SBIR-STTR Award

Kinetic BEI intends to design an electronically controlled, common rail, heavy fuel injection system suitable for application on engines in the 5-20 Hp range. The system will feature a Micro Fuel Injector and Micro Pump that are currently under development. This Phase I STTR will focus on developing the complete heavy fuel injection system, complete with an electronic controller. It will also facilitate development of higher pressure micro injectors and pumps, and fund the exploration of piezo actuation for better injector performance. This additional research and development effort will ultimately increase the odds of success, and speed up the timeline for application of this technology on current and future small engine development programs. The opportunity to expand the research and development of this miniature/micro fuel injection system through a Phase I STTR program will have far-reaching implications in both the military and commercial engine development programs.

Benefit:
Micro fuel injection systems are a critical component to the development of miniature engines and no viable solutions currently exist in the military or commercial markets. The results of this STTR effort will have an immediate impact on multiple current engine development programs, including three within the Kinetic BEI / Baker Engineering facilities, as well as other government funded and commercially funded engine development programs. Prime contractors have provided Letters of Interest in support of this technology. The electronically-controlled heavy fuel micro injection system will have a market in the area of small diesel engines, where upcoming emissions regulations will soon require more precise control of fuel/air mixing. The Micro Injector and self-regulating Micro Pump offer a viable solution for the needs of this marketplace. The Micro Injectors improvement in atomization and variable flow rate will make it possible to get good combustion at lower operating pressure. When a small controller is added, the result is a complete micro fuel injection system capable of supporting multiple fuels, including JP-8. The Micro Injector also offers advantages in gasoline direct injection (GDI) applications as well as small diesel engine applications. This injector is likely to have use in the GDI marketplace because it is smaller and simpler than the current injectors, and has higher operating pressure capability. The technology will also support biofuels. As the technology matures and manufacturing techniques improve, it is predicted that the operating pressure of the Micro Injector will continue to increase. The advantages of the Micro Injector in diesel engine operations are even greater than they are in GDI.

Keywords:
heavy fuel injection, heavy fuel injection, Small Engine,, engine development, diesel fuel injection, micro fuel injection, fuel pump

Phase II will enable KBEI to demonstrate a complete high pressure Micro Injection System on a Navy UAV engine in a laboratory environment. While the Micro Injectors and Micro Pump have been successfully proven at lower pressures, this STTR program has facilitated research and development of a higher pressure injection system designed for use with heavy fuels. At the conclusion of the Phase II STTR, the demonstration will include field capable hardware and controls operating a high BMEP-style engine. A TRL 7 for the complete fuel delivery system is expected. The Micro Injection system will feature a high pressure Micro Injector (target to 30,000 psi), a high pressure Micro Pump, and a small engine controller. The effort will include design and development, modeling and analysis utiling in-house Computtaional Fluid Dynamic analysis and Finite Element Analysis, as well as fabrication and demonstration of the hardware through bench testing and laboratory testing. In parallel to the demonstration, KBEI will execute a transition plan to provide field ready (TRL 8-9) system capable in field use. Strategic partners, engine suppliers and UAV integrators will be a key to a successful transition of the Micro Injection technology into the field.

Keywords:
Jp-8, Jp-8, Fuel Injection, Heavy Fuel, Micro, Diesel, Direct Injection, Uav, Fuel Pump