THE COMMON INTEREST
VITAL NEWS finds out why COMMON RAIL is more important than ever and how it measures up to emission regulations and consumer demands .
As the diesel car parc continues to grow , so do emission regulations , performance and fuel efficiency expectations . This has created a growing market for common rail system components . The call for common rail products are constant throughout the year , making them a reliable and sustainable revenue stream . So much so , if motor factors and garages do not cater for diesel vehicles , they could be missing out on over half the market .
2004
DIESEL
33 %
New car registrations by fuel type – 2004 vs . 2014
The FPS common rail range offers access to new and remanufactured programmes from leading OE manufacturers of common rail products such as Bosch , Delphi , Denso and VDO . The offering provides excellent coverage of the UK vehicle parc to meet all customer needs .
COMMON RAIL EXPLAINED
1 Fuel pump
2 Fuel rail
3 Injectors
4 ECU
PETROL
67 %
The principal components of a typical common rail system The common rail system precisely controls the relationship between fuel-injection pressure and injection timing . This helps achieve higher performance characteristics with the lowest amount of emissions , maximising fuel efficiency . The common rail system keeps fuel permanently available for injection at a pressure that is matched to the operating state of the engine with the help of the ECU that constantly measures extremely fine tolerances ensuring consistent performance .
3
1
2014
2
4
DIESEL
50 %
AFV
2 %
PETROL
48 %
When the ECU ’ s electromagnet is fired to control the injector , a small ball bearing ( 0.3mm ) is lifted off its seat to release high pressure on the top of the needle , allowing the pressure at the nozzle to overcome the needle spring pressure . This allows the injector to fire . As the injector operates within such fine tolerances , fuel quality is essential to avoid damage from contaminants .
Common rail pumps do not need to be timed with the engine as they are controlled by the ECU . The pressure control valve varies the rail pressure according to load demand . The high pressure pump has three elements , each placed 120 ° apart . The eccentric drive operates each element compressing the fuel , forcing it out of the outlet to the high pressure fuel rail , providing fuel to the engine when required .
EURO 4 / 5 / 6 VEHICLES
INCREASED NO . OF INJECTIONS
INCREASING TEMPERATURE
SMALL PORT DIAMETER
2000
1995
HIGHER PRESSURES
2005
2010
1800-2000 bar
1600-2000 bar
1990
1400-1600 bar
1985
1800-2700 bar
( eg 25,000 to 37,000 psi )
Single injection 200 bar
2016
Diesel systems : ‘ The technological evolution ’
COMMON RAIL
1980 ROTARY PUMPS
REMANUFACTURED STANDARDS
Remanufactured parts within the FPS common rail range use only OE quality component parts and adhere to OE repair processes . All units are built to the exacting tolerances in an ISO 14664 Class 7 clean room compliant assembly facility . The facility ’ s air is conditioned , pressurised and filtered 16 times per hour , removing particles down to 0.5 microns . All units are tested using the OE test plan data on OE recommended test benches . This ensures that all units meet the OE specification and has the correct ‘ coding ’ applied where required .
A range of common rail products are available from FPS on the F : Drive and MAM Autocat . For more information , please contact your local FPS representative .
THE 6 STAGES OF THE REMANUFACTURING PROCESS
1
1 . Core to unit strip down for cleaning and component assessment 2 . Replacement of all service wear , critical component and failed parts 3 . Re-assembly in Class 7 ISO : 14644-1 accredited clean room facility
2 3 4 5 6
4 . Testing in OE approved test facility equipped with latest Bosch and Hartridge test benches 5 . Unit validation and coding 6 . Laser engraved and labelled for full traceability before packaging
VITAL NEWS ISSUE 44 COMMON RAIL DIESEL 11