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Published: 2005

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The collaborative research program between the Department of energy and Electro-Motive Diesels, Inc. on the development of common rail fuel injection system for locomotive diesel engines that can meet US EPA Tier 2 exhaust emissions has been completed. This final report summarizes the objectives of the program, work scope, key accomplishments and research findings. The major objectives of this project encompassed identification of appropriate injection strategies by using advanced analytical tools, development of required prototype hardware/controls, investigations of fuel spray characteristics including cavitation phenomena, and validation of hareware using a single-cylinder research locomotive diesel engine. Major milestones included: (1) a detailed modeling study using advanced mathematical models - several various injection profiles that show simultaneous reduction of NOx and particulates on a four stroke-cycle locomotive diesel engine were identified; (2) development of new common rail fuel injection hardware capable of providing these injection profiles while meeting EMD engine and injection performance specifications. This hardware was developed together with EMD's current fuel injection component supplier. (3) Analysis of fuel spray characteristics. Fuel spray numerical studies and high speed photographic imaging analyses were performed. (4) Validation of new hardware and fuel injection profiles. EMD's single-cylinder research diesel engine located at Argonne National Laboratory was used to confirm emissions and performacne predictions. These analytical ane experimental investigations resulted in optimized fuel injection profiles and engine operating conditions that yield reductions in NOx emissions from 7.8 g/bhp-hr to 5.0 g/bhp-hr at full (rated) load. Additionally, hydrocarbon and particulate emissions were reduced considerably when compared to baseline Tier I levels. The most significant finding from the injection optimization process was a 2% to 3% improvement in fuel economy over EMD's traditional Tier I engine hardware configuration. the common rail fuel injection system enabled this added benefit by virtue of an inherent capability to provide multiple injections per power stroke at high fuel rail pressures. On the basis of the findings in this study, EMD concludes that the new electronically-controlled high-pressure common rail injection system has the potential to meet locomotive Tier 2 NOx and particulates emission standards without sacrificing the fuel economy. A number of areas to further improve the injection hardware and engine operating characteristics to further exploit the benefits of common rail injection system have also been identified.