Comparative tests of diesel injectors with current and upgraded nozzles

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Abstract

BACKGROUND: More than 60% of agricultural tractor failures are due to diesel engine failure. Half of diesel engine failures relate to the fuel supply system, which is mainly dependent on the service life of diesel injectors’ nozzles.

AIM: Increasing the durability of the nozzle by means of upgrading the nozzle needle.

METHODS: To increase the working life of the diesel injector nozzle, a new technical solution, the idea of which is applying a screw channel to the bearing surface of the needle, was proposed. The presence of the screw channel leads to axisymmetric pressure on the needle, which gives it increased stability and prevents the possibility of skewing and freezing. The Russian patent has been received for this invention. To confirm the expected effect, comparative laboratory tests were carried out with current and upgraded nozzle design. To carry out accelerated tests, the “dusty” fuel, obtained by adding quartz sand abrasive, was used. During the tests, the following were assessed: atomization quality, sealing cone tightness, hydraulic density, needle stroke and effective flow area. The assessment of wear of the mating surfaces of the nozzle depends on the value of the hydraulic density.

RESULTS: As a result of the experiment, it was found that the limiting value of hydraulic density for the current injectors occurs after 2500 operating hours and is characterized by a violation of tightness. For the upgraded injectors, the hydraulic density limit occurs after 4300 operating hours.

CONCLUSION: Applying a screw channel on the bearing surface of the needle helps to increase the service life of the diesel injector by 23%.

About the authors

Anzor L. Bolotokov

Kabardino-Balkarian State Agrarian University

Email: anzor.n@Inbox.ru
ORCID iD: 0000-0002-2977-4072
SPIN-code: 7116-4270

Cand. Sci. (Engineering), Associate Professor of the Technology for Maintenance and Repair of Machines in the Agricultural Industry Department

Russian Federation, Nalchik

Irina P. Troyanovskaya

South Ural State University; South Ural State Agrarian University

Author for correspondence.
Email: tripav63@mail.ru
ORCID iD: 0000-0003-2763-0515
SPIN-code: 6845-7532

Honorary Mechanical Engineer of the Russian Federation, Professor, Dr. Sci. (Engineering), Professor of the Tractors, Agricultural Machinery and Arable Farming Department, Professor of the Wheeled and Tracked Vehicles Department

Russian Federation, Chelyabinsk; Troitsk

Sergey A. Voinash

Kazan Federal University

Email: sergey_voi@mail.ru
ORCID iD: 0000-0001-5239-9883
SPIN-code: 9532-4604

Junior Researcher at the Intelligent Mobility Laboratory of the Institute of Design and Spatial Arts

Russian Federation, Kazan

References

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2. Fig. 1. The fuel injector with a screw channel of a needle: 1 — a body; 2 — a needle; 3 — a needle guide; 4 — a helical groove; 5 — a bearing part of the needle; 6 — a locking part of the needle; 7 — a fuel supply channel; 8 — an internal cavity of the body; 9 — nozzle holes; 10 — аn annular groove.

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3. Fig. 2. The FD-22 injector nozzles with (a) the upgraded and (b) the current needle.

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4. Fig. 3. The UTS1-VT-12/35 strain gauge station for fuel supply measuring.

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5. Fig. 4. The KI-35478 bench for diesel injectors testing.

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6. Fig. 5. The KI-3333 device for nozzles testing and adjusting.

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7. Fig. 6. Change in hydraulic density and effective flow area depending on operating time.

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8. Fig. 7. Change in hydraulic density depending on operating time during accelerated bench tests of (1) the upgraded and (2) the current nozzles.

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