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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Common Rail Injection for CAT MaK Engines
Stefan Haas
Engineering Supervisor Fuel Systems / Control & Monitoring
Caterpillar Motoren GmbH & Co. KG
Off-Highway Engines Conference
Frankfurt/Main, Germany
28 June 2011
2
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Content
Introduction
Systems Overview (Generation 1)
� Technical Data
� Mechanical System
� Electronical System
Performance Results
Operational Experience
� Examples
� Further Improvements
Future Developments (Generation 2)
3
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Introduction
Development of Caterpillar Common Rail - Why?
� Development of a fully flexible fuel injection system
� Part of a technology tool box for future products
� Enabling key objectives of upcoming products
� Maintain or improve current engine performance at morestringent emission levels (i.e. acceleration, fuel consumption, smoke reduction)
� Enable future power density increase
� Easy fuel system adaptation to different engine types, applications, emission technology, special customer needs
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
0
4
8
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16
2005 2010 2015 2020 2025
Time (Year)
NO
x E
mis
sio
n
(g/k
Wh
)
IMO I
IMO II IMO III
Incentives
§§
? Incentives ?
§§ §§§§ , Open Sea
ECA‘ s
Introduction
� NOx Emissions Legislation
5
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
0
1
2
3
4
5
2000 2005 2010 2015 2020 2025
Time (Years)
Su
lph
ur
Co
nte
nt
in F
ue
l (
%) Open Sea
ECA‘sAverage Today
Introduction
� SOx Emissions Legislation
6
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Content
Introduction
Systems Overview (Generation 1)
� Technical Data
� Mechanical System
� Electronical System
Performance Results
Operational Experience
� Examples
� Further Improvements
Future Developments (Generation 2)
7
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Technical Data
� Joint development of L‘Orange GmbH and Caterpillar Motoren GmbH & Co. KG for engine types M 32 and M 43
� Rated rail pressure: 1.500 bar
� Injection quantity per stroke at rated condition: 6.500 / 16.000 mm³
� Multi-shot capability (pre, main, post)
� All fuels acc. ISO8217 F-DMA up to ISO8217 F-RMK55
� Fuel temperature at pump inlet: 5 – 150 °C
� Typical fuel viscosity operating range: 2,5 – 16 cSt
� Maximum cold start viscosity: 145 cSt (F-RMK55 HFO at 80 °C)
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Safety Valve
Flow Limiter
Combination Valve
Connection to High Pressure Pumps
High Press. Line
Rail - Rail
Leak DetectionUnit
Mechanical System
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Core System• Injector booster• High pressure closed loopcontrol• Speed Timing Measurement
Performance System• Intake manifold pressure(Charge air)• Intake manifold temperature• Exhaust temperature• Turbine inlet temperature• Engine coolant temperature• Fuel rail pressure• Atmospheric pressure
Electronical System
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Content
Introduction
Systems Overview (Generation 1)
� Technical Data
� Mechanical System
� Electronical System
Performance Results
Operational Experience
� Examples
� Further Improvements
Future Developments (Generation 2)
11
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Performance Results
Fuel Consumption
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Performance Results
Engine Behaviour
� Improved torque at lowerspeed and part loadcompared to standardcombinator curve
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Performance Results
Soot Emissions
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Content
Introduction
Systems Overview (Generation 1)
� Technical Data
� Mechanical System
� Electronical System
Performance Results
Operational Experience
� Examples
� Further Improvements
Future Developments (Generation 2)
15
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Installation
� Parallel running on power grid
� Preheating and start ability on HFO
Fuel system reliability
� Mechanical parts (fuel types, operation regime)
� Electrics & Electronics (vibrations, fault identification)
� Fuel filtration
� Cleanliness
Operational Experience
16
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Engine start ability in HFO mode
Extended customer requirement
� 20 sec from engine start to rated speed (Standard: 30 sec)
Modifications made on
� Fuel injection system preheating
� Software
Improvements achieved on
� Engine start ability from initially 28.5 sec to less than 20 sec
Operational Experience - Examples
17
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Operational Experience - Examples
Engine start ability
� Engine start after 8.5 hrs standstill on HFO
� 0-600 RPM in approx. 18.6 sec
Blue: actual speed
Green: desired speed
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
High Pressure Pump
� Seized pump elements due to formation of deposits
� Composition of fuels in use suspected
� Modifications on pump element introduced
� No further pump failures
Operational Experience - Examples
19
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Operational Experience - Examples
Injector
� Stable injector behavior over the entire lifetime
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Fuel filtration (to prevent sudden injector failures)
� Mesh size
� Specific filter load, especially under HFO conditions
Cleanliness during assembly / maintenance
� High requirements on procedures
Maintainability / servicability
� Fault finding, cable and pipe routing and fastening
Further Improvements
21
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Content
Introduction
Systems Overview (Generation 1)
� Technical Data
� Mechanical System
� Electronical System
Performance Results
Operational Experience
� Examples
� Further Improvements
Future Developments (Generation 2)
22
Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Further rail pressure increase
� For EGR technology to prevent smoke
� To improve full load fuel consumption
� Rail volume close to injector to enable higher pressuresmaintaining multi-shot capability
� Further fine tuning to improve NOx-fuel consumption trade-off
� To allow higher power densities
Low-sulphur-fuel capability increase
Future Developments (Generation 2)
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Caterpillar Motoren GmbH & Co. KG, Stefan HaasCommon Rail Injection for CAT MaK EnginesOff-Highway Engines Conference, Frankfurt/Main, 28 June 2011
Thank you for your attention!