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Production Intent DME Fuel System Design

Production Intent DME Fuel System Design. Design Approach. Designed for CNC Manufacture-Avoids Capital Investment 35% Fewer Parts-Low Cost, Improved Reliability Higher Pressure Capability (400 Bar +) Poppet Solenoid, Low Leakage 75 HP/Cylinder Capability. Design Features-Pump.

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Production Intent DME Fuel System Design

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  1. Production Intent DME Fuel System Design

  2. Design Approach • Designed for CNC Manufacture-Avoids Capital Investment • 35% Fewer Parts-Low Cost, Improved Reliability • Higher Pressure Capability (400 Bar +) • Poppet Solenoid, Low Leakage • 75 HP/Cylinder Capability

  3. Design Features-Pump • 5-Cyl. Pump (vs 7) • Ø10.5 Plungers (vs Ø12.5) • 5 cc/rev (vs 11.7cc/rev) • Bolt-on Cam w/Cermet Insert • Machined Housings-No Castings • 8-Bolt Pattern-No Special Seals Needed

  4. Pump Assembly LOADING…

  5. Pump Assembly Procedure

  6. Common Rail Features • Vacuum Brazed Tube & Block • No Secondary Operations (Grinding or Straightening)-Proven Process • Integral Poppet Solenoid (Zero Leak) • No Solenoid O-Rings • Screw-In Fittings for Tubes

  7. Common Rail Assembly LOADING…

  8. Fuel Injector Features • Ø17mm Primary Diameter • Ø25mm Maximum Diameter • Axi-symmetric Design • No Leak-Vent Needed • Simple to Manufacture • Low Cost

  9. Injector Assembly LOADING…

  10. Control Module • Similar to Previous Design • Housing Modified for Bolt-On Bracket • New Rail Pressure Valve (Lower Cost) • Electronic Backpressure Valve Will Be Replaced w/Passive Valve • New, Low Cost Internal Filter

  11. Pressure Control Module Ass’y. LOADING…

  12. Prototype & Low Volume Production (2000 Units/Year) • AFT Can Produce Housings, Shafts, Cylinders, Semi Finished Plungers, Guide Plates, Injectors, Covers & Modules • Have Ordered State of Art CNC Equipment-Delivery in 6 Weeks • Outsource Finished Plungers, Slippers, Nozzle Valves, Solenoid Valves • Assembly & Test Can Be Done In-House

  13. CNC DemonstrationHAAS SL-20 W/Live Tools Ordered

  14. Prototype Cost & Lead Times • Prototype Cost & Lead Times Reduced by 50% • Changes Can Be Made Rapidly • Assembly Simplified-Field Serviceable • Easily Adaptable to Many Engines • Production Planned 2009

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