Injection Technology

Common-rail fuel injection and  hydraulic valve actuation.

The common-rail system has been successfully applied to WinGD low-speed engines since 2001, when the first RT-flex engine entered service. Concept-wise, at least two high-pressure pumps are installed for the fuel injection and servo oil systems. Fuel pumps are designed in two different sizes with the same basic layout. Careful design, constant improvement, and good quality control ensure a safe pressure supply for reliable engine operation. The same is valid for the servo oil pump, where different sizes are used to operate the exhaust valves. If one of these pumps is out of order, the remaining pump(s) have sufficient capacity to enable full engine operation.

All RT-flex engines, as well as the X82 and X92-B, are equipped with one injection control unit (ICU) per engine cylinder for injection control. Since 2001, ICUs with different sizes have been developed and tested. Many of the ICU’s internal parts are standardized and used on all versions. A constant improvement policy on all sub-components further enhances the reliability of the engine. The ICU function is monitored closely by the engine control system. Any possible malfunction and wear can be recognized before a major failure happens.

The new generation of common-rail WinGD X-engines use directly controlled fuel injection valves. The main control elements are the same in all these injectors, even though the outer size and shape is adapted for each engine type. This allows the use of key parts that are always reliable, well tested, and mature. On these engines, flow limiting valves (FLV) have taken over the cut-out function of the ICU. In the case of an injector failure, the FLV will stop the injection on that cylinder and the fuel rail pressure is maintained for undisturbed operation on all the other units.