Optimising the cam profile of an electronic unit pump for a heavy-duty diesel engine

For a fuel system with a tangent cam or a constant-velocity cam, the peak injection pressure continues to rise as the injection duration increases, but overly high peak pressures induce mechanical loads and wear, limiting the maximum engine speed and injection quantity. To improve the performance of an EUP (Electronic Unit Pump) fuel system for heavy-duty diesel engines, this work proposes a new pump cam, namely the constant-pressure cam. It helps the EUP run at a higher speed and deliver larger fuel quantities while maintaining a constant peak injection pressure, which improves the power of the heavy-duty diesel engine. A model based on the EUP was built to determine the three constraints for optimising the constant-pressure cam: 1) the pump pressure should equal the nozzle pressure; 2) the cam speed should decrease with the increase in the injection duration; and 3) the cam acceleration gradient should be zero. An EUP system was tested with the tangent cam and the optimised cam under different conditions. The experimental results show that the EUP system with the optimised cam delivers more injection quantity and runs at higher engine speeds while maintaining the same peak pressure as the tangent cam.