The new-generation of solenoid injectors equipped with pressure-balanced pilot valves for energy saving and dynamic response improvement

• Distinct pilot-valve setups, typical of modern Common Rail injectors, are compared.
• The analysis focuses on injector static leakages and the injector dynamic response.
• Experimental results are integrated or explained by means of simulation data.

A numerical–experimental analysis on a new generation of hydraulically controlled servo solenoid injectors for Euro 6 Diesel engine applications has been carried out. The main innovation of these high-pressure injectors is the replacement of the standard pilot-valve configuration with a pressure-balanced layout. The new setup is aimed at reducing clearance leakages and at improving the dynamic response of the needle to the electrical command.A previously developed advanced one-dimensional code for the simulation of Common Rail injection systems has been adapted to simulate the innovative injectors. In particular, electromagnetic, hydraulic and mechanical submodels have been set up for the pressure-balanced pilot-valve simulation.The validated numerical model of the injector has been applied to investigate the mechanics of the pressure-balanced pilot-valve and the sensitivity of the dynamic response of the needle to some of the innovative pilot-valve layout design parameters. Furthermore, the developed simulation tool has been used to examine the real impact that the replacement of the standard pilot-valve layout with a pressure-balanced one could have on the injected flow-rate performance.The comparative investigation between the standard and the innovative pilot-valve has been completed with an analysis of their experimental static leakages. A comparison has also been made with static leakages measured for hydraulically-controlled servo piezoelectric injectors. Finally, a simple and accurate thermodynamic flow model has been developed to predict static leakages in indirect-acting solenoid and piezoelectric injectors. This model has pointed out the significant dependence of static leakages on temperature and pressure.