Rlex Mechanical
Rlex Mechanical
Mechanical Features
(RT-flex Specific Parts only)
Chapter 20
Rail Unit(s)
WECS-9520,
E 90 Shipyard
Interface Box (SIB)
on the free end
WECS-9520, E 95
Cylinder Electronic
Unit Terminal boxes
Automatic filter
Supply unit
Rail Unit(s)
WECS-9520,
E 90 Shipyard
Interface Box (SIB)
on the free end
WECS-9520, E 95
Cylinder Electronic
Unit Terminal boxes
Automatic filter
Supply unit
Rail Unit(s)
WECS-9520,
E90 Shipyard
Interface Box (SIB)
or at the free end
(smaller engines)
WECS-9520, E95
Cylinder Electronic
Unit Terminal boxes
Supply unit
Control oil
Automatic filter Pumps
WECS-9520 Cylinder-Electronic
Unit boxes (E95) are fitted on the
outer front side
Protection bars
Control oil rail (some engine types only): Servo oil rail
The control oil rail contains 200 bar control oil (constant pressure) delivered by the control
oil pumps. VCU’s
RT-flex96C
Working principle:
Each ICU is pre-controlled by 2 or 3 rail valves to
Servo oil open or close the way for fuel from the rail to the
supply injection nozzles.
Fuel side Fuel for each injection, necessary stroke is calculated
and quantified, then injected, measured and corrected
for the next injection.
© Wärtsilä Land & Sea Academy Page 17 Chapter 20 19-Mar-08
RT-flex mechanical features Fuel Nozzle
To exhaust valve
The servo oil supply from the servo oil rail to
3/2 way valve the 3/2 way valve is done via connecting
element. The 3/2 way valve is pre-controlled by
a rail valve (same type as for ICU).
Rail valve
Main bearing oil The servo oil return pipe has a back pressure
supply of ~2-3 bar to dampen pressure peaks.
Connecting
element
VCU piston
HP-hoses to/
Servo oil supply from ICU
ICU
Trace heating
Fuel overpressure
regulating valve
VCU
Servo oil
return pipe
© Wärtsilä Land & Sea Academy Page 25 Chapter 20 19-Mar-08
RT-flex mechanical features Rail Unit Piping, Size 0
ICU
VCU
Servo oil
return pipe
© Wärtsilä Land & Sea Academy Page 26 Chapter 20 19-Mar-08
RT-flex mechanical features Rail Unit Piping, Size 1 MKI
Fuel rail:
VCUs The fuel rail contains high pressure
ICUs fuel of ~ 600 -900 bar delivered by
the fuel pumps of the supply unit
during engine operation. The rail
pressure is regulated depending on
engine load. For each cylinder, there
is an Injection Control Unit (ICU)
installed on the fuel rail. The ICUs
are actuated by help of control oil
pressure. WECS is activating the
ICUs for injection control. The rail is
Fuel rail
heated by a trace heating piping
system.
Servo oil return pipe
Servo oil rail:
The servo oil rail contains fine filtered
Main bearing oil supply (6-micron) high pressure servo oil, ~
80-190 bar, delivered by the servo oil
pumps of the supply unit, depending
on engine load. For each cylinder
Servo oil rail there is a Valve Control Unit /
exhaust valve actuator (VCU)
Control oil supply rail installed on the servo oil rail. WECS
is activating the VCUs for exhaust
Control oil return rail valve control.
SHD-valve arrangement:
- The SHD solenoid valve
(energised by Safety
System) enables control air
to the SHD-servo, that
activates the SHD-valve
itself to depressurize the fuel
system. (fuel drained to
overflow tank)
Trace heating
Main bearing oil supply pipe for Servo oil (and control oil)
upper side of VCU (flex96C-B common return pipe
only)
Rail unit general drain piping. Possible leaks of fuel, oil and water are collected for each
rail => Alarm to Alarm System „Rail Unit (FWD), General Leak“.
The leakage is drained to the sludge tank.
Rail valve are quick acting 3/2-way solenoid valves. Each cylinder unit has four
rail valves. Three of them are pre-controlling an ICU, one of them is
pre-controlling the VCU. Flex50 has only two rail valves per ICU.
Following an injection/return- or open/close command of WECS-9520, the
corresponding coils are energized for a very short time (normal operation
~1 ms, max. 4.5 ms), but with a high current impulse (~50-60A).
Iron core
This makes the valve spindle move towards the energized coil
(~0.3 mm stroke). Valve spindle
Control oil inlet
The high current impulse and the short travel of the valve
Inlet/outlet to ICU/VCU
spindle enable a very short actuation time, which is Outlet to return pipe
indispensable for precise injection- or exhaust valve control.
Damper Orifice
Main differences to a conventional
RTA-valve drive:
Oil inlet from
The exhaust valve is actuated by a exhaust valve
double piston drive, in order to save oil actuator pipe
volume
Two redundant exhaust valve stroke Double piston
sensors for monitoring drive
Damper Orifice
Main differences to a conventional
RTA-valve drive:
Oil inlet from
The exhaust valve is actuated by a exhaust valve
double piston drive, in order to save oil actuator pipe
volume
Two redundant exhaust valve stroke Double piston
sensors for monitoring drive
Double piston
drive
Measuring cone
RT-flex58T-B RT-flex60C
RT-flex60
RT-flex58T
The number of fuel- and servo oil pumps Servo oil pumps 2nd intermediate
depends on the number of cylinders. (shown here as „Bosch“)
gearwheel
Fuel pressure
retaining valve
Roller
Lower housing
High pressure
pipes
Collector Block
Swashplate angle encoder Case drain Control oil inlet Leak oil return
Visual indication High pressure
outlet
Non return
Valve / anti
cavitation port
Proportional
valve solenoid- Anti cavitation
Proportional inlet (from
valves valve position servo oil main
transmitter Proportional supply pipe)
valve
HP-outlet pressure
transmitter
RT-flex58T, MK1
The automatic filter unit filters the servo (and control-) oil to 6 m.
The by-pass filter has a mesh
size of 36 m.
The filter "sludge" goes back to
the crankcase.
The crank angle sensors are located on the free end of the crankshaft (or Geislinger Damper).
They are separated from the crankshaft by a special coupling. They create an exact digital signal of the
actual crankshaft position (0….360°) The CA sensors have a resolution of 0.1°
The spring loaded coupling absorbs all longitudinal and axial movement of the crankshaft. It drives a shaft
which is supported by two ball bearings. The bearings are oil lubricated. From the shaft a toothed belt
drives each sensor.