See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/303633505

DEVELOPMENT OF FUEL INJECTION SYSTEM ON SINGLE CYLINDER

INTERNAL COMBUSTION ENGINE (PART 3)

Technical Report · May 2016

CITATIONS READS

0 2,514

5 authors, including:

Hamizan Mustaffa Muhammad ABDUL HISYAM Abu Hassan

Universiti Malaysia Pahang Universiti Malaysia Pahang
7 PUBLICATIONS   0 CITATIONS    3 PUBLICATIONS   0 CITATIONS   

SEE PROFILE SEE PROFILE

Muhammad Muzani Masri Muhammad Syafiq Bin Rusli

Universiti Malaysia Pahang Universiti Malaysia Pahang
4 PUBLICATIONS   0 CITATIONS    4 PUBLICATIONS   0 CITATIONS   

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

DEVELOPMENT OF FUEL INJECTION SYSTEM ON SINGLE CYLINDER INTERNAL COMBUSTION ENGINE View project

All content following this page was uploaded by Muhammad Muzani Masri on 29 May 2016.

The user has requested enhancement of the downloaded file.

 Mechanical System Design, 24 May 2016
Universiti Malaysia Pahang, Pekan, Malaysia

DEVELOPMENT OF FUEL INJECTION SYSTEM ON SINGLE CYLINDER

INTERNAL COMBUSTION ENGINE (PART 3)

H. Mustaffa, M. A. H. Abu Hassan, M. M. Masri, M. S. Rusli, C. A. F. Che

Mohamad

Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26600 Pekan,

Pahang, Malaysia,
Email: mastermuzani@gmail.com

ABSTRACT

This project focus on the development of a single cylinder fuel injection engine system.
This project done by converting the base of the single cylinder internal combustion
engine into single cylinder direct fuel injection engine. Due to the less of findings and
production of a fuel injection system for a single cylinder engine, it will give us a great
advantage to analyze this type of engine. We will analyzed the injection timing speed
and opening, mass of fuel, and the different of pressure given to fuel injector. A single
cylinder internal combustion motorcycle engine will be used in this project. The
development of the intake manifold for air intake and fuel injector was design using
SolidWorks software and then fabricate the intake manifold according to design
drawing model. The intake manifold material is stainless steel. The injection timing
speed has been calculated with different pressure input given to fuel injector. Fuel
injector was been control using Arduino Uno board and Arduino software, and the
speed and opening was been set in software.

Keywords: Fuel Combustion, Fuel Injection, Testing and Analysis.

INTRODUCTION

The first commercially successful internal combustion engine (ICE) was created
by Etienne Lenoir in 1859 and the first modern ICE was created by Siegfried Marcus in
1864 then realized by Nikolaus Otto in 1867 [1]. ICE is the production of mechanical
power usually made available on a rotating output shaft from chemical energy contained
in the fuel [2]. Internal combustion engine can be further classified as reciprocating,
wankel, and rotary gas turbine [3]. Reciprocating engine has divide by 2 class which are
spark ignition engine and compression ignition engine [4]. Spark ignition engine where
the combustion process of the air-fuel mixture is ignite by spark from spark plug which
is contrast to compression ignition engine [5]. The operation of spark-ignition (SI)
engines is categorized by a non-repeatability of rapid combustion rate between different
cycles at identical engine operating conditions, commonly referred to as cycle-to-cycle
variation or cyclic combustion variability [6]. An SI engine starts the combustion
process in each cycle by use of a spark plug [7]. The spark plug gives a high-voltage
electrical discharge between two electrodes which ignites the air-fuel mixture in the
combustion chamber surrounding the plug [8]. The spark ignition engine has two type
which are 4-stroke and 2-stroke engine [9]. The spark ignition engine cycle are similar
to otto cycle, and during the normal operation of the engine as the fuel mixture is being
compressed an electric are is created to ignite the fuel [9-12]. For 4-stroke engine, each
cylinder requires four stroke of its piston which is two revolutions of the crankshaft and
to complete the sequence of events which produce one power stroke [1, 2].

A carburetor is a device that blends air and fuel for an internal combustion
engine [13]. The carburetor works on Bernoulli’s principle [14]; the faster air moves,
the lower its static pressure, and the higher its dynamic pressure [15]. The basic
function of carburetor are to control the power delivered by the engine [16], adjusting
the airflow inducted according to driver demand [17], to meter the fuel flow into the
inducted air steam, while keeping the air/fuel ratio in the optimum range over the
engine’s entire working range, and to homogenize the air and fuel mixture in order to
make the ignition and combustion proceed properly [18]. The carburetor atomizes the
fuel and mixes with air in different proportions for various load condition which are
starting, idling, cruising and accelerating, it must supply correct amount of air fuel
mixture in correct proportion under all load conditions and speed of the engine [19].
The temperature affects the vaporization of fuel, high temperature leads to high rate of
vaporization [20]. The main disadvantage of basing a carburetor’s operation on
Bernoulli’s principle is that, being a fluid dynamic device, the pressure reduction in
venture tends to be proportional to the square of intake air speed [21].

Fuel injection is a system for mixing fuel with air in an internal combustion
engine [22], and the functional objectives for fuel injection systems vary such as power
output, fuel efficiency, emissions performance, reliability, smooth operation, initial cost
and maintenance cost but all of them share the central task of supplying fuel to the
combustion process [23]. When air-fuel mixture is combined in balanced way it’s called
the stoichiometric mixture, this measurement is very important for anti-pollution and
performance tuning reasons [24]. When this mixture is achieved the system has it best
performance. For gasoline systems, the stoichiometric mixture is approximately 14.7
times the mass of air to fuel [9]. The fuel delivery system is responsible for fuel
delivering at the engine, and the system is composed by the fuel tank, the pipes, one or
more fuel filters, a fuel pump that could be mechanical or electric and the fuel metering
components [25]. Fuel injector use an electronic injection system for gasoline engine for
indirect injection [26]. The injection amount is regulated by opening or closing the fuel
injector. Because the supply pressure is low, a simple turbine pump is sufficient instead
of a roller vane pump [27]. The control unit keeps track of all essential data, speed, load,
or temperature of the engine, but as well as the throttle-valve angle and position, or
whether the air conditioning is on or off and regulates the amount of fuel injected
according to this variables, and the idle-speed operation can be steered or via bypass
[25, 27-29]. Advantage of electronic injection system over carburetor are the precise
controls the fuel injection system has over the carburetor allow the improved efficiency
and lower emissions of pollutants [30], also it make better atomization of fuel, better
flow due the elimination of the venture of the carburetor and reduced response time to
rapid changes in input such as rapid movement of the accelerator [31].

2
 EXPERIMENTAL SET UP

3D Design

A 3D design drawing model for intake manifold was create before fabricate the
experimental intake manifold product. The fuel injector was been placed at the top of
intake manifold with 45 into the intake port as shown in figure 1 below. The cylinder
body of intake manifold has 15cm meter length, 3cm diameter, and 0.2cm thickness of
cylinder. The material we use is grade 310/310s stainless steel which is used in fluidized
bed combustors, kilns, radiant tubes, tube hanger for petroleum refining and steam
boiler. These grades contain 25% chromium and 20% nickel, making them highly
resistant to oxidation and corrosion [32]. Figure 2, shows the design drawing in top, side
and front view.

Figure 1: 3D Design drawing model using SolidWorks Software.

3
 Top

Front Side

Figure 2: Plane view for intake manifold design

Experimental Design

A fuel injection test rig was developed as shown in Figure 3. The fuel injection
system composed of fuel tank, injection sensor, fuel pump 12V, AC-DC 12V inverter,
fuel ball valve and fuel pressure regulator to adjust the injection pressure with the
maximum pressure of 8 bar [28]. The fuel injection system was electronically controlled
by the Electronic Control Unit (ECU) developed using Arduino software. The injection
controller enable to adjust the injection timings (in ms) based on the desired experiment.

4
 Figure 3: Schematic diagram of fuel injection system with control unit

Experimental Procedure

In order to study the relationship between injection timings with the volume of
fuel injected, the experiment was conducted with different variation of injection timing
monitored by the controlling unit. Meanwhile, to study the effect of injection pressure
on the volume of fuel injected, the experiment conducted at a different injection
pressure. This experiment is repeated at different injection timings. The injection
pressures were adjusted by using the fuel pressure regulator. Then, for the data
collection, the fuel injected into a beaker was weighed with electronic weight balance
and recorded.

Figure 4: Precisa Series 320 XB electronic weight balance used to measure weight of
fuel injected

5
 RESULTS AND DISCUSSION

Mass of Fuel vs. Injection Timing

The Figure 5 shows there are a slightly different between the experiment result
and the actual result. This is due to random error that cause by the student. Making the
exact timing in stopping the injection flow system which sometime the student may or
may not stop the machine too soon or sometimes too late before the times run out. Also,
the coding which has been write in Arduino may have an error or wrong speed input set
cause the slightly different of value in data. The finite reaction of stopping the machine
is not a mistake; it is just the limitation of one part of experimental process, the human
making the mistake. Random error can be reducing by averaging several measurements
as shown in Table 1.

Table 1: Mass of fuel with constant pressure

Injection Mass of Fuel (g) Actual
timing
(ms) 1 2 3 Average

1.6 0.4255 0.4555 0.4464 0.442467 0.421

2 0.7004 0.7071 0.699 0.702167 0.7197

4 2.0318 2.0318 2.0415 2.035033 1.8169

8 4.789 4.789 4.7962 4.7914 4.1437

12 7.25 7.0525 6.6128 6.971767 6.2388

Figure 5: Graph between mass of fuel vs. injection time

6
Mass of Fuel vs. Pressure

Figure 4 show the amount of fuel in different type of pressure. The line
represent different injection flow (1.6, 2, 4, 8 and 12 ms) which is constant during the
experiment is conducted. The highest mass of fuel is by 12 ms of injection flow at the
pressure 4 bar. This is because the higher the pressure, the faster the injections flow of
fuel [23].

Table 2: Mass of fuel with Constant 1.6 ms Injection Time

Pressure Mass of fuel (g)

(bar) 1 2 3 Average

2 0.3572 0.3360 0.3231 0.3387

3 0.5746 0.5672 0.5783 0.5736

4 0.6060 0.5690 0.5637 0.5796

Table 3: Mass of fuel with constant 2 ms injection time

Pressure Mass of fuel (g)

(bar) 1 2 3 Average

2 0.4290 0.4279 0.4514 0.4361

3 0.7345 0.7332 0.7288 0.7322

4 0.8188 0.8190 0.8165 0.8181

Table 4: Mass of fuel with constant 4 ms injection time

Pressure Mass of fuel (g)

(bar) 1 2 3 Average

2 1.0507 1.0540 1.0558 1.0535

3 1.7804 1.7837 1.7763 1.7801

4 2.0558 2.0697 2.0675 2.0643

7
 Table 5: Mass of fuel with constant 8 ms injection time

Pressure Mass of fuel (g)

(bar) 1 2 3 Average

2 2.3356 2.3432 2.3413 2.3399

3 4.0373 4.0349 4.0350 4.0357

4 4.7388 4.7300 4.7242 4.7310

Table 6: Mass of fuel with constant 12 ms injection time

Pressure Mass of fuel (g)

(bar) 1 2 3 Average

2 4.9114 4.9417 4.9499 4.9343

3 6.2873 6.2879 6.2867 6.2873

4 7.3749 7.3581 7.3500 7.3610

Figure 6: Graph between mass of fuel vs. pressure

8
 CONCLUSIONS

In conclusion, electronic fuel injection system are the precise controls the fuel
injection system has over the carburetor allow the improved efficiency and lower
emissions of pollutants, also it can been adjusted the timing speed and opening by using
computer to adjust the opening and timing, and the mechanical component for fuel
injection speed. it make better atomization of fuel, better flow due the elimination of the
venture of the carburetor and reduced response time to rapid changes in input such as
rapid movement of the accelerator [31]. In high speed cycle, it best to have high speed
injection timing control and opening. To get much an accurate data for future study, it
necessarily need an additional sensor such as air intake, temperature sensor, cylinder
pressure sensor and etc. Which can improved the fuel injection timing and control it to
get better fuel consumption and efficiency.

ACKNOWLEDGEMENTS

Alhamdulillah after all of the hard work that had been poured by all of group member,
the project had been successfully completed. With the brainstorming and teamwork for
almost fourteen week by all of group member this project are conducted smoothly.
Special thanks to our lecturer , Dr. Kumaran a/l Kadirgama and Dr Muhammad Bin Mat
Noor who involve in this project together with us by giving us a lot of interesting
examples and inspect our work flow and at the same time lifted a little bit of pressure
from us, thanks a lot sir. Also thanks to outer cycle of the group such as friends,
relatives and family which also give moral support and indirectly injected a full spirit
towards us. Last but not least to the entire group member, thanks and really appreciate
for the commitment that you all showed through this project period. May all of our hard
work, give us a good result until graduation. Thank you.

9
 REFERENCES

[1] J. B. Heywood, "Internal Combustion Engine Fundamentals," vol. 2nd Edition,

p. 481, 2000.
[2] W. W. Pulkrabek, "Engineering Fundamentals of the Internal Combustion
Engine," vol. 2nd Edition, p. 504, June 20, 2003 2003.
[3] U. K. Saha, "Wankel rotary combustion engine," QIP-CD Cell Project, vol. 3,
pp. 1-28, 2006.
[4] M. A. B. Yunus A. Cengel, "Thermodynamic An Engineering Approach," vol.
7th Edition, pp. 764-978, 2011.
[5] R. O. Annegret Uberall, Peter Elits, Jurgen Krahl, "A literature research about
particle emissions from engines with direct gasoline injection and the potential
to reduce these emission," Fuel, vol. 147, pp. 203-207, 6 January 2015 2015.
[6] C. A. Karine Truffin, Stephane Richard, Cecile Pera, "Using large-eddy
simulation and multivariate analysis to understand the sources of combustion
cyclic variability in a spark-ignition engine," Combustion and Flame, pp. 1-19,
July 1, 2015 2015.
[7] H. Z. Macklini Dalla Nora, "High load performance and combustion analysis of
a four-valve direct-injection gasoline engine running in the two-stroke cycle,"
Applied Energy, pp. 117-159, 27 August 2015 2015.
[8] D. A. Parts, "Spark Plugs Automotuve," Catalog 2010, pp. 1-220, 2010.
[9] A. Elfasakhany, "Investigations on the effects of ethanol-methanol-gasoline
blends in a spark-ignition engine: Performance and emission analysis,"
Engineering Science and Technology, an International Journal, vol. 18, pp. 713-
719, 5 May 2015 2015.
[10] A. S. Boru Jia, Zhengxing Zuo, Anthony Paul Roskilly, "Design and simulation
of a two- or four-stroke free-piston engine generator for range extender
applications," Energy Conversion and managment, vol. 111, pp. 289-298, 27
December 2015 2015.
[11] B. T. Venkata Suman Movva, "Simulation of fluid flow in internal combustion
engine using wave action simulation," pp. 1-111, May, 2004 2004.
[12] W. K. Wei Yanju, Wang Wenrui, Lui Shenghua, Chen Xiao, Yang Yajing, Bai
Shanwen, "Comparison study on the emission characteristics of diesel and
dimethyl ether orginated particulate matters," Applied Energy, pp. 357-369,
2014.
[13] V. A. W. H. Frank William Pittcuk, "Fundamental of Motor Vehicle
Technology," vol. 4th Edition, pp. 1-395, 1992.
[14] D. L. A. W.H. Crouse, "Automotive Engines," Tata McGraw Hill, vol. 1st
Edition, 1985.
[15] W. W. H. Bruce R. Munson, Alric P. Rothmayer, "Fundamental of Fluid
Mechanic," vol. 7th Edition 2014.
[16] Dellorto, "Carburetor: Basic Principles," Moto, pp. 1-34, 2007.
[17] V. Ganesan, "Simple Carburetor Operation," International Journal of
Automative and Mechanical Engineering, pp. 20-77, 2003.
[18] U. A. C. C. Program, "Principles of gasoline and diesel fuel systems," US Army
Bradley Fighting Vehicle System Mechanic, vol. 7 edition, pp. 1-125, 2010.
[19] U. K. Saha, "Internal Combustion Engine: Carburetor," QIP-CD Cell Project,
vol. 7, pp. 1-40, 2006.

10
 [20] T. Company, "Carburetor Identification, Troubleshooting and Service,"
TecumsehPower Engines & Transmissions, pp. 1-41, 2007.
[21] D. R. Bhola, "CFD analysis of flow through venturi of a carburetor," National
Institute of Technology Rourkela, pp. 1-42, 2011.
[22] R. M. Omar I. Award, Obed M. Ali, I.M. Yusri, A.A. Abdullah, A.F. Yusof,
M.M.Noor, "The effect of adding fusel oil to diesel on the performance and the
emissions characteristics in a single cylinder CI engine," Journal of the Energy
Institute, pp. 1-15, 2016.
[23] F. D. Ricardo Pimenta, "Fuel injection system (gasoline)," SIAUT - Sistem
Automovels, pp. 1-37, 2010.
[24] U. S. E. P. A. EPA, "Inventory of U.S. Greenhouse Gas Emissions and Sinks:
1990 - 2013," p. 564, April 15, 2015 2015.
[25] F. D. Luca, "History of Fuel Injection," American Bosch Arma Corporation, pp.
1-9, 2007.
[26] F. A. S. Technology, "Electronic Fuel Injection System ands Components,"
Industrial Drive Ashland, pp. 1-16, 2007.
[27] C. A. Karine Truffin, Stephane Richard, Cecile Pera, "Description of the fuel
injection pump," International Journal of Automative and Mechanical
Engineering, vol. 3, pp. 310-331, 2005.
[28] N. Enright, "Basic principles of opeation and applications of fuel injection
systems in petrol-powered cars," Limerick Institute of Technology, pp. 1-25,
2008.
[29] U. K. Saha, "Internal Combustion Engine: Fuel Injection Systems," QIP-CD
Cell Project, vol. 12, pp. 1-40, 2010.
[30] J. S. Taehoon Kim, Sungwook Park, "Effect of turbulence enhancement on
combustion process using a double injection strategy in direct-injection spark-
ignition (DISI)," International Journal of Heat and Fluid Flow, vol. 56, pp. 124-
136, July 21, 2015 2015.
[31] B. National, "Petrol injection systems for spark ignition engines," Business and
Technology Education Council, vol. 1, pp. 1-9, 2007.
[32] N. D. Institute, "Design guidelines for the selection and use of stainless steel,"
American Iron and Steel Institute, pp. 1-54, 2005.

11

View publication stats