Study on Preventing Adjustment of Fuel Pump Oil in Cummins Engine Performance Test
Volume 27 (2005) No. 1 Research on Performance and Purification of Cummins Engine Extinguishment of Adjusting the Fuel Level of Fuel Pumps Song Zhengyuan, Duan Xiaojun (Dongfeng Cummins Engine Co., Ltd., Xiangfan 44104, Hubei, China. Dongfeng Cummins Engine Co., Ltd. Long-term research and development of corresponding improvement strategies, such as: test control system, fuel oil pump, engine assembly process, engine test parameters, etc., have made this problem solved. 1Overview There is a long-term problem with iSmil recorded in engine inspections. The main reason is to pay more attention to the gluing machine in Tengkuang, and to launch a series of systems to ensure the performance of the engine. For the nifi issuer, according to the 4 pounds±Hisaki, the pong is not only from the realit胗9e, the adjustment of the oil supply is often low to a high adjustment, and the 'brother's fuel supply ratio is greater than that of the development machine.å¡ å¡ çž’ çž’ çž’ çž’ çž’ çž’ çž’ çž’ çž’ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡ å¡. This change undermines the authority and seriousness of the product's oil content. It also brings with it issues such as high emissions and high power, which leads to the impact of the entire vehicle, and the fuel oil is also subjected to some kind of embarrassment. damage. Dongfeng Cummins Engine Co., Ltd. (OCEQ has been exploring and working for more than three years, starting from February 1, 2004, and occupies the total revised date of revision: 20M-10~26. Achieved to eliminate the adjustment of fuel oil (1% of the construction machinery still need to adjust the fuel oil). 2 Factors affecting low engine qualification test at the first time and measures for improvement 2.1 Influencing factors The reasons for the low production rate of the machine at the first time are: a. There is a difference between the product test bench and the production bench; b. There are many suppliers of C parts, such as supercharger fuel injectors, pistons, piston rings, cylinder heads, etc., which have not been validated in actual development, causing great deviations; e The separation of localization dates for performance parts such as superchargers, fuel injectors, fuel pumps, pistons, piston rings, and cylinder heads has also caused this difference; through practice, the system improvements shown in Table 1 have been summarized. Table 1 2.2.1 Improvement of test control system 2.2.1.1 Improvement of test bench From 2003 to 2004, all test benches were repurchased and rebuilt, and they have been put into production. 2.2.1.2 Modification of test control conditions Modification of engine air intake system Geese According to the distribution of site space and gantry, 12 gantry air intake systems are divided into 5 sets of 9 production gantry; No. 2 system supply 4 quality inspection benches; No. 5 system supplies 11 and 12 product development benches. The control principles of the five systems are the same. The host uses a constant temperature and humidity machine, the compressor is an imported fully enclosed compressor, and all the temperature and humidity sensors, pressure gauges, dampers and actuators are imported products with high reliability. The entire system is controlled by a computer. Intake regulation system supply indicators are measured by supply pressure, temperature, and humidity. Other control conditions are performed with the transformation of the gantry or independently. Cummins engine factory test parameters and related descriptions are shown in Table 2. Table 2 Field B than the furnace i This army: This people I = m line Me Tao class twisted Mao Mao shouted 1: "Outside of the water 41 /. R Series two The extraction has been lL.li leeches SlFWt party seven to tR buckle ftM persimmon flTT section. In the air. lL evenly 1. Would like to p. Intake IB, coffee song points! , Moya Force Tt: export cypress. Intercool SIR put ft ft and humble meeting StH dcixai grinding away. 岜 丨丨 .-.tEa 222 Fuel Pump Improvement bi for Fuel Pumps of Different Types and Manufacturers Compliant to Europe I I. 2.2.2.1 Reconstitution of Fuel Parameters to Determine Fuel Quantity Parameters of P Fuel Pump and P7100 Fuel Pump), Uniform a In the product test bench, the refueling test fuel pump oil content and inlet pressure were forced to be unified, see Table 3. Numbers to ensure the accuracy of the product; 2.2.2.2 oil amount adjustment device to set the fuel pump in The mass production of the engine factory test cannot be adjusted as the product requirements are clearly defined in the DCEC standard, while referring to the corresponding structure of the BOSCH and DENSO fuel pump, the various governors of the fuel pump plant are required to comply with the DCEC product standard PES018DCEC fuel oil pump protection Regulation specification (draft f1 requires the implementation of a fuel mass anti-adjustment device and a partial tamper-resistant plum blossom bolt structure. The specific structure is described below. RQV-K governor tamper and anti-adjustment structure (for P7100 fuel pump X ~ 9 use quincunx type anti-adjustment screws; screws 10, 11 are equipped with metal anti-adjustment sheath; use 12 lead seals. -K speed governor in kind 2 RCV/R801 governor tamper and anti-adjustment structure. Screw-shaped anti-adjustment screws are used at screws 13-19; metal anti-adjustment sheaths are installed at screws 2022. Corresponding corresponding physical photos see. Torsion bolt (a) and anti-kind metal cover (t) diagram 3 RSV governor governor tamper and anti-adjustment structure. RQ-K governor tamper and anti-adjustment structure corresponding to the physical lighting screws 23 ~ 32 using quincunx type adjustment screws; screws 26, see the film. 27 metal anti-adjustment jacket. 2.2.2.2 Conformity improvement and control of fuel quantity parameters The test of oil quantity conformity on the unqualified engine's fuel pump shows that there is a big problem in the conformity of its oil quantity, as shown in Table 4. The model is designed to meet Euro 210PS. , Fuel pump production serial number: 009340N2D (In April 2002 production X engine production test point torque is 690NN product requirements 565 ~ 620Nh/2500r/mn); torque point torque is 750Nm (product requirements improvement and control measures are as follows: a Requirement to be fueled by the pump supplier to process conversion of the oil uniformity requirements into specific quantified values, and reflected in the on-site operating documents, to facilitate the direct control of the adjuster. bL requires fuel to be supplied by the pump supplier to ensure that each cylinder injection volume must meet product requirements, rather than the average oil volume of the six cylinders meeting product requirements. c The fuel pump supplier is required to perform patch management on the fuel pump adjustment test bench to establish consistency and achieve compliance and consistency of fuel pump delivery. dL requires that the fuel pump supply m oil advance angle be raised from the general term to the key term, and the control tolerance should be increased from the original ±0l5CA to ±0.3CA to reduce the impact on the engine performance. The fuel pump supplier is required to control the cleanliness of the pump fuel chamber system, especially the size of foreign particles, in accordance with the injector bore diameter principle, and to implement the standard 249EQ- 07-2000 of the host plant (cleanliness of the fuel system of the B series engine components.) (Limits) 5, to ensure good atomization of the injector, and to ensure that the engine is free to accelerate the smoke index. f. Requires fuel pump suppliers to clearly specify and strictly control the torque timing of the fuel pump timing screw, and to strictly control the possible process requirement to avoid timing deviation of the fuel pump in the assembly due to the timing nut being not tightened. ±3 Nm gL established a benevolent fuel pump inspection system at DCEC, and strictly inspected the supply of Changzhou. The fuel pump supplier shall provide the following data: fuel pump standard flow (according to EUR1 fuel pump, 210PS provides X oil retest and correction standards, on-site operating documents, management standard documents for fuel pump test rigs, and fuel quantity for each type of fuel pump Control standards: Each fuel supply must provide two fuel pumps with oil detection data reports to ensure the consistency of the supply and demand control standards.In an abnormal case, a fuel pump with data can be used for comparative inspection and analysis. hLDCEC tests the 100% fuel level of the fuel pump with unqualified performance in the engine delivery test and serves as a basis for evaluating the quality of the fuel pump. 2.2.3 Improvement of engine assembly process 2.2.3.1 Engine top dead center process control method The engine top dead center process control method is changed from the original push meter detection side to the pressure plate digital display measurement meter detection This is the engine advance angle control process improvement key. The accuracy of the control can be improved to the measuring process of the digital display of 0l01°CA pressure plate. 2.2.3.2 Fuel Pump Assembly The C engine uses P and P7100 fuel pumps. From the beginning, the product has been equipped with a keyless structure (a round hole with a mounting hole in the gear chamber and a semi-circular key with no fuel pump camshaft). At present, the P and P7100 fuel pumps used in the B engine have all been changed from the original shape of the waist hole to the circular hole without key assembly. The assembly torque of the fuel pump lock nut has different rules for the different ways of the keyless and round holes of the round hole. Round hole without key: P fuel pump does not have such a structure. In order to solve the fuel pump assembly, due to the rotation angle error caused by the rotation of the gear, a method of fixing the crankshaft gear fixture is adopted to ensure the accuracy of the fuel pump timing assembly. After the fuel pump fuel gear lock nut is tightened, it is marked so that when the performance fails during the test, the gear room cover is added to the oil port to inspect the place to determine whether there is a deviation during the timing. The following factors affect the deviation of the locknut mark: a. The problem of the locknut spring washer. Compared with BOSCH parts, the presence of high points at the opening of the spring washer, thickness of the spring washer, surface hardness, size of the race, and surface treatment (friction coefficient, etc.) will attenuate the tightening torque of the locknut of the fuel gear, and therefore are equivalent. After the dimension structure design of the BCSCH parts was adopted, the problem was solved. H hole surface and burning cone surface problem by the pump camshaft. The poor fitting of the gear cone hole surface and the camshaft of the fuel pump camshaft causes mutual sliding. c. Fuel oil lock nut tightening torque fp title. Different types of fuel pump corresponding to the torque requirements and spring pad related requirements are different, as long as the design can be equivalent to the relevant requirements and dimensions of BCSCH, that problem has been solved. 2.2.3.3 Before the test, add the oil temperature control test to control the oil temperature. 2.2.4 Improvement of process control management The accuracy of the engine's factory test system is ensured by the standard engine's benchmark transmission between rigs and the installation of the test rigs in accordance with Cummins's practice. The production consistency of the first batch of small batch engines is adopted. The test review will formulate production control standards and continue to amend them in future mass production. Cummins's first batch of small H-engines “consistent production. The trial-test review was conducted by the ACE department of the Quality Department. The specific approach was as follows: After product consistency, small-lot L-level product drawings were issued, and suppliers produced a batch of Fuel pumps, for example, 25 units; bL small batches, such as 25 engines, are first manufactured by the manufacturing department for 6nin; c. The ACE department performs 5-10 runs for 17 to 20 hours; and the dAZE department performs performance tests on the grounded engine. The method (steady state, not 6nin) performs the performance test; e. If the engine meets the product requirements, the ACE department formulates the acceptance test for the delivery test, ie the production test specification, based on the correlation established in the tests (a) and (d). Issued to the manufacturing department. On the contrary, to find out the reasons; the above-mentioned behavior in most cases is not to change the product is mainly to establish a preliminary correlation, through the continuous revision of the future production. 2.2.4.1 Test system management The engine performance test is a special test. The corresponding standards stipulate the methods for the engine to perform dynamic, economic and other important performance tests on the bench. The test results are not only affected by the accuracy of the instrument, but also It is also affected by the test conditions. Therefore, the engine bench test system not only needs to carry out static calibration of each measuring instrument, but also controls the relevant test conditions in the test and uses the standard engine to dynamically calibrate the bench test system. a Use of standard engines. In the early stages of the introduction of Cummins engines, benchmark transmissions between benches were conducted between the product development test benches and production test benches, but this practice was not adhered to. In the improvement, the original 160PS VE fuel pump standard engine was reactivated and a 210PS Euro I standard engine was reassembled for reference transmission. bL benchmark delivery route management. The standard engine is used for calibration transmission. The delivery route is: the quality inspection benches are calibrated by the product development benches, and then the quality inspection benches are used to calibrate the production benches and pass the inspection method of the quality inspection bench according to the performance test method. The status of production quality is assessed. c. Engine Test Bench Installation Review. The engine needs to be reviewed on the vehicle and the engine test bench installation needs to be reviewed. The assessment criteria were conducted in accordance with GB. The engine used was in accordance with the maximum 235 PS plan assumed by the B engine test system. 2.2.4.2 Production Consistency Review There are many factors affecting production consistency. After eliminating these factors, how to properly convert product standards into production control standards still requires a lot of meticulous work. Due to the accumulation of historical problems, DCEC has done a lot of cross-test verification work in the development of accurate production control standards, mainly related to gantry test, batch correlation test of BOSCH fuel pump, batch-related correlation of domestic fuel pumps from different manufacturers. Sex test etc. To verify the correlation between the product development test bench and the production test bench; and the test verification of the engine test bench. 3 Conclusion To truly eliminate fuel pumping must start from the following aspects: change the concept, improve the key links, determine the production control standards, and attach importance to the relevant factors. Fuel pump as a key, weak, "convenient" The parts and components are repeatedly adjusted in different production and sales links to achieve a certain level of carrier demand. To produce a complete vehicle that satisfies the requirements of the emission standards, the key to the control process lies in the non-adjustment of the fuel pump, and in order to carry out a series of effective improvements and basic work, these need to be supported and implemented by the vehicle and host plant. Therefore, we snoring that in the production, service, and use, any adjustment of the fuel pump must be made by the fuel pump manufacturer professionally (on page 23). The vehicle test was carried out to burn pure diesel oil and E10 ethanol diesel fuel respectively. The cumulative mileage of a single vehicle was about 50,000 km. The test evaluation of the test focused on environmental protection, technology, and economy. The test results show that the use of vehicle ethanol diesel, the locomotive has a good operation and drivability, there is no significant change in the power acceleration performance, tail gas emissions significantly reduced, especially when the vehicle is climbing, accelerating. During the driving test, the replacement test of pure diesel and ethanol diesel was also conducted. No fuel-related faults were found. In addition, a fuel consumption test of 100 kilometers under different speeds was conducted. See the results. From the experimental results, it can be seen that the mass fuel consumption per 100 km of the blended fuel E10 is not much higher than that of the diesel fuel. This is consistent with the results of the bench test. Aid; fuel pump manufacturers in order to safeguard their own interests, should first of all design and application of structural anti-lock device on the fuel pump (anti-adjusting plum blossom bolts); for the engine does not have the fuel pump anti-adjustment device host before the engine test The plant should make up its mind to install anti-adjustment devices on the fuel pump adjustment points after the engine test, and to safeguard the common interests of the engine plant and the fuel pump manufacturers so as to produce products that truly meet the requirements of national regulations. 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