Mercedes Mullins
The primary function of a diesel fuel feed system is to control the supply of fuel to the engine. The fuel tank, supply pump, and filter are all part of the low-pressure side of the fuel system, while the high-pressure side includes the high-pressure pump, accumulator, fuel injector, and nozzle. The fuel tank stores the fuel supply, maintains its temperature, and dissipates heat from the fuel returning from the engine. Fuel filters are crucial for preventing damage and premature wear by trapping fine particles and water before they enter the injection system. Modern diesel fuel injectors use piezoelectricity to achieve extremely precise fuel injection. The diesel fuel system as a whole ensures that a precise amount of atomized and pressurized fuel is injected into each engine cylinder at the right time.
| Characteristics | Values |
|---|---|
| Main purpose | Control the fuel supply to the engine |
| Function | Inject a precise amount of atomized and pressurized fuel into each engine cylinder at the proper time |
| Fuel tank | A reservoir that holds the fuel supply and helps maintain its temperature at a level below its flash point |
| Fuel tank characteristics | Capable of storing enough fuel to operate the engine for a reasonable length of time, closed to prevent contamination, vented to allow air to enter and replace fuel, has openings to fill, discharge, and drain |
| Fuel supply pump | Draws fuel from the tank and delivers it to the high-pressure pump, can be electrically or mechanically driven by the engine |
| Fuel filters | Removes water and contaminants from fuel, can be a one-stage or two-stage system |
| Fuel injection pump | Metered amount of fuel is highly pressurized for the fuel injectors, can be operated by hand to bleed and prime the engine |
| Fuel injectors | Deliver a precise amount of atomized and pressurized fuel into each cylinder, can use piezoelectricity for high precision and to handle high pressure |
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What You'll Learn
Fuel tank design and function
The fuel tank is an essential component of the diesel fuel system, which comprises everything from the fuel tank to the engine's fuel injectors. The tank's design and function are crucial to ensuring the efficient and safe operation of the engine.
The primary function of the fuel tank is to store enough fuel to operate the engine for a reasonable length of time. The size and shape of the tank can vary depending on its specific purpose. For example, in the "gravity system", the fuel tank is mounted at the highest position to utilise gravity in feeding fuel into the carburetor float chamber. This design is typically used for smaller vehicles such as bikes and quads. On the other hand, the pressure feed system employs a hermetically sealed (airtight) fuel tank.
The fuel tank must be closed to prevent contamination by foreign objects, including water, which is a common issue in diesel fuel systems. Water can cause rapid oxidation of ferrous metal components, leading to injection component seizure and metering component failure. To mitigate this, fuel tanks are typically designed with multiple openings. Three openings are required: one to fill the tank, one to discharge fuel, and one to drain it. Additionally, the tank must be vented to allow air to enter and replace the fuel drawn by the engine, while also preventing excessive pressure accumulation.
The fuel tank also plays a crucial role in maintaining the fuel temperature. It helps to keep the fuel temperature below its flash point and dissipates heat from the fuel returned from the engine. This excess fuel, heated by contact with hot engine components, is returned to the tank to improve the vehicle's low-temperature operability.
Furthermore, the fuel tank should be constructed to be corrosion-resistant and leakproof, with the ability to withstand pressures of at least 30 kPa. These design considerations are essential to prevent fuel leaks and ensure the safe operation of the diesel fuel system.
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Fuel injection systems
The primary function of a fuel injection system is to deliver fuel into the engine cylinders, while precisely controlling the injection timing, fuel atomization, and other parameters. The main types of injection systems include pump-line-nozzle, unit injector, and common rail.
The high-pressure side components include a high-pressure pump, accumulator, fuel injector, and fuel injector nozzle. The high-pressure pump delivers fuel to the accumulator, which then sends it through tubing to the injectors. The fuel injectors deliver a precise amount of atomized and pressurized fuel into each cylinder. Modern diesel fuel injectors, such as those found in common rail fuel systems, use piezoelectricity, which allows for extremely precise fuel injection and can handle very high pressures.
Fuel atomization, or the process of breaking down fuel into very small particles, is a critical aspect of fuel injection systems. Small droplets ensure that all the fuel has a chance to vaporize and participate in the combustion process, resulting in increased power and fuel economy, decreased engine noise, and smoother operation.
To ensure the proper functioning of fuel injection systems, fuel filtration is essential. Fuel filters help remove contaminants and prevent damage to the system. Most diesel fuel systems employ multiple stages of filtration to ensure the purity of the fuel.
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Fuel filters
The main function of a diesel fuel feed system is to control the supply of fuel to the engine. The fuel feed system is comprised of several components, one of the most important being the fuel filter.
The primary filter is usually located somewhere on the fuel line between the fuel tank and the engine. Its purpose is to remove larger particles. The secondary filter is typically found near the engine and is designed to withstand higher pressures and remove smaller particles that could damage the engine. One-stage systems, on the other hand, remove both larger and smaller particles in a single filter.
Box-type filters are completely replaceable and do not require cleaning. In contrast, filters with replaceable elements must be thoroughly cleaned when replacing elements, ensuring that no dirt residue migrates to the intricate parts of the fuel injection system.
DEUTZ fuel filters, for example, provide highly efficient separation of harmful particles and water, preventing diesel fuel gelling and ensuring consistent engine performance. Poorly filtered fuel can compromise engine performance, fuel consumption, and even shorten the engine's lifecycle. Therefore, timely changing of fuel filters and proper disposal of old filters are crucial for the optimal performance of diesel engines.
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Fuel lines
The main purpose of a diesel fuel feed system is to control the supply of fuel to the engine. Diesel fuel feed systems use an injector to supply the fuel to the engine cylinders.
Diesel fuel feed systems consist of various components, including the fuel tank, fuel supply pump, fuel filter, high-pressure pump, accumulator, fuel injector, and fuel injector nozzle. The fuel tank stores enough fuel to operate the engine for a reasonable length of time. It is designed to prevent contamination by foreign objects and has openings for filling, discharging, and draining fuel.
The fuel supply pump, or lift pump, draws fuel from the tank and delivers it to the high-pressure pump. Modern fuel pumps can be driven electrically or mechanically by the engine. The high-pressure pump then delivers the fuel to the fuel injector, which injects a precise amount of atomized and pressurized fuel into each engine cylinder.
There are three types of diesel fuel lines: heavyweight lines, medium-weight lines, and lightweight lines. Heavyweight lines are used for high pressures between the injection pump and injectors, medium-weight lines are used for light or medium fuel pressures between the fuel tank and injection pump, and lightweight lines are used where there is little to no pressure. Diesel fuel must be filtered multiple times to prevent damage to the engine components. A typical system may have three stages of progressive filters: a filter screen at the tank or transfer pump, a primary fuel filter, and a secondary fuel filter.
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Fuel pumps
The primary function of a diesel fuel feed system is to inject a precise amount of atomized and pressurised fuel into each engine cylinder at the right time. The fuel feed pump is a crucial mechanical component of this system, supplying fuel to the diesel injection system.
There are two main types of fuel pumps: low-pressure and high-pressure. The low-pressure side of the fuel system includes the fuel tank, the fuel supply pump, and the fuel filter. The fuel supply pump, also known as the lift pump, is responsible for drawing fuel from the tank and delivering it to the high-pressure pump. It is often sized to deliver more fuel than the engine consumes, with the excess serving functions like cooling the injectors and maintaining a constant fuel temperature. The low-pressure side also includes a fuel filter, which is essential for preventing damage and premature wear on the system by removing contaminants.
The high-pressure side of the fuel system includes the high-pressure pump, accumulator, fuel injector, and fuel injector nozzle. Modern high-pressure pumps are electrically or mechanically driven by the engine, with the latter type using the plunger and cam method of fuel injection. The high-pressure pump is critical as it pushes fuel through the lines and filters, preventing issues like air being drawn into the system or collapsed hoses.
To ensure the proper functioning of the fuel injection system, manufacturers must pay close attention to the sizing and placement of fuel pumps within the system.
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Frequently asked questions
The main purpose of a diesel fuel feed system is to control the supply of fuel to the engine.
A diesel fuel feed system injects a precise amount of atomized and pressurised fuel into each engine cylinder at the right time. This fuel mixes with hot compressed air to cause combustion.
A diesel fuel feed system consists of a fuel tank, fuel supply pump, fuel filters, high-pressure pump, accumulator, fuel injector, and fuel injector nozzle.
Fuel injectors use pressure-operated valves to spray a small amount of fuel into the engine at the right time. Modern fuel injectors use piezoelectricity to achieve extremely precise fuel injections.
