Analysis of Rail Pressure Stability in an Electronically Controlled High-Pressure Common Rail Fuel Injection System via GT-Suite Simulation

Hongfeng Jiang, Zhejun Li, Feng Jiang, Shulin Zhang (), Yan Huang and Jie Hu
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Hongfeng Jiang: School of Automotive and Information Engineering, Guangxi Eco-Engineering Vocational and Technical College, Liuzhou 545006, China
Zhejun Li: School of Mechanical and Automotive, Guangxi University of Science and Technology, Liuzhou 545616, China
Feng Jiang: School of Mechanical and Automotive, Guangxi University of Science and Technology, Liuzhou 545616, China
Shulin Zhang: School of Mechanical Engineering, Liuzhou Institute of Technology, Liuzhou 545616, China
Yan Huang: School of Mechanical Engineering, Liuzhou Institute of Technology, Liuzhou 545616, China
Jie Hu: School of Mechanical and Automotive, Guangxi University of Science and Technology, Liuzhou 545616, China

Energies, 2025, vol. 18, issue 3, 1-33

Abstract: The high-pressure common rail (HPCR) injection system, a key technology for enhancing diesel engine performance, plays a decisive role in ensuring fuel injection precision and combustion efficiency through rail pressure stability. This study establishes a coupled simulation model of an electronically controlled HPCR injection system and a diesel engine, using GT-Suite to systematically investigate the effects of fuel supply pressure, camshaft speed, high-pressure pump plunger parameters, and inlet and outlet valve characteristics on rail pressure fluctuations. Gray relational analysis quantifies the correlation between these factors and rail pressure variations. The results demonstrate that increasing camshaft speed, injection pulse width, plunger mass, plunger length, plunger spring preload, inlet valve spring preload, and outlet valve body mass reduces rail pressure fluctuations, while variations in fuel supply pressure, plunger spring stiffness, and valve spring stiffness have minimal impact. Notably, the influence of outlet valve spring preload, inlet valve spring stiffness, and inlet valve body mass on rail pressure is nonlinear, with optimal values observed. Gray relational analysis further identifies inlet valve spring preload as having the highest correlation with rail pressure fluctuations (0.815), followed by inlet valve spring stiffness (0.625), with outlet valve spring preload (0.551) and stiffness (0.527) showing relatively lower correlations. This study provides valuable insights for optimizing the HPCR injection system design and contributes to advancements in diesel engine technology.

Keywords: high-pressure common rail (HPCR) system; rail pressure fluctuations; gray relational analysis (GRA); diesel engine (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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