Delivering Reduced CO2 with BorgWarner’s High Efficiency Heavy Duty Fuel Injection System Integrating Advanced Closed Loop Injection Control

Authors

C. Cardon MSc, M. Ralph, S. Crossley MEng, A. Potter BEng (Hons), C. Hudson  BEng (Hons), Dipl.-Ing. (FH) B. Gruber, S. Bhari MSc, BorgWarner, UK; P. Marois MSc, BorgWarner, Luxembourg:

Year

2023

Print Info

Production/Publication ÖVK

Summary

The paper describes the BorgWarner F3 fuel injection system (FIS), at its core is a miniaturised needle control valve, driven by the new ETC7 multicore ECU. Together the system is capable of up to 9 injection events per combustion cycle, aided by high speed signal processing and low lift inertia of the miniaturised control valve. This brings high BSFC benefits through the smaller closely timed injections and low parasitic losses. This benefit is maintained over life of the product, by an advanced closed loop injection algorithm. A sensor integrated into each injector is capable of on board signal processing, with the ECU providing on the fly correction to the FIS.

The new system brings significant vehicle packaging benefits; ETC7 ECU integrates 30% more I/0 within the same footprint as the preceding single core controller. Combined with BorgWarner’s modular model based software, the resulting control system is future-proofed for all anticipated regulations. The miniaturised valve design enables greater flexibility in injector packaging, not only reducing weight and size but also making it suitable for usage in a wider range of engine sizes and applications. The system provides true common rail functionality, with both remote pump and unit injection system architecture and validated for rail pressure of up to 2500bar.

In production today, the F3 FIS has contributed to a 3% vehicle fuel efficiency benefit over the previous F2 applications.

F3 represents a significant step toward sustainable reduction of emissions in commercial vehicles whilst we pursue the ultimate goal of carbon reduction.

ISBN

978-3-9504969-2-5