Fuel Pump System Research Articles

Numerical Analysis of the Structural and Flow Rate Characteristics of the Fuel Injection Pump in a Marine Diesel Engine

A reciprocating fuel pump system was investigated using a modeling approach. The diesel pump system comprises a variable-sized barrel and plunger. This study investigates the effect of diesel, propane, and DME fuels on the plunger barrel’s deformation and flow rate characteristics. It compares the barrel and plunger displacement as a function of working pressure. Based on the multi-field coupling theory, a numerical fluid–solid thermal coupling model was developed to characterize the operational fluctuations in deformation and clearance. Due to the distinct deformation patterns of the two components, the appropriate clearance for the pump’s head and stem must be set independently. In addition, significant AMESim parameters compared and confirmed the discharge flow rates of three distinct fuels. The results show that the maximum displacement for the plunger stem was 0.00266 mm at 7.5 mm from the top of the stem, which was 6.94% lower than the literature result. The DME fuel showed flow stability initially (from 0.0 to 0.4 s) when using a plunger diameter of 23.85 mm. According to the plunger diameters, the marine fuel injection pump’s discharge flow rates increased, minimizing the wearing between the barrel/plunger. The research findings revealed that the suggested structural and flow rate model is recommended for alternative marine fuel applications.

Optimisation of Reliability and Maintenance Plan of the High-Pressure Fuel Pump System on Marine Engine

Abstract This paper presents a method of adjusting and designing the maintenance scheme for the high-pressure fuel pumps of a slow-speed two-stroke marine engine, MAN 6S70MC-C. The maintenance database for the marine fuel system was obtained from the planned maintenance software, and covered a period of 11 years. During this period, 29 failures occurred that required corrective actions. Our methodology includes failure mode analysis, risk analysis, reliability calculation and maintenance interval adjustment. Each failure is described using a failure mode analysis, based on a combination of the mode and cause of failure. The objective of this study is to recommend a new preventive maintenance interval based on the exponential reliability results and the analysed maintenance data. The initial maintenance plan for each fuel pump was set to 8,000 running hours, whereas in the modified plan, it is recommended to set this to 4,000 hours. Our results show an increase in the system reliability from 60% to 95% when the new modified maintenance plan is applied. In addition, the results and the recommended initial maintenance schedule are validated based on three similar types of engine with the same fuel pump system. The new maintenance approach can reduce the risk of component failure, which will lead to increased reliability of the fuel pump system and the optimisation of maintenance costs.

A Study on Gasoline Direct Injection (GDI) Pump System Performance using Model-Based Simulation


 
 
 This paper focuses on a simulation study of a newly developed high-pressure fuel pump system for small engine. When an engine is operated at high speed in a typical Gasoline Direct Injection (GDI) system, its pump will perform extra pumping requiring continuous engine work. Because it is driven by the engine’s camshaft, the extra pumping action is both unavoidable and parasitic. In this study, a new GDI pump has been designed and built to only operate at a constant speed, regardless of engine load and speed. The pump is driven by an electric motor via a camshaft and is intended for a four-stroke, 0.2 litre, single-cylinder, spark ignition engine. The electric motor is governed by a control unit called the Engine Control Unit (ECU). The GDI pump will supply fuel to a rail up to its maximum pressure capacity. The pump is developed in accordance with a physical model-based design approach and is simulated using Matlab- SimscapeTM. Based on the calculation and simulation performed, the designed pump pressure is capable of producing discharge exceeding 4.5 MPa. Theoretical calculation also shows that the pressure developed by the pump reaches 10.54 MPa when a two lobe cam is used. In addition, the pressure developed by the pump is recorded to be 11.15 MPa, with an error of 5.8 % when a similar condition is applied to the physical modelling.
 
 

Failure Analysis of Timing Device Piston and Supply Pump Vanes in Fuel Injection System for Transport Utility Vehicles

The present work deals with the failure analysis of timing device piston and vanes in supply pump of a fuel pump system used in transport utility vehicles. Investigations for evaluating the failure of timing device piston and supply pump in transport utility vehicles are carried out. Failure data of eighty fuel injection pumps used for diesel engines are collected and analysed in the present work. The fuel injection pumps considered in present work are distributer type. Cracks are observed on the surface of failed timing device piston, and this crack occurrence is accounted to insufficient fuel supply that leads to dry running and elevates the friction. The presence of fuel impurities also contributes to the failure of timing device piston. Elevated friction between vane and rotor (i.e. vane housing) has been identified as the root cause of vane and subsequently supply pump failure. Effects of vane failures are incomplete fuel combustion due to reduced pressure and efficiency of the engine. Reasons for the vane failure are dry running of pump, and rusts on the surface due water presence are identified. The failure effects of timing device piston and vanes of supply pump are discussed. Scanning electron microscopy and energy-dispersive spectroscopy of the failed components have been carried out. Remedial actions to avoid the failure of timing device piston and vanes of supply pump have been suggested in the present work.

Automated Fuel Pump System using UPI Payment

In our society, the major problem in the petrol station is waiting for a long time to fill the petrol, even though the filling is done the money handling take longer by implementing this project we can do it quickly. Now UPI ID is available in the petrol station for the transaction purpose only. This idea will eliminate the human resources used in the station. The right quality can ensure by maintaining the proper density of petrol/diesel. To measure fuel quantity regularly, we insert a device inside the underground storage tank. It gives the reading of fuel quantity in the display unit. Automation helps build trust among the customers. At a petrol pump trust is the most significant factor in growing sales. Most of the customers will come from a nearby locality if they generate strong word of faith then more customers will visit.

The impact of the quality of diesel fuel on the efficiency of engines

High-quality diesel fuel is the guarantee of work of an internal combustion engine. Low ambient temperature has an influence on the physical and chemical properties of diesel fuel. It becomes a reason for failure of details of a high pressure fuel pump system. This issue is more acute in the Republic of Sakha (Yakutia) where the surrounding air temperature can reach up to -60C and where the essential goods are delivered to the regions of the Far North by winter roads. The article illustrates the results of experimental study of the quality of arctic diesel fuel taken from different filling stations of the Republic of Sakha (Yakutia). It also suggests a way of increase of fuel efficiency for equipment operated in the North. The article also presents a mathematical model of fuel cost during winter time. The main operational properties of arctic diesel fuel are studied. The work was carried out in the laboratory of “General, analytical and physical chemistry” department. The samples of diesel fuel were divided into three categories according to their geographic locations: central, northern and riverside. Three samples of arctic diesel fuel from different filling stations were taken in each of the regions. The study revealed that the chosen main properties of diesel fuel, such as: density, viscosity, fractional structure and low-temperature properties differ from standard values.

Robust Control for Electric Fuel Pump with Variant Nonlinear Loads Based on a New Combined Sliding Mode Surface

A class of electric fuel pump system equipped in More-electric Engines with variant loads is studied. A novel robust control method based on a combined linear and quadratic integral sliding mode surface is proposed. The linear sliding mode surface with improved exponential reaching law guarantees that nominal system has satisfying performance with reduced chattering, while the quadratic integral sliding mode surface is responsible for compensation of mismatched uncertainties, enhancing system’s robustness. Besides, mathematical model of electric fuel pump with variant load and leakages is established, which reflects both steady and dynamic characteristics of the fuel pump. In addition, it is proved that combined sliding mode surface can be reached in finite time and remains there. Stability of closed-loop system is proved as well. The effectiveness of the proposed method is verified by simulation results.

Modelling, formal refinement and partitioning strategies for a small aircraft fuel pump system in Hybrid Event-B

A case study centred on a fuel supply system for a small aircraft is presented in Hybrid Event-B, an extension of conventional Event-B that allows for the modelling and verification of hybrid and cyberphysical systems exhibiting nontrivial continuous behaviour. In contrast to many such case studies, which concentrate predominantly on timing issues, the focus in the present work is on nontrivial physical behaviour, and on the effect that this has on various refinement and partition strategies. More liberal proof obligations are developed to add flexibility to the decomposition process. • Hybrid Event-B modelling of an aircraft fuel system. • Investigation of partitioning strategies. • New verification conditions for decomposition.

Development of Wobble-Plate-Type Fuel Pump in Compression Ignition Engine Fueled With Dimethyl Ether

This experimental work describes the operation of a wobble-plate-type fuel pump for the stable supply of dimethyl ether (DME) fuel and evaluates its application possibility in a compression ignition engine. To achieve this, different types of flow control valves (normally open and normally closed types) were installed on the wobble-plate-type fuel pump. At the same time, the variations in fuel flow rate, torque, and temperature variation in the main parts of the pump were investigated under various operating conditions using a pump performance test system. In addition, a dummy-rail, which has half the volume of a common-rail, was installed to analyze pump stability under high flow rate/high load conditions. The wobble-plate-type fuel pump has showed satisfactory performance for DME fuel supply. The maximum flow rate (∼60 kg/h) is two times higher and the maximum torque value (∼32 N m) is three times higher than the required fuel flow and torque for stable driving of the DME engine (∼30 kg/h and ∼10 N m), respectively. Application of dummy-rail in wobble-plate-type fuel pump system would be a good solution to control the instability of pump operation in high flow rate/high load conditions.

자동차 연료펌프 구동용 보이스 코일 전자기 엑츄에이터의 설계 및 해석

캠샤프트의 구동력을 활용한 기계식 연료펌프 시스템을 대체할 솔레노이드 격막 연료펌프는 최근 각광받고 있는 고효율 그린카 부품 중 하나이다.하지만 솔레노이드 격막 연료펌프의 경우 왕복운동에 필요한 자속을 오직 솔레노이드에 의존하므로 전력소비가 비교적 큰 단점이 있다. 따라서 본 연구에서는 전력소모를 최소화 하기 위하여 영구자석형 VCA 연료펌프 시스템을 제안한다. 또한 상용전자기해석소프트웨어인 MAXWELL을 활용하여 유한요소 해석을 통해 기존의 솔레노이드 격막 펌프와의 전력소모 및 동적 성능을 비교 분석한다.

Development of Double Gear Fuel Pump for Heat Management Improvement

A unique double gear fuel pump system with operation mode switching capability for aircraft engines was developed to solve the heat management problem of current high efficiency turbofan engines and improve specific fuel consumption (SFC). Mode switching from parallel operations to series operations was found to reduce the discharge flow and pump work to nearly half. This resulted in the reduction of the rise in fuel temperature due to the fuel recirculation at the high altitude low Mach number flight condition. Air cooled oil cooler (ACOC) is usually required for sufficient oil cooling at descent or approach flight conditions. Since fuel consumption at those conditions is not very high, most of the gear pump discharge fuel flow proportional to the engine speed is returned to the fuel pump inlet resulting in significant heating. The ACOC that provides additional cooling capability degrades SFC due not only to the increased weight but also to the wasted fan discharge air. By reducing fuel temperature rise at the pump at those flight conditions, the necessity of ACOC may be eliminated. Further, it is shown that a reduction by half of the double gear pump weight can be achieved by increasing pump speed twice without incurring a durability penalty. Extensive tests showed sufficient steady state pump performance, switching characteristics, and durability.

A Study on Wear of Brush and Carbon Flat Commutator of DC Motor for Automotive Fuel Pump

In an automotive fuel pump system, a small DC motor is widely used to drive the pump and driven by a automotive battery. Recently a bio-fuel, usually a mixture of gasoline and ethanol has been used due to shortage of gasoline and environmental aspect. It affects strongly the performances of a DC motor, especially commutation phenomena, what kind of fuel is used. Therefore the authors have started to investigate the influence of ethanol on the commutation phenomena. They have been reporting the wear of brush and carbon flat commutator in gasoline and ethanol so far. In this paper commutation period, arc duration, brush and commutator wear are examined in ethanol 50-gasoline 50%. Brush wears are very small compared with the previous results. Namely in the present test a mechanical sliding wear is predominant rather than erosion by arc due to short arc duration. Further, an area eroded by arc is observed to re-appear as a sliding surface. From these results a threshold arc energy between arc erosion and mechanical sliding wear is obtained, and a wear model is proposed to explain the above wear pattern on the sliding surface.

Gas Turbine Mach Number Control With Simplified Fuel System

The compressor exit Mach number control theory presented here will enable improved control of transient compressor working point trajectories of a turbine engine. This will allow the steady working line to be raised towards the surge boundary with the advantage of increased thrust and reduced specific fuel consumption. This new control method can replace the rigid acceleration and deceleration limiters of the fuel control loop, and achieve superior surge avoidance performance. This paper documents the theoretical and practical study of Mach number controllers designed for implementation with a simplified fuel pump system and the subsequent testing of the controllers on an aeroengine in the sea level test bed in DERA Pyestock. The new controller incorporated two Mach number dynamic limiting control loops (one each for acceleration and deceleration) besides the NH controller. Several designs were tested successfully and demonstrated not only Mach number control from idle to full power, but also surge avoidance. Engine start control was also tested in the latest engine test.

Virtual fuel-pump design

Some concepts of virtual product are discussed. The key technologies of virtual fuel-pump development are in detail analysed, which include virtual fuel-pump product modeling, intelligent simulation, distributed design environment, and virtual assembly. The virtual fuel-pump development prototype system considers requirement analysis, concept design, injection preferment analysis, detailed design, and assembly analysis.