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CHAPTER 1

INTRODUCTION In recent years, legislative and market requirements have driven the need to reduce fuel consumption while meeting increasingly stringent exhaust emissions. This trend has dictated increasing complexity in automotive engines and new approaches to engine design. A key research objective for the automotive engineering community has been the potential combination of gasoline engine specific power with diesel like engine efficiency in a cost competitive, production feasible power train. !ne promising engine development route for achieving these goals is the potential application of lean burn direct injection "#I$ for gasoline engines. In carburetors the fuel is sucked due to the pressure difference caused by the incoming air. This will affect the functioning of the carburetor when density changes in air are appreciable. There was a brief period of electronically controlled carburetor, but it was abandoned due to its complex nature. !n the other hand in fuel injection the fuel is injected into the air.

FIG 1.1: Schematic Diagram of GDI Engine

CHAPTER 2 LITERATURE SURVEY

TRANSITION OF FUEL SUPPLY SYSTEM The transition of the fuel supply system used in automobiles is graphically shown below. In carburetor the fuel from the fuel chamber is sucked in by the pressure variation caused due to the incoming air. The fuel then mixes with the air and reaches the cylinder through the inlet manifold. &here as in a port injection system the fuel to the cylinder is supplied by a separate fuel injector placed near the inlet valve of the cylinder. And in a direct injection system the fuel to the cylinder is supplied by a fuel injector placed inside the cylinder

'I( ).% Transition of fuel supply

ADVANTAGES OF FUEL INJECTION OVER CARBURETOR The fuel injection eliminates several intake manifold distribution problems. !ne of the most difficult problems in a carbureted system is to get the same amount and richness of air fuel mixture to each cylinder. The problem is that the intake manifold acts as a storing device, sending a richer air fuel mixture to the end cylinders. The air flows readily around the corners and through various shaped passages. *owever the fuel, because it is heavier is unable to travel as easily around the bends in the intake manifold. As a result, some of fuel particles continue to move to the end of the intake manifold, accumulating there. This enriches the mixture going the end cylinder. The center cylinder closest to the carburetor gets the leanest mixture. The port injection solves this problem because the same amount of fuel is injected at each intake valve port. +ach cylinder gets the same amount of air fuel mixture of the same mixture richness. Another advantage of the fuel injection system is that the intake manifold can be designed for the most efficient flow of air only. It does not have to handle fuel. Also, because only a throttle body is used, instead of a complete carburetor, the hood height of the car can be lowered. &ith fuel injection, fuel mixture requires no extra heating during warm up. ,o manifold heat control valve or heated air system is required. Throttle response is faster because the fuel is under pressure at the injection valves at all times. An electric fuel pump supplies the pressure. The carburetor will depend on differences in air pressure as the force that causes the fuel to feed into the air passing through.

'uel injection has no choke, but sprays atomi.ed fuel directly into the engine. This eliminates most of the cold start problems associated with carburetors. +lectronic fuel injection also integrates more easily with computeri.ed engine control systems because the injectors are more easily controlled than a mechanical carburetor with electronic add ons. /ulti port fuel injection "where each cylinder has its own injector$ delivers a more evenly distributed mixture of air and fuel to each of the engine0s cylinders, which improves power and performance. 1equential fuel injection "where the firing of each individual injector is controlled separately by the computer and timed to the engine0s firing sequence$ improves power and reduces emissions.

ELECTRONIC FUEL INJECTION The main components of electronic fuel injection are described below. %. +ngine 2ontrol 3nit "+23$ ). 1ensors -. 'uel Injectors

Engine Control Unit (ECU): This unit is the heart of electronic injection system which is responsible for metering the quantity of fuel supplied to each cylinder. The unit contains a number of printed circuits boards on which, a series of transistors, diodes and other electronic components are mounted. This makes the vital data analysing circuits responding to various input signals. After processing the input data, the power output circuits in the control unit generates current pulses which are transmitted to the solenoid injectors to operate the injector for the required period. 'or example, when the pedal of the vehicle is stepped on, the throttle valve "this is the valve that regulates how much air enters the engine$ opens up more, letting in more air. The engine control unit "+23$ 5sees5 the throttle valve open with the help of sensors and increases the fuel rate in anticipation of more air entering the engine. It is important to increase the fuel rate as soon as the throttle valve opens6 otherwise, when the gas pedal is first pressed, there may be a hesitation as some air reaches the cylinders without enough fuel in it. 1ensors monitor the mass of air entering the engine, as well as the amount of oxygen in the exhaust. The +23 uses this information to 7fine tune the fuel delivery so that the air to fuel ratio is just right. The +23 generally works in two operating modes, namely open loop and closed loop. In closed loop !xygen sensor is used to sense the quantity of excess !xygen in the smoke and this information is used for the next cycle of injection. This is also called feedback mode. !n the other hand in open loop system the !xygen sensor is not used.

ECU

Engine

Exh !"# 8 Fig2.1: Open loop Operation mode

ECU

Engine

Ox$gen Sen"%&

Exh !"#

FIG 2.2: Clo ed loop Operation mode FIG 2.2: Clo ed loop Operation mode

Engine Sen or : In order to provide the correct amount of fuel for every operating condition, the engine control unit "+23$ has to monitor a huge number of input sensors. *ere are just a few9

Fig 2.): 'ario& Sen or & ed in a GDI $ tem

!a

airflo" en or Tells the +23 the mass of air entering the engine The device measures the amount of oxygen in the exhaust gas

O#$gen en or

and sends this information to the electronic control unit. If there is too much oxygen, the mixture is too lean. If there is too little, the mixture is too rich. In either case, the electronic control unit adjusts the air fuel ratio by changing the fuel injected. It is usually used with closed loop mode of the +23.

%hrottle po ition en or

/onitors the throttle valve position "which determines

how much air goes into the engine$ so the +23 can respond quickly to changes, increasing or decreasing the fuel rate as necessary

Coolant temperat&re en or Allows the +23 to determine when the engine has reached its proper operating temperature

'oltage en or /onitors the system voltage in the car so the +23 can raise the idle speed if voltage is dropping "which would indicate a high electrical load$

!anifold a( ol&te pre &re en or /onitors the pressure of the air in the intake manifold. The amount of air being drawn into the engine is a good indication of how much power it is producing6 and the more air that goes into the engine, the lower the manifold pressure, so this reading is used to gauge how much power is being produced.

Engine peed en or /onitors engine speed, which is one of the factors used to calculate the pulse width.

Cran* +ngle

en or

/onitors the position of the piston and gives the

information to the +23. Accordingly the +23 adjusts the valve timing.

Fuel Injectors: The solenoid operated fuel injector is shown in the figure above. It consists of a valve body and needle valve to which the solenoid plunger is rigidly attached. The fuel is supplied to the injector under pressure from the electric fuel pump passing through the filter. The needle valve is pressed against a seat in the valve body by a helical spring to keep it closed until the solenoid winding is energi.ed. &hen the current pulse is received from the electronic control unit, a magnetic field builds up in the solenoid which attracts a plunger and lifts the needle valve from its seat. This opens the path to pressurised fuel to emerge as a finely atomi.ed spray. The amount of fuel supplied to the engine is determined by the amount of time the fuel injector stays open. This is called the pulse width, and it is controlled by the +23. The injectors are mounted in the intake manifold so that they spray fuel directly at the intake valves. A pipe called the fuel rail supplies pressuri.ed fuel to all of the injectors.

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Fig 2.,: Electronic F&el In-ector ELECTRONIC FUEL INJECTION There are two types of electronic fuel injection. They are, %. /ultipoint 'uel Injection "/='I$ ). (asoline #irect Injection "(#I$ MULTI POINT FUEL INJECTION 'MPFI( +ngines with multi port injection have a separate fuel injector for each cylinder, mounted in the intake manifold or head just above the intake port.

Fig 2..: F&el In-ection in a !/FI $ tem

Thus, a four cylinder engine would have four injectors, a >: would have six injectors and a >< would have eight injectors. /ulti port injection systems are more expensive because of the added number of injectors. ?ut having a separate injector for each cylinder makes a @

big difference in performance. The same engine with multi port injection will typically produce %A to 4A more horsepower than one with carburetor because of better cylinder to cylinder fuel distribution.

CHAPTER ) * GASOLINE DIRECT INJECTION

Fig ).1: + GDI S$ tem In conventional engines, fuel and air are mixed outside the cylinder. This ensures waste between the mixing point and the cylinder, as well as imperfect injection timing. ?ut in the (#I engine, petrol is injected directly into the cylinder with precise timing, eliminating waste and inefficiency. ?y operating in two modes, 3ltra Bean 2ombustion

%A 'ig9 ;

/ode and 1uperior !utput /ode, the (#I engine delivers both unsurpassed fuel efficiency and superior power and torque. The (#I engine switches automatically between modes with no noticeable shift in performance. All the driver notices is a powerful driving experience, and much lower fuel bills. It0s the best engine on the market.

In internal combustion engines, gasoline direct injection "(#I$ is a variant of fuel injection employed in modern two and four stroke petrol engines. The petrolCgasoline is highly pressuri.ed, and injected via a common rail fuel line directly into the combustion chamber of each cylinder, as opposed to conventional multi point fuel injection that happens in the intake tract, or cylinder port.

+OR,ING The fuel from the fuel tank enters into the high pressure fuel pump through the fuel feed line. The high pressure pump pressuri.es the fuel up to (#I requirement. The high pressure fuel pump moves into common rail, fuel gets stored in the common rail which is connected to the injector. &hen +23 gets output signals to injector fuel is sprayed into the cylinder and it continues. 'or safety of common rail it has a critical value or threshold value ehen it reaches that particular value the fuel pressure sensor senses the signals to +23. +23 inturn switch off the high pressure fuel pump thereby cutting off fuel. 1imilarly excess pressure in common rail is relieved by relief valve which opens and excess high pressure fuel goes to fuel tank and the cycle repeats

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CHAPTER TECHNICAL FEATURES

There are four technical features that make up the foundation technologies are The 3pright 1traight Intake =ort supplies optimal airflow into the cylinder. The 2urved top =iston controls combustion by helping shape the air fuel mixture. The *igh =ressure 'uel =ump supplies the high pressure needed for direct in cylinder injection. The *igh =ressure 1wirl Injector controls the vapori.ation and dispersion of the fuel spray.

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Fig ,.1: %echnical Feat&re of GDI Engine

CHAPTER . COMBUSTION MODES IN GDI


Two Combustion Modes: In response to driving conditions, the (#I engine changes the timing of the fuel spray injection, alternating between two distinctive combustion modes stratified charge "3ltra Bean combustion$, and homogenous charge "1uperior !utput combustion$. 3nder normal driving conditions, when speed is stable and there is no need for sudden acceleration, the (#I engine operates in 3ltra Bean /ode. A spray of fuel is injected over the piston crown during the latter stages of the compression stroke, resulting in an optimally stratified air fuel mixture immediately beneath the spark plug. This mode thus facilitates lean combustion and a level of fuel efficiency comparable to that of a diesel engine. The (#I engine switches automatically to 1uperior !utput /ode when the driver accelerates, indicating a need for greater power. 'uel is injected into the cylinder during the piston0s intake stroke, where it mixes with air to form a homogenous mixture. The homogenous mixture is similar to that of a conventional /=I engine, but by utili.ing the

%Fig ..1: %"o com(& tion mode

unique features of the (#I, an even higher level of power than conventional petrol c

CHAPTER / CHARACTERISTICS OF THE GDI ENGINE


In-cylinder Airflow: The (#I engine has upright straight intake ports rather than hori.ontal intake ports used in conventional engines. The upright straight intake ports efficiently direct the airflow down at the curved top piston, which redirects the airflow into a strong reverse tumble for optimal fuel injection.

%4 Fig 0.1: Compari on of f&el in-ection

Precise Control over the Air/Fuel Mixture: The (#I engine0s ability to precisely control the mixing of the air and fuel is due to a new concept called wide spacing,5 whereby injection of the fuel spray occurs further away from the spark plug than in a conventional petrol engine, creating a wide space that enables optimum mixing of gaseous fuel and air. In stratified combustion "3ltra Bean /ode$, fuel is injected towards the curved top of the piston crown rather than towards the spark plug, during the latter stage of the compression stroke. The movement of the fuel spray, the piston head0s deflection of the spray and the flow of air within the cylinder cause the spray to vapourise and disperse. The resulting mixture of gaseous fuel and air is then carried up to the spark plug for ignition. The biggest advantage of this system is that it enables precise control over the air to fuel ratio at the spark plug at the point of ignition.

Fig 0.2: /reci e Control o1er the +2F 3atio

The (#I engine0s intake ports have been made straight and upright to create a strong flow that facilitates mixing of the air and fuel. Air is drawn smoothly and directly down through the intake ports toward the cylinder, where the piston head redirects it, forcing it %8

into a reverse vertical tumble flow, the most effective flow pattern for mixing the air and fuel and carrying the mixture up to the spark plug. The (#I engine0s pistons boast unique curved tops forming a rounded combustion chamber the most effective shape for carrying the gaseous fuel up to the spark plug. In addition to its ability to mix thoroughly with the surrounding air, the fuel spray does not easily wet the cylinder wall or the piston head. In homogeneous combustion "1uperior !utput /ode$, fuel is injected during the intake stroke, when the piston is descending towards the bottom of the cylinder, vapori.ing into the air flow and following the piston down. Again, it0s all in the timing. ?y selecting the optimum timing for the injection, the fuel spray follows the movement of the piston, but cannot catch up. In this case, as the piston moves downward and the inside of the cylinder become larger in volume, the fuel spray disperses widely, ensuring a homogenous mixture. Fuel Spray: Newly developed high-pressure swirl injectors provide the ideal spray pattern to match each engine operational modes. And at the same time by applying highly swirling motion to the entire fuel spray, they enable sufficient fuel atomization that is mandatory for the GD even with a relatively low fuel pressure of !"#g$cm%.

Fig0.): F&el Spra$ Characteri tic %:

!timi"ed Confi#ur$tion of the Combustion Ch$mber : The curved top piston controls the shape of the air fuel mixture as well as the airflow inside the combustion chamber, and has an important role in maintaining a compact air fuel mixture. The mixture, which is injected late in the compression stroke, is carried toward the spark plug before it can disperse. Re 0i1 #i%n %2 0%3e& 2!e0 4%n"!56#i%n In conventional gasoline engines, dispersion of an air fuel mixture with the ideal density around the spark plug was very difficult. *owever, this is possible in the (#I engine. 'urthermore, extremely low fuel consumption is achieved because ideal stratification enables fuel injected late in the compression stroke to maintain an ultra lean air fuel mixture.

CHAPTER 7 GDI VS MPFI

THE DIFFERENCE BET+EEN NE+ GDI AND CURRENT MPI 'or fuel supply, conventional engines use a fuel injection system, which replaced the carburetion system. /=I or /ulti =oint Injection, where the fuel is injected to each intake port, is currently the one of the most widely used systems. *owever, even in /=I engines there are limits to fuel supply response and the combustion control because the fuel mixes with air before entering the cylinder. /itsubishi set out to push those limits by developing an engine where gasoline is directly injected into the cylinder as in a diesel engine, and moreover, where injection timings are precisely controlled to match load conditions. %;

TECHNICAL FEATURES %he GDI engine fo&ndation technologie

Item Bore x Stroke (mm) Displacement Number of !lin"ers Number of &al'es ompression -atio ombustion ,amber

GDI 81.0 x 89.0 1834 #$%4 #ntake( )* +x,aust( ) 1).0 ur'e" /op 0iston 2pri3,t Strai3,t #n% !lin"er Direct #n4ection .0

Conventional MPFI 10.. 1lat top 0iston Stan"ar" 0ort #n4ection 3.3

#ntake 0ort 1uel S!stem 1uel 0ressure (50a) TECHNICAL

CHAPTER 8 CARS +ITH GDI TECHNOLOGY


In 199/ gasoline direct injection appeared in the automotive market. /itsubishi was the first with a GDI engine in the Dapanese market with its (alantCBegnum0s ,G4) %.< B inline four. It was subsequently brought to +urope in %@@; in the 2arisma, although +urope0s then high sulphur unleaded fuel led to emissions problems, and fuel efficiency was less than expected. It also developed the first six cylinder (#I powerplant, the 0G5, -.8 B >:, in %@@;. /itsubishi applied this technology widely, producing over one million

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(#I engines in four families by )AA%.

Fig 6.1: !it &(i hi galant

In 1998, Toyota0s #4 direct injection system first appeared on various Dapanese market vehicles equipped with the S7 and 87 engines. Toyota later introduced its #4 system to +uropean markets with the 1+79FSE engine found in the )AA% Avensis. and 31 markets %@

in )AA8 with the )G39FSE engine found in the Bexus (1 -AA. Toyota0s 2G39FSE >: uses a more advanced direct injection system, which combines both direct and indirect injection using two fuel injectors per cylinder, a traditional port fuel injector "low pressure$ and a direct fuel injector "high pressure$ in a system known as #4 1.

Fig 6.2: :e#& GS );;

)A

In 2:::, the >olkswagen (roup introduced its gasoline direct injection engine in the >olkswagen Bupo, a %.4 litre inline four unit, under the product name 5'uel 1tratified Injection5 "FSI$. The technology was adapted from Audi0s Be /ans prototype race car E<. >olkswagen (roup marques use direct injection in its ).A B '1I turbocharged and naturally aspirated four cylinder engines.

Fig 6.): 'ol* "agen :&po

)%

In 2::2, the Alfa Eomeo %8: with a direct injection engine, the DT1 "Det Thrust 1toichiometric$ went on sale and today the technology is used on almost every Alfa Eomeo engine.

Fig 6.,:+lfa 3omeo 1.0 In 2::7, 'ord introduced its new 'ord +co?oost engine technology designed for a range of global vehicles "from small cars to large trucks$. The engine first appeared in the )AA; Bincoln /FE 2oncept under the name %"in Force. The new global +co?oost family of

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4 cylinder and : cylinder engines features turbo charging and direct injection technology.

Fig 6..::incoln !<3 concept

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In 2::8, ?/& released the G: x#rive8Ai equipped with a direct injected twin turbo engine.

Fig 6.0: =0 #Dri1e.;i

In 2::9, 'errari began selling the front engine 2alifornia with a direct injection system, and announced that its new 48< Italia car will also feature a direct injection system, a first for 'errari mid rear engine setups. =orsche also began selling the @@; and 2ayman equipped with direct injection. 'ord produced the new generation Taurus 1*! and 'lex

)4

with a -.8 B twin turbo +co?oost > : with direct injection.

Fig 6.5:Ferrari California

)8

In 2:1: Infiniti will produce the /8: which includes #I.

Fig 6.6:Infiniti !.0

2:1:9 *yundai 1onata )A%% model will come with (#I engines. *yundai0s Theta I 4 engine family is a proprietary design, engineered in ,amyang, Forea and currently in production for applications all over the world at volumes exceeding ) million annually. The new Theta II ).4B (#I engine is a derivative of the Theta with major upgrades in technology and architecture. It features a unique block, valve train, front end accessory

):

drive "'+A#$, intake manifold, pistons, rods, crankshaft and variable induction system.

Fig 6.4:>$&ndai onata 2;11 model

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CHAPTER 9 OBJECTIVES OF GDI

MAJOR OBJECTIVES OF THE GDI ENGINE &ltra-low fuel consumption, which betters that of diesel engines. 'uperior power to conventional () engines. +fficient emission control.

VEHICLE FUEL CONSUMPTION Fuel Consum!tion durin# Idlin#: The (#I engine maintains stable combustion even at low idle speeds. /oreover, it offers greater flexibility in setting the idle speed. 2ompared to conventional engines, its fuel consumption during idling is 4AH less.

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Fig 4.1: Compari on of F&el con &mption Fuel Consum!tion durin# Cruisin# %rive: At 4AkmCh, for example, the (#I engine uses -8H less fuel than a comparably si.ed conventional engine.

Fig4.2: %or?&e fl&ct&ation @ f&el con &mption &etter Fuel 'fficiency: The concept of wide spacing makes it possible to achieve a stratified mixture, enabling the (#I engine to offer stable, ultra lean combustion, allowing a significant improvement in fuel efficiency. In addition to ultra lean combustion, the (#I engine achieves a higher compression ratio because of its anti knocking characteristic and precise control of injection timing. These features contribute )@

to drastically lower fuel consumption. The (#I engine improves fuel economy by --H in the Dapanese %A %8 mode driving cycle which represents typical urban driving conditions.

'mission Control: =revious efforts to burn a lean air fuel mixture have resulted in difficulty to control ,!x emission. *owever, in the case of (#I engine, @;H ,!x reduction is achieved by utili.ing high rate +(E "+xhaust (as Eatio$ such as -AH that is allowed by the stable combustion unique to the (#I as well as a use of a newly developed lean ,!x catalyst.

CHAPTER 1: ACHIEVEMENTS OF GDI

ACHIEVEMENTS 'n#ine !erform$nce: 2ompared to conventional /=I engines of a comparable si.e, the (#I engine provides approximately %AH greater outputs and torque at all speeds.

-A

Fig 1;.1: Compari on of Engine performance

(ehicle Acceler$tion: In high output mode, the (#I engine provides outstanding acceleration. The following chart compares the performance of the (#I engine with a conventional /='I.

Fig 1;.2: Compari on of 1ehicle acceleration Im!roved (olumetric 'fficiency: 2ompared to conventional engines, the /itsubishi (#I engine provides better volumetric efficiency. The upright straight intake ports enable smoother air intake. And the vapori.ation of fuel, which occurs in the cylinder at a late stage of the compression stroke, cools the air for better volumetric efficiency.

Fig1;.): Compari on of 'ol&metric efficienc$

-%

Incre$sed Com!ression )$tio: The cooling of air inside the cylinder by the vapori.ation of fuel has another benefit, to minimi.e engine knocking. This allows a high compression ratio of %), and thus improved combustion efficiency.

Fig1;.,: Compari on of compre ion ratio

CHAPTER 11 CONCLUSION

The world need to protect the environment , and the more stringent emission regulations that evolved year after year have challenged vehicle manufacturers among other things to produce vehicles that not only conform to regulations but also consistently exceed them. The (#I engine does this and has technology "adaptive learning$ to ensure that as the engine ages it will continue to conform by adjusting itself as the engine components and emission devises wear.

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(asoline direct injection "(#I$ engine technology has received considerable attention over the last few years as a way to significantly improve fuel efficiency without making a major shift away from conventional internal combustion technology. In many respects, (#I technology represents a further step in the natural evolution of gasoline engine fueling systems.

CHAPTER 12 REFRENCE

+,+E(I J +,>IE!,/+,TAB A,ABI1I1, I,2. K2ost J ?enefits of the (asoline #irect Injection +ngineL, Arlington, >A )))A@.

I!,( DI, FI/, K+ffect of /otion on 'uel 1pray 2haracteristics in A (#I +ngineL, Institute for Advanced +ngineering, %@@@ A% A%;;.

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#!/F3,#&AE, KA course in I2 enginesL. 2E!31+CA,(BI,, KAutomotive mechanicsL. www.mitsubishi motors.co.jp www.auto.howstuffswork.com www.boschusa.com www.delphi.com

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