Components of fuel systems in diesel, hydrogen ICE, natural gas and hydrogen fuel cell technologies

Fuel pump

The fuel system is a critical part of any engine, playing a pivotal role in powering vehicles efficiently and effectively. As fuel technologies evolve, a better understanding of the fuel system enables Original Equipment Manufacturers (OEMs) to meet their emission goals, optimize vehicle performance, ensure safety and comply with regulations.

 The fuel system is part of the powertrain and includes all components necessary for regulating fuel delivery to the engine. This includes: the fuel tank, pump, filter, injectors and sensors. On the other hand, the fuel delivery system and its components are a subset of the fuel system; it specifically focuses on components directly involved in delivering fuel from the tank to the engine.

This article looks at the key components of fuel systems across different engine types, including diesel ICE, hydrogen ICE, natural gas and hydrogen fuel cells.

Components of the fuel system in diesel engines

Diesel engines are well-suited for use in heavy-duty applications due to their torque and durability. The fuel system in a diesel engine comprises several key components, including:

Filtration: Advanced filtration technology used in Cummins diesel engines removes contaminants such as debris and water from the fuel before it gets to the fuel injectors. Given the extreme fuel pressures in diesel engines and fine nozzle holes on injectors, fuel quality can significantly affect engine performance and longevity.

Fuel Pumps: Diesel engines commonly use multiple fuel pumps: The low-pressure pump pulls fuel from the tank and delivers it to the high-pressure pump, which then pressurizes and regulates fuel flow to the injectors. In commercial trucks, these pumps are designed to ensure optimal fuel delivery in the most demanding driving conditions. The high-pressure pump is particularly critical in achieving the required injection pressure for efficient combustion.

Fuel Rail: The fuel rail is a manifold responsible for distributing fuel to the injectors. It ensures even and efficient delivery of fuel across all engine cylinders. Furthermore, the fuel rail enables the fuel system to deliver the optimal fuel pressure across a range of engine operating conditions, which is crucial for consistent engine performance and emissions reductions.

Pressure Sensor: Located in the fuel rail, these components are essential for maintaining the appropriate fuel pressure, which is critical for maintaining engine integrity and performance. The pressure sensor measures the fuel pressure and communicates with the engine control unit (ECU) to fire the injectors long enough to deliver the correct amount of fuel. The fuel pressure sensor can also be used to detect issues with the fuel system, such as leaks.

Mechanical Dump Valve: Many common rail diesel fuel systems have a mechanical dump valve (MDV) located in the fuel rail. The MDV is a spring-loaded valve that is forced open when fuel pressure exceeds a pre-set limit. It acts as a safety device to release pressure if it exceeds safe limits and protects the fuel system components from damage. Some diesel engines even possess electronic dump valves which can be used for improved fuel pressure control.

Fuel Injectors: Fuel injectors deliver precise amounts of fuel into the combustion chamber with spray patterns that ensure optimal mixing of fuel and air. This precision is vital for efficient combustion, maximizing fuel efficiency and reducing emissions. In commercial vehicles, the performance of fuel injectors directly impacts engine efficiency, power output and emission levels.

Plumbing: Both metallic and non-metallic fuel lines seal and transfer fuel throughout the system. Appropriately sized fuel plumbing is critical for meeting engine application demands and preventing leaks. In commercial vehicles, robust plumbing is essential to withstand the rigors of long-distance travel and varying operating conditions.

Components of the fuel system in natural gas and hydrogen ICE engines

Natural gas and hydrogen ICE engines will play a critical role in the shift to reducing emissions. One benefit of these engines is that they fit the same envelope as a diesel engine, requiring less change to the vehicle. Gaseous fuel systems have fewer components than an equivalent diesel fuel system but are still critical to delivering optimal performance and meeting stricter emissions.

Filtration: Filtration in natural gas and hydrogen ICE vehicles cleans the fuel and removes compressor oils. This is critical for the performance and longevity of the engine. For example, in natural gas-powered trucks, compressor oils adversely affect the fuel system.

On-engine Shut Off Valve and Pressure Regulator: Since natural gas and hydrogen engines are expected to deliver diesel-like performance, on-engine pressure regulators may be used to regulate the fuel pressure delivered to the injectors. This ensures accurate fueling at any engine operating condition. Shut-off valves may also be integrated into the regulator. These valves prevent fuel flow to the engine when the vehicle is shut off.

Injectors: Gaseous fuel injectors ensure the correct amount of fuel enters the combustion chamber. For instance, in hydrogen ICE vehicles, the injector is designed to handle the unique properties of hydrogen while still meeting engine performance demands.

Components of the fuel system in hydrogen fuel cell vehicles

Hydrogen fuel cells represent a cutting-edge approach to sustainable transportation. Their fuel systems include:

Fuel Injector / Proportion Control Valve: Fuel cells may opt for either an injector or proportional control valve to regulate the flow of hydrogen to the fuel cell stack. It ensures the precise amount of hydrogen is delivered to the stack to react with oxygen and generate electricity, which provides power to the vehicle.

Ejectors: These help to recirculate unused hydrogen back to the fuel cell stack. This is critical for increasing efficiency and ensuring durability of the fuel cell.

Hydrogen Re-circulation Pump: Working in conjunction with the ejector, this pump recirculates unused hydrogen from the fuel cell stack back into the system.

Purge Valve and Water Drain Valve: These components are responsible for removing excess water and non-hydrogen contents to maximize the efficiency of the system.

Pressure Relief Valve: This is a safety device that protects the fuel cell stack from excessive fuel pressure. It is a critical component in all hydrogen fuel cell vehicles for safe operations under all conditions.

Shut Off Valve: This valve allows fuel flow into the injector and acts as an on/off valve that closes when the engine is shut off.

The fuel system is an integral part of any engine; each component ensures the efficient and safe operation of the engine. Cummins is at the forefront of developing low-emissions engine technology. As technology advances and the demand for cleaner fuel options increases, understanding these components and how they optimize engine performance is vital.

Cummins Components Business Unit

Components Business Unit

Why you should become a Cummins Home and Small Business dealer

Cummins dealer smiling next to home generator

For more than 100 years, Cummins Inc. has been dedicated to making people’s lives better by powering a more prosperous world. As a company, we seek to be customer-driven, innovative, responsible, and trustworthy so that we can truly make a difference now and in the future.

But exactly what does Cummins do? At a high level, we create power solutions. You’ll find Cummins products and solutions for on- and off-highway engines, turbochargers, electronics, fuel systems, generators and power systems, and more. We’re not in this on our own, though. With a broad network of Cummins-authorized dealers in the home and small business power solution space, we count on our independent dealers and their local relationships. If you’re interested in becoming a Cummins-authorized dealer, keep reading to find out the benefits and how to get started.

Does Cummins make Home Generators and Small Business generators?

Yes, Cummins offers generators that are sufficient for residential homes and small businesses, including:

  • 13-20 kW air cooled emergency standby generators
  • 25-150 kW liquid cooled emergency standby generators
  • 9,500-watt portable, dual fuel heavy duty generators
  • 2,500-4,500-watt portable, lightweight inverter generators
  • 300-1,000-watt portable lithium battery powered power stations

In the midst of severe weather, increased blackouts, and aging power grids, generators are becoming more and more important. Consider this: 83% of power outages were the result of weather-related incidents from 2000 to 2021.

When these outages occur during extreme temperatures, generators are critical to keeping homes and businesses comfortable, safe, and operational. Families won’t have to worry about losing their heat or everything inside their refrigerators. Businesses won’t have to worry about the potential financial impact that comes with an outage—which can be as much as $12,500 a day for a small business. 

All of these reasons are likely why search terms like “Cummins generator dealers near me” are so popular on Google and other search engines. Local people are consistently looking for the right generator solution. Cummins-authorized dealers can help ensure they have the power they need, no matter what.

What are the benefits of being a Cummins Generator Dealer for Home and Small Business?

Of course, if you’re thinking about becoming a Cummins-authorized dealer, the fact that there’s a market isn’t the only perk. Here are eight more reasons why you should become a Cummins-authorized Home and Small Business generator dealer.

  1. You’ll be backed by the Cummins brand, a name that’s synonymous with support, reliability, and sustainability. Cummins generators are quality, trustworthy equipment that you and your customers can count on.
  2. You will receive state-of-the-start training. Cummins provides courses and the certification path required to become a Cummins-authorized partner and product expert. Our technical training and certifications provide knowledge on Cummins home generator service like installation, maintenance, and repair.
  3. You can connect to a robust network of Cummins resources. Our dealers have access to a world-class set of tools, including training, a dedicated account executive, an online portal, sales and training certifications, and so much more.
  4. You’ll receive “preferred parts” pricing. By becoming an authorized dealer, you’ll get the best parts pricing around so you can maximize your profits. You can also pass these savings on to your customers to ensure your pricing is competitive.
  5. You can capitalize on marketing support. Cummins regularly invests in brand-building and lead generating campaigns to drive customers to our dealers. 
  6. You have access to warranty claim submission. Warranties don’t have to be a hassle for you or your customers. As an authorized-service dealer, you can submit warranty claims on behalf of your customer to improve customer satisfaction and loyalty. 
  7. You can join the ChannelOne Partner Rewards Program. This competitive rewards program helps you maximize your earning power.
  8. You can list your company on the Cummins Parts & Service Locator. The Cummins service locator makes it easy for local customers to connect with your business, and it increases your overall brand visibility.

How to become a Cummins Dealer: It’s easier than you think

Stop missing out on all of the local online traffic searching for “Cummins authorized dealer near me,” and bring great products to your community! It takes just four simple steps to get started.

  1. Complete the online “Become a Dealer” interest form. A regional Cummins Account Executive will contact you to start the discussion.
  2. Share additional information about your business, your experience, and why you’re interested in becoming a Cummins dealer.
  3. Fill out and return the necessary paperwork to be processed by the Cummins team.
  4. Complete your required product training and become a Cummins Home and Small Business Dealer.

At Cummins, our company is dedicated to providing great products and services to customers throughout the world. If you’re ready to join our world-class network, get started now.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

How do I calculate what size generator I need?

Customers talking to Cummins dealer

There are several great reasons why you might be considering a standby generator for your home or small business. In the event of a power outage (caused by severe weather, for example), having a standby generator helps ensure ongoing safety and comfort. And in the case of a business, the ability to reduce downtime and maintain operations is a significant advantage.

Standby generators—also known as permanent or whole-house generators—offer reliable and efficient backup power solutions for a wide range of applications. If you’re currently exploring your options, we imagine you have a few concerns. You’re probably looking for a generator that’s sold and serviced by a reputable company, and want to determine the right generator capacity for your needs.

In this article, we’re going to help you answer a key question: “What size generator do I need to run my house or small business in the event of a power outage?” Keep reading for an overview of how to find the perfect Cummins Inc. standby generator for your needs.

What is the rule for generator sizing?

When it comes to understanding generator sizing, one important rule to keep in mind is that the generator needs to be able to power everything requiring electricity, but it also needs to have additional capacity to account for various appliances’ starting wattage. Otherwise, you might find yourself in a situation where your generator simply won’t cut it, potentially leaving your home or small business without the power it needs.

Next, we’ll cover a basic framework for calculating your power needs.

How to Calculate Standby Generator Size

Here’s a simple, three-step process for assessing your needs and priorities, understanding generator sizes, and finding what size generator is going to work best. 

Let’s take a look at what this process looks like.

Step 1: Understanding Generator Sizes

Here’s a basic formula for how to calculate standby generator size:

  1. First, create a list of everything in your home or small business that would need to be powered by the generator in case of an emergency. This should include anything that requires electricity and isn’t something you would want to go without should you lose power. It’s important to not only consider running wattage, but starting wattage as well—since most appliances will require a few seconds’ worth of extra wattage to get started. There are several online sources for determining appliances’ wattage requirements.
  2. Add together each item’s running watts. When in doubt, err on the side of overestimating wattage requirements since it’s much better to have a little more power available than is needed as opposed to having to adapt to a generator that lacks sufficient power.
  3. Then, to roughly account for starting wattage, add the single-highest starting watts figure to the total.
  4. To ensure a margin of safety—and to account for potential future needs—you should multiply that figure by at least 1.25. The resulting number is the minimum generator capacity you should consider.

You can also use our home generator sizing calculator to estimate your power needs.

Step 2: Assessing Your Needs

It’s important to understand your priorities. While getting the right size and type of generator that fits your budget are important, it’s also important to consider how you intend to use the generator.

  • Will it need to be capable of maintaining enough power for your home or small business in case of an emergency?
  • Do you envision having a permanently-installed generator, or is portability important?

How you answer these questions should help provide context for the next step: exploring generator sizing and zeroing in on the perfect product for your needs.

Step 3: Finding the Right Generator

In addition to the generator size calculator, our online buyer’s guide to home generators is a great starting point for exploring your options. Cummins offers three main types of standby generators suited for a home or small business:

  • Permanently-installed 13-20 kW air-cooled home standby generators that can be powered up when needed. 
  • Permanently-installed 25-150 kW liquid-cooled home standby generators that can be powered up when needed. 
  • Heavy-duty, gasoline- or propane-powered 9,500-watt dual fuel portable generators that can provide backup power for a home or small business. 

Cummins: Reliable and Affordable Standby Power Solutions

At Cummins, we build versatile, high-quality standby generators for homes and small businesses. Don’t let their quietness fool you—they’re powerful and reliable. 

When you’re ready to explore your options, you can reach out to request an on-site assessment. One of our authorized dealers will help you assess your needs, evaluate different generator types and capacities, and understand how much a generator might cost to have installed.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

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