Correlation between needle behavior and fuel flow rate for gasoline direct injection injector using X-ray phase contrast imaging technique

Abstract

• Effects of needle behavior on fuel flow rate of GDI injectors were analyzed. • The movement of armature and ball was quantitatively analyzed through the X-ray visualization. • Flow rate of the second injection gradually increased as dwell time was shortened. To meet strong emission regulations such as Euro-7, which is expected to be implemented in 2025. The multiple-injection strategy is one of well-known solutions to reduce exhaust gas and improve combustion performance on GDI engine. In order to realize multiple-injection strategy, it is necessary to secure excellent flow rate repeatability within short period. Therefore, the purpose of this study was to analyze the flow rate repeatability of GDI injector under various multiple injection conditions and to correlate with needle behavior of GDI injector and flow rate repeatability. To analyze flow rate repeatability, the injection rate data was obtained by the Bosch method and the individual flow rates of 110 shots were analyzed under several experimental conditions. The movements of the ball and armature inside the injector were visualized using the X-ray phase contrast imaging (XPCI) technique, and the individual behaviors of the ball and the armature were quantitatively analyzed by image post-processing analysis. In this study were used two test GDI injectors with same structure. Whereas Flow rate results were different on shorter dwell time conditions. This study revealed that a specific injector had unstable injection rate and worse Shot to Shot (STS) deviation under dwell time 0.7 ms. In addition, armature bouncing appeared in a specific GDI injector. This armature bouncing affects unstable flow rate characteristics because when armature lift up again, the position of armature was different at every time.