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1 한국동력기계공학회지제18권제6호 pp 년 12월 (ISSN ) Journal of the Korean Society for Power System Engineering Vol. 18, No. 6, pp , December 2014 커먼레일시스템용저압유압회로의성능특성에관한연구 A Study on the Performance Characteristics of Low Pressure Hydraulic Circuit of Common Rail System 이춘태 * Choon-Tae Lee* ( 접수일 : 2014 년 09 월 17 일, 수정일 : 2014 년 11 월 05 일, 채택확정 : 2014 년 11 월 05 일 ) Abstract: High common rail injection technology has revolutionized the diesel industry. Over the last decade it has allowed engine builders to run higher injection s as much as above 1,300bar in order to increase engine efficiency, while reducing emissions. This common rail system has low circuit which is consist of low, cascade overflow valve and flow metering unit. The low s purpose is to feed fuel oil to the high. The cascade overflow valve keeps in front of the metering unit constant and provides lubrication for the high. The metering unit, known as the MPROP or fuel regulator, regulates the maximum flow rate delivers to the rail. In this paper, we have investigated the performance characteristics of each components and total low circuit of common rail system. Key Words:Common Rail, High Pressure Pump, Low Pressure Pump, Cascade Overflow Valve, MPROP 1. 서론최근, 디젤엔진의고압화에의한엔진성능향상에관한많은연구가진행되어커먼레일시스템 (CRDI, common rail direct injection) 이개발되었고엔진성능이획기적으로발전하는계기를마련하였다. Fig. 1에나타낸바와같은커먼레일시스템은 1,300~1,800bar(=kg f /cm 2 ) 까지연료를고압으로압축하여연료분사장치내의커먼레일과다구형분사구를통하여미립입자로분사함으로서엔진성능을높이고유해가스배출을최소화시킬수있게되었다. 이러한커먼레일시스템에사용되는고압펌프는주로레이디얼피스톤펌프 (radial piston ) 를사용하여초고압을발생시키지만레이디얼피스톤펌프는고압화에는유리하지만흡입성능이나빠불리한면이있다. 이러한흡입성능의단점을보완하기위하여별도의저압유압회로를설치하여저압의연료를고압펌프에공급하고있다. Fig. 1 Overview of common rail direct injection system * 이춘태 : 신라대학교자동차기계공학과 charity@silla.ac.kr, Tel : *Choon-Tae Lee : Department of Automotive & Mechanical Engineering, Silla University charity@silla.ac.kr, Tel : 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월 51

2 커먼레일시스템용저압유압회로의성능특성에관한연구 이러한커먼레일의저압유압회로에대한해외의연구는대부분커먼레일시스템의인젝터에대한해석 1-4) 이주를이루고있다. 국내의경우, 김정 환 5) 등이경유의윤활성이커먼레일고압펌프에 미치는영향에대하여연구하였고, 정재우 6) 등에의하여대체연료인 DME (dimethyl ether) 를사용한경우의펌프성능을실험적으로규명하였다. 또한장주섭 7) 과김홍열 8) 등에의해서커먼레일전체시스템을대상으로한연구가진행되었지만저압유압회로에대한자세한연구는제시되지않았다. 그리고최근고압펌프의특성에대한연구 9) 가일부진행되었으나저압유압회로에대한자세한연구는아직까지거의전무한실정이다. 따라서본논문에서는커먼레일의저압유압회로에대한기본적인성능특성과성능을결정하는주요설계변수의변화에따른저압유압회로의성능변화에대하여해석을실시하였다. 2.1 고압펌프 (high ) 고압펌프는커먼레일시스템의연료분사에필요한고압을발생시키고커먼레일내에높은압력의연료를지속적으로공급하는역할을한다. 특히 D엔진, S엔진의고압펌프는엔진캠축에의해구동되며저압펌프에서송출된연료를바로고압으로만들어커먼레일로전송하고출구제어방식을사용한다. U엔진, A엔진, J엔진의고압펌프는타이밍체인또는벨트에의해구동되며고압펌프와저압펌프그리고압력조절밸브가일체로구성되어있는입구제어방식이다. 고압펌프에대한이론식과성능특성에대한설명은기존의연구 9) 에서자세히제시되어있다. 2. 커먼레일저압유압회로유압시스템의특성분석 Fig. 2와같이커먼레일시스템의저압유압회로는고압펌프에연료를공급하는저압펌프와고압펌프의윤활및저압유압회로의압력을일정한값이상으로제한하는오버플로밸브 (cascade overflow valve) 그리고연료분사에필요한연료량만을고압펌프로공급함으로서유량조절에의한커먼레일의분사압력을조절하는비례전자식유량제어밸브 (MPROP) 등으로구성되어있다. Fig. 2 Low hydraulic circuit of CRDI system Fig. 3 High of A-type engine 2.2 저압펌프 (low ) 저압펌프는레이디얼피스톤타입 (radial piston type) 인고압펌프의낮은흡입성능의단점을개선하기위해고압펌프의흡입측에일정압력의유량을공급하는역할을한다. 저압펌프는기계식과전기식으로분류할수있다. 기계식은엔진시동과동시에타이밍체인또는벨트로연결된고압펌프가회전하면고압펌프내부의구동샤프트에의해저압펌프도작동한다. 주로기어형식으로고압펌프와일체로조립되어있고 U엔진, A엔진, J엔진등에적용된다. 기계식저압펌프는고압펌프와일체형이므로연료탱크와의거리가멀어연료배관에서의공기유입, 겨울철시동불량등의문제점이발생할수있다. Bosch사의 CP3에서는 Fig. 4(a) 의왼쪽그림과같이외접형기어펌프를사용하였고 Denso사의 HP3에서는오른쪽그림과같이트로코이드형기어펌프를사용하였다. 반면, 52 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월

3 이춘태 전기식저압펌프는 ECU에의해구동되며엔진시동시 3~5초간작동후엔진회전수신호를입력으로받아시동이켜진상태에서계속작동한다. 전기식저압펌프는연료탱크내부또는외부에장착되며 D엔진, S엔진등에적용된다. 전기식저압펌프의형상은 Fig. 4(b) 에나타내었다. (a) Mechanical type (b) Electric type Fig. 4 Various types of low 기어펌프의형상설계와관련된치형의높이, 반경은다음과같은식 (1) 과 (2) 로주어진다. 여기서 는기어이두께, 은펌프의회전수, 는접촉각, 는회전각, 은체적효율을나타낸다. 2.3 오버플로밸브 (cascade overflow valve) 오버플로밸브는고압펌프와저압펌프사이에위치하며, 고압펌프의윤활작용과저압유압회로의압력을일정하게유지시켜주는역할을하는밸브이다. 오버플로밸브는 Fig. 5와같이고압펌프의캠챔버 (cam chamber) 부의윤활을위한디플레이트교축 (deflate throttle) 과윤활교축 (lubrication throttle) 그리고저압유압회로압력을일정압력이하로제한하는오버플로교축 (overflow throttle) 등으로구성되어있다. 오버플로밸브는저압유압회로의압력에의해스풀의변위가결정되고이로인한유로 (flow pass) 가결정된다. 오버플로밸브는디플레이트교축을통해서항상소량의유량을고압펌프의캠챔버에공급하여고압펌프의윤활작용을하게된다. 그리고저압유압회로의압력이상승하면, 스풀이상승하여윤활교축이열리게되고추가의연료가고압펌프의캠챔버로공급된다. 저압유압회로의압력이더욱상승하면오버플로교축이열리게되고, 연료는저압펌프의입구로흐르게되어저압유압회로의압력은일정하게유지하게된다. (1) (2) 여기서 h는치형의높이, r은치형의반경, m은기어모듈 (module) 그리고 Z는기어잇수를나타낸다. 이와같은기어펌프에서의토출유량은식 (3) 과같이표현할수있다. (3) 단, 이다. Fig. 5 Schematic of cascade overflow valve 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월 53

4 커먼레일시스템용저압유압회로의성능특성에관한연구 2.4 비례전자식유량제어밸브 (MPROP) 비례전자식유량제어밸브는고압펌프의입구또는출구에설치되어연료분사에필요한연료량만을고압펌프로공급함으로서유량조절에의한커먼레일의분사압력을조절하는기능을하는밸브이다. 비례전자식유량제어밸브는엔진 ECU로부터의전기적인신호 (duty) 에의해필요한연료량만커먼레일에공급함으로서연료탱크로되돌아오는연료량을감소시켜연료의온도상승을억제하고엔진으로구동되는고압펌프의부하를감소시켜배기가스배출을억제하는효과가있다. 비례전자식유량제어밸브는엔진의종류에따라다양한방식의밸브를사용하고있다. Table 1에비례전자식유량제어밸브의종류를나타내었다. 풀밸브로구성되어있으며밸브를제어하여고압펌프로유입되는연료의양을조절한다. ECU에서전류를최대로가한경우, MPROP 밸브의유로는닫히고저압펌프에의해공급된연료는오버플로밸브에의해일부는고압펌프내부의윤활역할을하고나머지대부분은저압연료리턴부를통해연료탱크로모두되돌려보내진다. 반면, ECU에서전류를가하지않은경우, 저압의연료는소량만윤활에이용되고나머지는모두고압펌프로보내져가압되어커먼레일로보내진다. Table 1 Various types of the proportional flow control valve Engine type Location Valve type Delphi KJengine Bosch D-engine (1st generation) High inlet High outlet IMV (Inlet Metering Valve) DRV (Pressure Control Valve, DruckRegelVentil) Fig. 6 Schematic showing configuration of the MPROP 3. 커먼레일저압유압회로시뮬레이션결과 Bosch D-engine (2nd generation) High inlet MPROP (Magnetic PROPortional valve) 그리고아래의 Fig. 6에비례전자식유량제어밸브의구조를나타내었다. 비례전자식유량제어밸브는솔레노이드와 NO(normally open) 형식의스 아래의 Fig. 7에커먼레일저압유압회로의특성해석에사용한시뮬레이션모델을나타내었다. 시뮬레이션은유공압시스템해석용소프트웨어인 LMS Imagine Lab사의 AMESim을사용하여해석하였다. 시뮬레이션모델에는저압유압회로를구성하는저압펌프, 오버플로밸브, MPROP, 펌프입구부의교축등저압유압회로의주요부품에대한모델링이포함되어있고저압유압회로전체의성능을검증하기위하여 3개의피스톤으로작동하는고압펌프의시뮬레이션모델도포함하였다. 그리고 Table 2에해석에사용한주요파라미터값들을나타내었다. 54 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월

5 이춘태 의구조적특성에기인한것이다. Fig. 7 Simulation model of the CRDI low circuit using AMESim Table 2 Simulation parameters Parts Parameter Unit Value Low Cascade Overflow Valve MPROP Number of teeth Z - 10 Gear module m mm 2 Width of the tooth b mm 12 Contact angle deg 20 Volumetric efficiency Lubrication throttle overlap mm 1.7 Overflow throttle overlap mm 3.4 Lubrication throttle diameter mm 0.35 Spring constant N/mm 2.0 Spool diameter mm 6.0 PWM Frequency Hz 185 Gain of solenoid - 12 Time constant - 9e-5 Maximum underlap mm 2.8 Spool diameter mm 7.0 Fig. 8 Variation of flow rate of the low according to inlet throttle diameter Fig. 9에서오버플로밸브의디플레이트교축은직경이작아 0.005lpm 정도의매우적은유량이빠져나감을알수있다. 윤활교축은스풀의이동에의해입구압력약 3.8bar에서열리기시작해서 0.4~0.5lpm의유량이윤활을위해빠져나감을알수있다. 그리고오버플로교축은약 4.7bar에서열리기시작하여이후급격히유량을오버플로교축을통하여저압펌프로배출함을알수있다. 여기서윤활교축과오버플로교축의열리는압력 (cracking ) 은오버플로밸브의스프링상수, 스풀의형상, 교축의오버랩의길이등에따라결정된다. Fig. 8에펌프의회전속도와흡입부교축의직경의변화에따른저압펌프의토출유량변화를나타내었다. 그림에서와같이흡입부교축의직경에따라서토출유량은일정회전수이상에서는일정한값으로유지됨을알수있다. 또한저압펌프의토출유량은약 24% 의유량변동율을나타내고있다. 이것은 10개의기어로구성된저압펌프 Fig. 9 Flow rate through throttles of the cascade overflow valve 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월 55

6 커먼레일시스템용저압유압회로의성능특성에관한연구 Fig. 10과 Fig. 11에 MPROP의변위및솔레노이드입력에따른밸브의개도와유량특성을나타내었다. Fig. 10에서와같이 MPROP의최대변위는 2.8mm이고솔레노이드의입력이가해지지않은상태에서의최대유량은 3.13lpm이며솔레노이드최대입력에서유량은 0이됨을알수있다. 또한 Fig. 11에서와같이 MPROP의솔레노이드입력 (duty) 에따른유량변화는 10~30% 입력영역에서선형적으로변화함을알수있다. 량은 Fig. 8과같은유량특성을나타내고있으며, 토출압력은오버플로밸브의영향으로저압유압회로설정압력인 4.7bar를중심으로유지됨을알수있다. Fig. 12 Outlet flow rate and of the low in low circuit Fig. 10 Flow rate and flow area of the cascade overflow valve with spool displacement Fig. 13에는저압유압회로전체에서, MPROP 밸브제어입력에의한고압펌프의출구압력변화를나타내었다. 그림에서와같이펌프의회전수를 1,000RPM으로설정하고고압펌프의출구압력을 1,300bar로설정한경우, MPROP 솔레노이드입력에따라펌프의출구압력이연속적으로제어되고있음을확인할수있다. 따라서 MPROP의제어입력에따라커먼레일시스템의공급압력을제어할수있음을알수있다. Fig. 11 Flow rate of the cascade overflow valve with solenoid input Fig. 12에저압유압회로전체에서, 저압펌프의회전속도변화에따른저압펌프의토출유량과압력의변화를나타내었다. 그림에서와같이토출유 Fig. 13 Outlet of the high according to MPROP solenoid input 56 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월

7 이춘태 4. 결론이상과같이커먼레일저압유압회로의특성해석을통하여다음과같은결론을얻을수있었다. (1) 저압펌프흡입부교축의직경을적절히설계하면저압유압회로의공급유량을일정한유량으로제한할수있다. (2) 저압유압회로의최고압력은오버플로밸브의스프링상수, 스풀의형상, 교축의오버랩의길이등을적절히선정하여설정할수있다. (3) 고압펌프의출구압력의제어는 MPROP의스풀개도면적의변화가큰영향을미친다. 따라서스풀개도면적을적절히설정함으로서공급압력을선형적으로제어할수있다. Reference Common-rail Compressing Ignition Engine", Transactions of KSAE, Vol. 17, No. 2, pp J. S. Jang, Y. H. Yoon, 2009, "Analysis Model Development for Component Design of the Fuel Injection System for CRDI Engines", KSAE, Vol. 17, No. 3, pp H. Y. Kim, J. Y. Koo, H. K. Na and C. S. Kim, 1998, "Simulation of High Pressure Common-rail Fuel Injection System", Transactions of KSAE, Vol. 6, No. 5, pp C. T. Lee, 2013, A Study on the Performance Characteristic of Common Rail High Pressure Pump, Transactions of KSPSE, Vol. 17, No. 6, pp W. Liu, J. Wang, 2012, "Simulation on Pressure Control of Common Rail Line in High Pressure Fuel Injection System", 2011 International Conference on Computer Science and Information Technology, Vol. 51, pp Z. Reif, 2009, "High Pressure Common Rail Injector Problem Analysis", Advanced Engineering, Vol. 3, pp X. L. J. Seykens, L. M. T. Somers and R.S.G. Baert, 2004, "Modelling of Common Rail Fuel Injection System and Influence of Fluid Properties on Injection Process", Proceedings of VAFSEP H. E. Merritt, 1991, "Hydraulic Control Systems", John Wiley. 5. J. H. Kim, J. B. Park, H. Y. Song, J. G. Kim and D. K. Kim, 2009, "A Study on HFRR of Diesel on Fuel System Component Durability", Proceeding of the KSAE, pp J. W. Chung, N. H. Kim, J. H. Kang, S. W. Park, H. K. Lee and S. K. Choi, 2009, "A Study on the DME Application Performance of a High Pressure Fuel Pump for an Electric Controlled 한국동력기계공학회지제 18 권제 6 호, 2014 년 12 월 57

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