Professional Documents
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Pump Operation
The heart of the inline injection pump is the plunger and barrel
assembly, (at left). This is where fuel at supply pump pressure
is pressurized to injection levels ranging from 140 to 1,350 Bar,
(2,000 to 20,000 PSI) and the precise control of fuel delivery is
accomplished by changing the point of register of the helical
control edge of the plunger, (the helix), with the spill/fill port.
Because the plunger fits so precisely in the barrel (approximate
clearance is only 2 to 4 microns), there are no sealing rings to
retain the injection pressure as the plunger pumps fuel they
seal by the viscosity of the fuel only. Pumping plungers and
barrels are lapped together to provide this seal. Never
interchange a plunger from one barrel to another. Even the warmth caused by holding a plunger in
your hand can cause it not to fit in its barrel. Plunger and barrels
are sold as a matched set. The pump camshaft lobe provides a
constant mechanical stroke length of the pumping plunger. The
plunger is rotated indirectly by the governor to provide changes
in fuel delivery. The upper edge of the pumping plunger has a
vertical groove which connects the hydraulic pressure above the
plunger to the milled recesses below. Near the top is a helix (or
control edge) this edge provides precise control of fuel delivery
by covering and uncovering the fill/spill ports as the plunger is
driven upwards in the barrel. The barrel may have either one or
two control ports, also called fill/spill ports. Any fuel that does
leak by the plunger is usually collected in an annular groove cut
into the barrel or the plunger and a corresponding duct in the
barrel provides a means of returning this leakage fuel to the
charging gallery. Without this method of returning to the charging
gallery, any fuel that leaks by the plunger would end up in the
engines oil supply and cause it to dilute and lead to engine
damage. The design of these pumps is
so precise that fuel leakage by the
plungers is very rarely the cause of
diluted engine oil and if this occurs all
other leakage possibilities should be
eliminated before suspecting the pump
as the cause.
When the pumping plunger is at its
bottom position, fuel from the pump
gallery enters through the fill/spill port/s
and floods the area above the plunger
and down the vertical groove to the
milled recesses. The plunger is now
forced upward by the camshaft. Initially
this upward motion merely displaces
fuel back to the charging gallery
because the fill/spill ports/s is/are still
uncovered.
After a short period of upward travel, the plunger
leading edge covers the inlet or fill/spill port/s. This is
known as port closure and is critical to the timing of
the injection event. Continued upward movement will
raise the pressure and then force fuel past the
delivery valve into the high pressure line, open the
injection nozzle, and inject fuel into the combustion
chamber. Injection will continue until the plunger has
risen far enough to enable the lower control edge of
the helix to uncover the inlet or fill/spill port/s. At this
time, pressurized fuel will rush down the vertical
groove on the plunger and exit through the now open
port/s. This is known as spill and is the end of
pressurization; the pressure will collapse back from
the nozzle through the open port in the barrel and will
continue to drop until the delivery valve closing
pressure is reached, typically 2/3 of nozzle opening
pressure, (NOP). The delivery valve will then close
sealing the barrel chamber from the high pressure
line. This closing maintains a residual pressure in the
high pressure line so the system is ready for the next
injection to that cylinder. After the end of fuel
delivery, the plunger will continue to be forced
upward by the camshaft, but this movement will not
cause any further injection it merely displaces fuel
through the open fill/spill port/s back to the charging
gallery.
Pump Housing
The pump housing is the frame that
encases all the injection pump
components and is a cast aluminium,
cast iron, or forged steel enclosure The
pump housing is usually flange mounted
by bolts to the engine cylinder block to be
driven by an accessory drive on the
engine gear train. In some offshore
applications of inline, port helix metering
injection pumps, the pump assembly is
cradle mounted on its base, in which
case, it is driven by means of an external
shaft from the timing gear train.
Cam Box
The cam box is the lower
portion of the pump housing
incorporating the lubricating oil
sump and main mounting
bores for the pump camshaft.
Camshaft main bearings are
usually pressure lubricated by
engine oil supplied from the
engine crankcase and the
cam-box sump level is
determined by the positioning
of a return port. In older
injection pumps, the pump oil
was isolated from the main
engine lubricant and the oil
was subject to periodic checks
and servicing.
Camshaft
The camshaft is designed
with a cam profile for each
engine cylinder and supported
by main bearings at the base
of the pump housing. It is
driven at 1/2 engine rotational
speed in a four-stroke cycle engine by the pump drive plate, which is itself, either coupled directly to
the pump drive gear or to a variable timing device. Camshaft actuating profiles are usually
symmetrical, that is, geometrically similar on both
sides of the toe, and mostly inner base circle (IBC
the smallest radial dimension of an eccentric).
However asymmetrical (the geometry of each cam
ramp or flank differs) and mostly outer base circle
(OBC: the largest radial dimension of an
eccentric) designs are used.
Tappets
Tappets are arranged to ride the cam profile and
convert the rotary motion of the camshaft to the
reciprocating action required of the plunger.
A retraction spring is integral with the tappet
assembly. This is required to load the tappet and
plunger bases to ride the cam profile and it is
necessarily large enough to overcome the low
pressure (vacuum) established in the pump
chamber on the plunger return stroke. This low
pressure can be considerable when plunger
effective strokes are long but it does enable a
rapid recharge of the pump chamber with fuel
from the charging gallery. The time dimension
within which the pump element must be
recharged decreases proportionately with pump
rpm increase.
The Barrel
The barrel is the stationary member of the
pumping element; it is located in the pump
housing so its upper portion is exposed to
the charging gallery. This upper portion of
the barrel is usually drilled with diametrically
opposed ports known as fill and spill ports
that permit through flow of fuel to the barrel
chamber to be charged. Some older
systems had only one port this was changed
as pump pressures became higher in order
to provide a hydraulic balance at the spill
point to prevent the plunger from being
hammered against on side of the barrel as
pressure collapse occurs. Because it
contains the spill ports, both its height and
rotational position in relation to the plunger
is critical. Barrels are often manufactured
with upper flanges so that their relative heights
can be adjusted by means of shims and fastener
slots permit radial movement for purposes of
calibration and phasing.
Plunger
Plungers are the reciprocating (something that
reciprocates, moves backward and forward such
as in the action of a piston in an engine cylinder)
members of the pump elements and they are
spring loaded to ride their actuating cam's
profile. Plungers are lapped to the barrel in
manufacture, to a clearance close to 2µ,
ensuring controlled back leakage directed
toward a viscous seal consisting of an annular
groove and return duct in the barrel. Each
plunger is milled with a vertical slot, helical
recess/es, and an annular groove. In current
truck engine applications, a lower helix design is
generally used but both upper helix and dual
helix designs are sometimes observed. The
positioning and shape of the helices (plural of
helix) on a plunger are often described as the
plunger geometry.
Plunger geometry describes the physical shape
of the metering recesses machined into the
plunger and this defines the injection timing
characteristics. The function of the vertical slot is
to ensure a constant hydraulic connection
between the pump chamber above the plunger
and the plunger helical recess/es. A plunger with
a lower helix will have a constant beginning,
variable ending of delivery timing characteristic
because the fill/spill port will always close at the
same amount of plunger upward travel and will
open depending on its rotational position.
Upper helix designs will be of the variable beginning, constant ending type. Double helix designs are
designed with both an upper and a lower helix. Double helix designs will have a variable beginning
and variable ending of delivery; this geometric design tends not to be often used in highway diesel
engines.
Fuel is pulled under suction from the fuel tank through hydraulic
hose by the transfer pump. A primary fuel filter and or water
separator may also be in series with the pump and tank; or a
more rudimentary pre-cleaner can be integral with the charging
pump. The charging or transfer pump is responsible for
producing charging pressure. It discharges to a secondary
filter(s) and then to the charging gallery in the upper housing of
the injection pump. Charging pressures range from 1 to 5 atms
(15-75 psi) depending on the system. In some cases, a hand
primer is fitted to the transfer pump assembly. Its only function
is to prime the system manually after it has been opened or run
dry. Transfer pumps are capable of delivering far more fuel the
engine requires so there is usually a return line from the
charging gallery to return excess fuel to the tank. This helps to
remove any bubbles that form due to aeration and to keep the
fuel cool.
Governor or Rack Actuator Housing
Either a governor or rack actuator
housing must be incorporated to a
port helix metering injection pump.
This acts as the control mechanism
for managing fuelling. A Diesel
engine must use a governor to
control the amount of fuel injected
because unlike a gasoline engine
there is no throttle to control the
amount of air ingested. Gasoline
engines are managed to run on a
stoichiometric fuel ratio of 14.7: 1,
but diesels run with an excess of
air at all times. A diesel can have
as much as 1000 times the air
required to burn the fuel inside the
cylinder under certain operating
conditions. Therefore we must
precisely control the fuel quantity or
the engine would quickly
accelerate to self destruction,
(1000 RPM per sec). Consider an
engine fuel system that is designed to deliver 185 mm3. of fuel for each injection pulse at peak
torque. While this engine is idling, (no load), it may need only 18.5 mm3. per pulse, just to keep the
engine running while it is cold (enough to overcome the friction and inertia of the pistons and
crankshaft etc.). As the engine warms these factors will reduce (less friction etc.), if we supply the
same amount of fuel the engine will run faster and faster until it disintegrates. A governor’s job is to
sense engine speed and limit it by cutting the fuel delivery to the amount necessary to maintain its
speed. To run the above engine at 1200 RPM under no load may require only 20 mm3 of fuel but as
load is applied the requirement will increase perhaps as high as full fuel or 185 mm3. per cycle. The
governor can precisely control fuelling to accommodate this. The governor will control low idle, (the
slowest speed that the engine will run), high idle, (the maximum engine speed), and will manage
fuelling in between these points based on driver input and load conditions.
Mechanical governors were originally designed by James Watt in 1788 to control the steam engine of
his day. Mechanical governors use a set of flyweights that spin in relation to engine RPM. The
flyweights always try to reduce engine fuelling and by that engine speed. Governors match adjustable
spring tension against the centrifugal force generated by the governor weights. The governor will
have a main spring and an idle spring and in most cases a torque control spring it may also have a
starting spring. The combined effort of these springs is to push the engine fuel control rack towards
full fuel. The main governor spring tension is affected by the throttle position under all operating
conditions the governor will find a balance between spring force and weight force to control engine
fuelling and therefore engine speed. Mechanical Governors are set so that at maximum engine speed
the governor weights can overcome the combined tension of all the spring and hold fuelling to a level
that the engine will not exceed its maximum speed. Mechanical Governors such as the one above
have not been used on highway applications since the 1990s.
Crude attempts were made to control engine emissions on turbocharged versions of these
mechanically controlled inline pump engines, their prime purpose was to reduce visible smoke
emissions. When a turbocharged engine is accelerated there is always a period of “lag” before the
exhausted heat energy can spin up the turbo to increase engine breathing, however on acceleration
the rack would move to full fuel and the available air could not combust the entire fuel load this would
result in a puff of black smoke on acceleration.
These systems were variably called a puff limiter or smoke
limiter or an aneroid. These devices functioned to delay
the fuel racks travel to full fuel until there was sufficient air
to combust the large fuel load. They consisted of a simple
device that physically limited the racks travel until boost
pressure acting on a diaphragm could overcome spring
pressure holding the device restricting the racks travel.
Most of these were on off devices if boost was below a
certain level say 5PSI they held the rack at a proportion of
full travel approximately 60 to 80%. Once boost pressure
exceeded the 5PSI the rack would be allowed full travel.
These aneroids were commonly tampered with by drivers
thinking they could get better fuel economy and
performance but remember that any fuel that exits an
engine as black smoke is wasted fuel so the tell tale signs
that an aneroid has been tampered with, that is a puff of
black smoke on acceleration indicates a loss of efficiency
rather than a gain.
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