This is a unique approach for diesel engines for current &
near-future requirements (emissions & performance) with
cost-effective and ease of customer acceptance. While developing
the FIE system with In-line Fuel Injection Pump, the study focused
on influence of the parameters such as cam-velocity, fluctuation of
supply fuel pressure, plunger-barrel clearances, fuel pressure
across pump-speeds, anchor residual clearance and at Injector side
valve matching clearance, valve lift, injector opening pressure,
nozzle flow coefficient, injector needle lift. The development
includes the selection and optimization of Non-Electronic injectors
with suitable hole-size and number of holes, The Fuel Injection
pressure and delivery valve in conventional In-line Fuel Injection
pump with static timing throughout the engine operation. The
cooled-EGR is optimized to meet reduced NOx level with static fuel
injection timing through-out the testing cycle. The PM level was
brought down by optimizing injection pressure along with adaptation
of low-cost Partial Oxy Cat-con (passive regeneration). The
development was focused to certify the engine for an automotive
application with latest emission norms, the IOBD-II requirements
also considered and suitable algorithm and logic were developed
with small ECU. The Developed engine with Inline FIP technology was
proved both at Engine-level (Power, Torque, Emissions, BSFC,
Durability) and at Vehicle-level (Drivability, on-road Fuel
Economy) and it was resulted with at par to better than Common Rail
System, the base engines, but at reduced engine cost with ease of
customer acceptance with respect to maintenance at long-use of the
vehicle. The same engine with simple FIE system has been verified
for Off-Highway applications with BS-V (CEV / Trem V equivalent)
requirements.