Design of an Optically Accessible Intake Manifold for Characterization of Liquid and Gaseous Jets in PFI Operating Conditions

The intake manifold and its components play a key role in the proper formation of air–fuel mixtures suitable for correct engine operation. In this article, starting from the original intake manifold design fitted to an optically accessible spark-ignited engine, a new solution was developed so as to allow the application of high-speed imaging of the fuel jet located between the runner and intake valves (Port Fuel Injection). To compare the two designs in terms of overall engine performance parameters such as volumetric efficiency, 0D/1D simulations were performed in motored conditions. Measurements at different crankshaft speed values were used for calibrating the intake line parameters and providing boundary conditions. Finite Element Analysis (FEM) was performed in SolidWorks to verify the structural strength of the new design when operating in the most critical conditions, i.e., boosted operation. As an overall conclusion, the results show that the new design guarantees a wider range of intake pressure values during the intake stroke, thus expanding the possible operative points. This can be obtained without compromising structural integrity, given that predicted safety factors were well above acceptable limits even for relatively high boost levels.