Key fuel injection system features for efficiency improvement in future diesel passenger cars

Diesel will continue to be an indispensable energy carrier for the car fleet CO emission targets in the short-term. This is particularly relevant for heavy-duty vehicles as for mid-size cars and SUVs. Looking at the latest technology achievements on the after-treatment systems, it can be stated that the concerning about the NOx emission gap between homologation test and real road use is basically solved, while the future challenge for diesel survival is to keep its competitiveness in the CO vs cost equation in comparison to other propulsion systems. The development of the combustion system design still represents an important leverage for further efficiency and emissions improvements while keeping the current excellent performance in terms of power density and low-end torque. The paper describes the results achieved in developing a new diesel combustion system for car application that, leveraging on the high flexibility of the latest fuel injection technology, combines outstanding power and fuel efficiency with low pollutant emissions in ultralight engine designed for lower maximum peak cylinder pressure. The study has been carried out on a 0.5l single-cylinder engine on which an advanced and last generation common rail system, capable of very high injection pressure, has been installed. Through an extensive DoE-based test campaign in which all engine operating parameters have been carefully parametrized, the capability to achieve high power density and excellent fuel economy with low engine-out pollutant emissions has been demonstrated and discussed in the paper.