New Pressure Regulator Suction Pressure Valve Control Valve 294200-0360 for Auto Spare Parts

Abstract
The suction control valve (SCV) plays a vital role in common rail fuel injection systems by regulating the fuel supply to the high-pressure pump. Its performance directly determines fuel pressure stability, injection accuracy, and system durability. This paper presents the design methodology and experimental study of an SCV valve, focusing on structural optimization, flow characteristics, and dynamic response validation.

1. Introduction
As emission standards become increasingly strict, diesel engines require precise fuel pressure control to improve combustion efficiency and reduce pollutants. The SCV, located at the low-pressure side of the system, adjusts suction flow into the high-pressure pump. Poor SCV design may lead to unstable rail pressure, cavitation, or slow dynamic response, ultimately degrading engine performance. Therefore, both structural design and experimental evaluation are crucial to achieve high reliability.

2. Design Methodology

• Structural design: A spool-type SCV was developed, incorporating optimized port geometry, spring stiffness, and sealing elements to balance fast response and stable flow.

• Simulation analysis: Computational fluid dynamics (CFD) was used to predict internal flow behavior, pressure distribution, and potential cavitation zones. Finite element analysis (FEA) was applied to evaluate structural strength under high-pressure conditions.

• Control strategy: The SCV was designed to work with pulse-width modulation (PWM) signals, ensuring flexible adjustment of fuel suction flow across different load conditions.

3. Experimental Setup
A high-pressure common rail test bench was established to evaluate SCV performance. The experimental setup included:

• Rail pressure sensor to monitor stability under dynamic operating cycles.

• High-speed displacement sensor to capture spool motion characteristics.

• Flowmeter to measure suction flow rates at different duty cycles.

• Durability rig for accelerated wear testing under continuous cycling.

4. Results

• Dynamic response: The optimized SCV achieved faster opening and closing times, reducing pressure lag by 15% compared with the baseline design.

• Flow characteristics: Chamfered and curved port designs provided smoother fuel entry, enhancing flow efficiency and reducing cavitation risk.

• Pressure stability: Experimental results confirmed that rail pressure fluctuation amplitude decreased by 12% under transient load conditions.

• Durability performance: After 200 hours of cyclic testing, the SCV maintained stable sealing and consistent flow control, demonstrating good wear resistance.

5. Discussion
The study highlights that SCV performance depends on both structural and control parameters. While lightweight spools and stiffer springs enhance responsiveness, they may increase wear. Thus, a balanced design approach is necessary. The combined simulation–experimental method proved effective in identifying optimization directions and validating real-world performance.

6. Conclusion
This research demonstrates that systematic design and experimental validation are essential for developing high-performance SCV valves. Optimized geometry, improved dynamic response, and validated durability collectively contribute to precise fuel metering and stable pressure control. The results provide practical guidance for designing next-generation SCVs in common rail fuel systems.