Exergy Engineering and Diesel Technology Company 1

[Gspool]

thread71-233953

In reference to an old thread I would like to suggest there is another side to the comments made by Mr. Buelna and the performance of the Common Rail System built for the TRC engine project. In short the Common Rail fuel system for this project was built on a shoestring budget through Detroit Diesel Corporation and was continually subjected to "over pressure" testing by the very animated Dr. Marius Paul. Note that Terry mentions it was a 20ksi system yet in the docs referenced (by Dr. Paul) it includes claims of the worlds highest injection pressure of 105+ ksi. (I am sure Dr. Paul had seen it at least for a little bit of time as I had to deal with the resultant carnage.) Maybe the simple control knob for rail pressure proved too big a temptation!
Great fun though and I apologize to Terry for any long lasting trauma our system may have caused!
Exergy Engineering is not the same Company as DTC but several engineers here including myself are former GM/DTC/Bosch fuel system engineers. No matter which engine manufacturer you talk with they all have a love/hate relationship with their fuel system supplier whether in-house or purchased externally. I have seen this time and time again with GM/DTC/Bosch and now Exergy. Exergy has the capability and knowledge base to deal with custom design fuel systems, inspite of our perhaps spotty heritage...

Greg

 

[tbuelna]

Greg,

I remember that "simple control knob"! And you're correct, keeping Marius away from that rail pressure control was tough (he was a very large Romanian). However, rest assured. We never took the rail pressure above about 22ksi while I was in the dyno room.

That DTC 2 injector CR system was definitely shoestring. It seemed to give acceptable performance for the brief amount of testing we did with the TRC engine. The engine had lots of other issues, so the fuel system was the least of our worries.

The only problem we had with the fuel system was getting the HP fuel lines to seal properly after each rebuild. But that was not DTC's fault, because we made our own HP lines. It usually took a few tries to eliminate all of the leaks. Re-sealing a 20ksi hydraulic circuit is not easy.

Hope things are well at Exergy. I talked to Randy about some work last year, but my budget fell through.

Regards,
Terry

 

[Gspool]

Terry,

I was hoping you would read my "tongue in cheek" as intended, simply that,... a comment on past challenges
and characters we have all had the opportunity to work with in the past..

Thanks for the kind words about the fuel system as it truely was an assemblage of parts left over from an 80s era GM program. We did our best with what we had at hand.

Interestingly we were using an inlet metered high pressure pump that was considered extremely risky at the time. Top engineers at Bosch thought the concept was destined to fail due to cavitation issues. All Bosch light/medium duty Common Rail systems use an inlet metered high pressure pump now... I guess we didn't know at the time that it couldn't possibly work!

20ksi sealing issues no longer exist as we now work with 30ksi and up fuel systems at Exergy every day.

Please do keep us in mind should any diesel fuel system design or testing needs come up.

One question for you, we have an ever present need for Bosch P style nozzle blanks, finshed P style nozzles without the final EDM or drilled spray hole pattern. Any suggestions?

Warmest Regards,

Greg