ODYSSEUS Common Rail System

Press article HEINZMANN (June, 2010)

Today’s challenges are optimum combustion engine efficiency, international emission legislation in all fields of industrial diesel engine applications such as marine, genset, railway or heavy-duty off-road vehicles as well as the interactions between diesel fuel injection, combustion process and exhaust gas after-treatment.

These challenges demand the benefits of an electronically controlled common rail fuel injection system in accordance with the same durability and reliability of a conventional mechanical diesel fuel injection system.

The advantages of CR fuel injection technology are:

Permanently high fuel system pressures at any engine speed/load point => additional degree of freedom for combustion process optimisation and timing due to speed independent control of rail pressure
Flexibly programmable multiple injection strategy
Engine speed/load dependent injection mapping

The major development tasks for engine raw emission is to conform to required NOx and particulate matter limits as well as to keep engine efficiency and specific fuel oil consumption attractive for engine end users. Here, common rail fuel injection technology in connection with considerately designed and well developed electronic fuel injection (EFI) control system is the right solution.

HEINZMANN offers the ODYSSEUS Common Rail Fuel Injection System including complete fuel injection equipment (HP pumps, injectors, accumulators, HP piping, safety valves, etc.) for different engine sizes, applications and fuel qualities.

The product range of HEINZMANN Hydraulic High-Pressure Components covers the following engine power outputs:

ODYSSEUS “S” for engines up to 130 kW
ODYSSEUS “M” for engines up to 560 kW
ODYSSEUS “L” for engines up to 1.500 kW
ODYSSEUS “XL” for engines up to 6000 kW
ODYSSEUS “MP” Micro Pilot common rail fuel injection system for gas engines

Additionally, HEINZMANN looks back on more than 90 years of experience with speed governing of industrial engines starting with mechanical flywheel governors to today’s second generation of digital engine management systems DARDANOS including all aspects of state-of-the-art engine control, monitoring and diagnosis meeting the international requirements of classification societies such as German Lloyd, Lloyd’s Register, ABS and DNV. HEINZMANN solves all customer needs with regards to instrumentation, cable harness design and adaptation as well as commissioning and worldwide customer care.

The development of common rail systems for single engine main propulsion installations is not only a real challenge for the hydraulic parts of injection system (rail, pipes and injectors) but also for the hard- and software development of the electronics. Since there is no mechanical back up system available the classification societies require a system layout with a “hot” redundancy. Here, customer can rely on HEINZMANN solutions and expertise.

The ultra-high precision ODYSSEUS hydro-mechanical components and the sophisticated engine management systems DARDANOS forge an integrated and complete solution for modern fuel injection technology. All key components – hydraulics, electronic hardware and software – are developed and manufactured in-house exclusively by HEINZMANN.

HEINZMANN test-rigs have been upgraded for operation with real bunker fuel quality (no substitute!) similar to HFO large-bore engine testing facilities. The HEINZMANN HFO test bench is built up in accordance with well-known professional HFO systems. Real HFO and MDO are supplied pre-treated. Fuel is heated up to 140…160 °C before entering HEINZMANN fuel injection equipment for temperature stress close to reality. At fuel inlet and outlet pressures, temperatures and viscosities are measured and recorded online.