Thanks Gary for the background on the 80% on-time.
Seems to be the standard, but never knew
where it came from. Clearly 100% provides no further control of the air/fuel
ratio which as you point out can be particularly bad for piston engines (or any
boosted engine) but less so for the rotary. Given your statement that the full
open position could occur at some point before 100% pulse duration would expect
to keep it fully open – then some “margin” is clearly
desirable – so it appears that 80% provides that margin.
Ed
From: Rotary motors in aircraft
[mailto:flyrotary@lancaironline.net] On
Behalf Of Gary Casey
Sent: Monday, June 22, 2009 7:44
AM
To: Rotary
motors in aircraft
Subject: [FlyRotary] Re: Duty
Cycle for Injectors
Just a little historical anecdote: When we at Bendix were
developing the very first US
production fuel injection system (remember the Cosworth Vega?) we sized
the injectors for about 80% on-time at maximum manifold pressure, minimum air
temperature and full power. This is a compromise, of course - a low-flow
injector is desireable to have the most accuracy at idle when the pulse width
is very short. But if the injector approaches 100%, there will be
a pulse width less than 100% when the injector will stay fully open,
creating a step in fuel flow. This is a
normal occurence during cold engine operation when the enrichment
algorithm commands more flow, but it turns out that a max engine speed there is
little or no need for cold enrichment regardless of temperature, so the effect
is pretty much ignored. The idea of sizing the injectors for 80% duty
cycle had nothing to do with racing applications, but it applies there,
too. The obvious problem encountered when undersizing the injectors is
that once 100 duty cycle is reached the flow is limited - the engine will lean
out if the rpm or air flow goes higher. Not a good thing.
Inceidentally, there is no concern for injector relaibility or
durability. It is a simple solenoid valve and running at 100% duty cycle
would theoretically make it last longer - it is the total number of open-close
cycles that wears the injector. As injectors wear the flow generally
increases and most modern injectors are rated for a billion cycles with a flow
increase of less than 3%. The coil is cooled by the fuel itself, so
overheating is not a concern.
-----Inline Message
Follows-----
I remember reading that the 80% duty cycle rule (of
thumb)was originally developed for the racing industry.
Given that probably 100% will never be reached in the day to
day vehicle use - the 80 % duty cycle most probably doesn't apply for
sizing. However bigger injectors are standard in vehicles where the RPM limit
is much higher than what we may experience in our Aviation application, even if
for only short periods of time.
Given that our RPM is on the high end for climb and
take-off, but not as high as it could be (not max RPM), and cruise is for the
most part only 6,000 rpm, do we really have to held to the 80% DC rule, where
perhaps 90% DC (for short periods of time) may well give sufficient safety
margin to maintain longevity of the injectors.
Not that there is a major benefit in having borderline
injector duty cycle, as you so rightly pointed out - it's just that it
would be interesting to know!
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