We develop injection systems for diesel, spark-ignition and gaseous-fuel engines – from micro-diesel, passenger-car and commercial-vehicle engines to large-scale power units. We can provide you with support throughout the development process, from the initial concept to design, simulation and prototype construction, and from vendor management to the start of production and beyond. We continuously verify our results on our numerous test benches where we can conduct tests using real-life fluids, allowing us to reproduce realistic engine behavior, for instance. On our temperature-conditioning test bench, we examine injection systems at temperatures from -40°C to +140°C, and our optical-system test bench delivers valuable information on injection spray and mixture formation.
Even today we are working on the solutions for tomorrow
In future, we will see even higher injection pressures helping to bring down fuel consumption and emissions. In the case of the diesel engine, the trend is moving toward pressures of 2,500 to 3,000 bar, and for the spark-ignition engine, pressures of up to 1,000 bar will be possible in the long term. Our developers make sure that the safety of the injection system is always given even under extreme loads of this type. We are also expecting further improvement to injection systems from injection-rate shaping and optimized nozzle-hole geometries. Our experts are at work in this field too – in some cases using tools we have developed ourselves, like the “Injection Analyzer” that provides detailed information on injection rate and mass.
IAV provides support in developing the entire supply system
IAV develops fuel supply systems for diesel and spark-ignition engines as well as SCR supply systems for exhaust-gas aftertreatment. Working with our colleagues from other departments, we can offer you an all-inclusive package covering every component from tank to injector.
Together with overarching project management, the design, package, components and vehicle-testing teams reliably ensure the development of supply systems that are ready to go into production. In all projects, we pay attention to giving systems the greatest possible level of efficiency – for example, demand-controlled fuel pumps guarantee minimal energy usage which has a positive effect on CO2 emissions.
New solutions for alternative fuels
For a long time now, we have been focusing attention on the effects alternative fuels have on components and systems – for instance, our specialists are examining new materials that are not impaired by bio-fuels, as well as heating strategies that prevent bio-diesel fuels from flocculating at low temperatures. For diesel engines, we optimize fuel filters (giving them the highest possible level of water-separation efficiency) so that even if poor-quality fuels are used, the downstream injection system benefits from optimum protection. For spark-ignition engines, for example, we are working on solutions that minimize gas emission from fuels with a view to meeting the strictest US standards in the future too.