Bachelor's Thesis

Common-rail System for Large Engines

Final Thesis 3.17 MB

Author of thesis: Thomas Geldmacher

Acad. year: 2025/2026

Supervisor: Ing. Radim Dundálek, Ph.D.

Reviewer: Ing. Kamil Řehák, Ph.D.

Abstract:

The common-rail injection system has become the dominant fuel injection architecture for diesel engines due to its ability to precisely control injection pressure, timing, and fuel quantity independent of engine speed. This thesis provides a high-level overview of the system by examining its individual components and their operating principles, as well as the specific adaptations necessary for its use in large diesel engines exceeding 130 kW per cylinder. Furthermore, specific examples of large diesel engines from multiple manufacturers and across several sectors, equipped with common-rail systems, are provided. Finally, current development trends including increasing injection pressures, advanced control strategies, and alternative fuel compatibility are discussed.

Keywords:

common-rail, fuel injection, large diesel engines, high-pressure pump, injector, pressure accumulator, electronic control unit, injection pressure, marine, locomotive

Date of defence

17.06.2026

Result of the defence

Defended (thesis was successfully defended)

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Grading

B

Process of defence

The student presented the committee with the progress of the work, the results and conclusions of the thesis, and answered the reviewer's questions. Prof. Novotný asked about the differences between injection systems. The student answered correctly and showed good orientation in the topic. Doc. Lízal asked about the difference between engines and turbines. The student explained that turbines are cleaner than diesel engines. Prof. Novotný then asked about the maximum efficiency of internal combustion engines. The student gave 50.7%; after Prof. Novotný's clarification, the student acknowledged it may be higher and that internal combustion engines can be more efficient than turbines. Doc. Jan asked what 300 MPa means for the materials used, noting the pressure may be a problem for individual components such as seals. A discussion then developed between the committee and the student on the manufacture of injection systems.

Language of thesis

English

Faculty

Department

Study programme

Fundamentals of Mechanical Engineering (B-STI-A)

Composition of Committee

doc. Ing. František Lízal, Ph.D. (člen)
doc. Ing. Vít Jan, Ph.D. (člen)
doc. Ing. Jiří Šremr, Ph.D. (člen)
prof. Ing. Pavel Novotný, Ph.D. (předseda)
doc. Ing. Pavel Charvát, Ph.D. (místopředseda)

Supervisor’s report
Ing. Radim Dundálek, Ph.D.

The bachelor’s thesis by Thomas Geldmacher provides a well‑structured and technically sound overview of common‑rail injection systems for large diesel engines. The student demonstrates strong command of the topic, working effectively with technical literature and manufacturer documentation. The thesis clearly explains the function of individual components, their control strategies, and the specific adaptations required for engines exceeding 130 kW per cylinder. The breadth of the research, including detailed descriptions of high‑pressure pumps, accumulators, injectors, and real‑world applications across marine, rail, industrial, and power‑generation sectors, is a notable strength. While the work is comprehensive, some chapters remain predominantly descriptive and could benefit from deeper analytical synthesis. Nevertheless, the thesis meets the assignment objectives and represents a high‑quality and professionally written piece of work.
Evaluation criteria Grade
Splnění požadavků a cílů zadání A
Postup a rozsah řešení, adekvátnost použitých metod A
Vlastní přínos a originalita B
Schopnost interpretovat dosažené výsledky a vyvozovat z nich závěry B
Využitelnost výsledků v praxi nebo teorii A
Logické uspořádání práce a formální náležitosti A
Grafická, stylistická úprava a pravopis A
Práce s literaturou včetně citací A
Samostatnost studenta při zpracování tématu A

Grade proposed by supervisor: A

Reviewer’s report
Ing. Kamil Řehák, Ph.D.

The bachelor’s thesis by Mr. Geldmacher deals with the topic of common-rail systems for large engines. The thesis is a literature review and is based on 54 sources. Considering the review-based nature of the thesis, I consider this number of sources to be rather borderline, but still sufficient to meet the stated objectives. The thesis is clearly structured and has a total length of 48 pages. In the introductory part, the author appropriately presents the motivation for addressing the topic, identifies the problem, and formulates the objectives of the thesis. This is followed by basic information related to the topic. The author then provides a historical overview of fuel injection systems, ranging from mechanical systems through unit pump and unit injector systems to common-rail systems. The subsequent sections focus specifically on common-rail systems, with the discussion gradually narrowing down to the specifics of their application in large engines. The individual chapters are logically arranged and clearly written. I also appreciate that the text is suitably supplemented with representative examples from the individual categories, which contributes to the clarity and illustrative value of the thesis. The final part of the thesis presents development trends and future perspectives in the field. However, I would have expected a more substantial contribution from the author, particularly a deeper focus on identifying trends that can be expected in the near future, as well as on current challenges in the area of common-rail systems for large engines and the ways in which research and development are responding to these challenges.Overall, the thesis can be considered to be of a good standard. The text is written in a readable manner, the chapters follow each other logically, and the thesis contains only a minimal number of stylistic shortcomings. The stated objectives of the thesis have been fulfilled. Based on the above, I recommend the bachelor’s thesis for defence.
Evaluation criteria Grade
Splnění požadavků a cílů zadání B
Postup a rozsah řešení, adekvátnost použitých metod C
Vlastní přínos a originalita C
Schopnost interpretovat dosaž. výsledky a vyvozovat z nich závěry C
Využitelnost výsledků v praxi nebo teorii C
Logické uspořádání práce a formální náležitosti B
Grafická, stylistická úprava a pravopis B
Práce s literaturou včetně citací C
Topics for thesis defence:
  1. What are the main development trends that can be expected in the near future in the field of common-rail systems for large engines?
  2. What technical measures do you consider necessary to meet future emission limits for large engines equipped with common-rail systems?

Grade proposed by reviewer: C

Responsibility: Mgr. et Mgr. Hana Odstrčilová