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1Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
By : L.M.NaikDeputy General ManagerEngineering - Common Rail System Bosch Ltd, Bangalore
Theory 1:
Duration : 60 minutes
Introduction to
2Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 1-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Contents
Technology drivers Market demands Modern diesel engine requirements Necessity of electronic diesel control
Theory 1
3Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 1-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Technology Drivers
Electronic diesel control Emission regulations(Exhaust gas and Noise) Further fuel economy improvements Further improvements in
- Reliability- Durability
of engine/vehicles Competitive costs and prices
Theory 1 - Introduction
4 Internal | Department | dd/mm/yyyy | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent,it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 1-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Market Demands in Diesel sectorCosts DI Combustion SystemFuel Consumption
Fuel Price
Power Turbo charged-Inter cooledHigher injection Pressure
CompetitorGasoline
Emissions Injection PressureElectronic Diesel Control
Legislation Limits
Comfort EDC with essential factorsPilot Injection
DriveabilityNoise
Theory 1 - Introduction
5Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
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1940 1950 1960 1970 1980 1990 2000 2010Year of Introduction
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Naturally Aspirated Engine Turbo Engine Turbo Engine with Intercooling
Specific Power Output
Theory 1 - Introduction
6Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 2-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Diesel Fuel Injection System
An Overview Inline injection pumps; standard, control sleeve Distributor injection pump; Axial and Radial, VE EDC Single plunger injection pump; PF,UIS,UPS Accumulator injector system (CRS)
Theory 1 - Introduction
7Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 2-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Diesel fuel injection system
Overview:The combustion process that take place inside a diesel engine are essentially dependent on the way in which the fuel is injected into the combustion chamber.
The most important criteria are the timing and duration of injection, degree of atomization and the distribution of fuel inside the combustion chamber.
The various factors which affect the mixture formation:
Start of injectionInjection characteristics (injection duration and rate of injection)Injection pressureInjection direction andThe number of injection jets
8Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Cam driven Fuel Injection Pump
Pressure generation and injection are coupled
Theory 1
9Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | May 2008 | Module 2-Theory 1 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Inline (PE) fuel injection pump
PE Standard in-line injection pumps
1 Pump barrel
2 Inlet port
3 Helix
4 Pump plunger
5 Plunger return spring
6 Rotational travel due to action of control rack (Injected fuel quantity)
7 Camshaft
10 Internal | Department | dd/mm/yyyy | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent,it may not be reproduced or given to third parties.
Break even pointC
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Functions
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Beyond B-B Electronic systems cheaper and better
ElectronicSystems
MechanicalSystems
Conventional fuel injection system vs Electronic Diesel Control
11Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Fuel Injection Pump+Governor+Timer
Engine
Gear lever
Gear box
Wheels
Mechanical coupling
Drivers demand
Mechanical (Diesel) Fuel Injection System:
Conventional fuel injection system
12Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Electronic Control does not replace Mechanical Control completely.It aids the Mechanical Control in improving overall performance
Improve the Fuel Metering Accuracy Improve the Fuel Injection Timing Optimize the Combustion Process Provide Safety Mechanisms Improve the Driver Comfort Level
Motivation for Electronic Control:
Role of electronics in fuel injection
13Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Drivers demand
Fuel Injection Pump
Engine
GearLever Wheels
Electrical Coupling
Mechanical Coupling
Electronic Diesel Control (EDC)
Gear BoxTransmission Controller (TC)
Electronic (Diesel) Fuel Injection System:
Electronic Diesel Control
14Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Pressure Generation & FIEnozzle
pressure
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1980 20001990 19950
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Unit Injector
Distributor pump
Common Rail
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Indirect Injection
Direct Injection
Diesel engine and emission control
15Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
By : L.M.NaikDeputy General ManagerEngineering Common Rail System Bosch Ltd, Bangalore
Theory 2:
Duration : 60 minutes
16Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Technology Demands on FIE
High pressure potential (> 2000 bars)
Realisation of the ideal rate of injection via pressure modulation alone
Capability of realising staged (boot) as well as pilot injection where pilot is
separated from the main injection
Flexibility of selecting start of injection as well as end of injection
Moderate initial rise of main injection
Sharp cut off of the injection end
flexibility of selecting peak injection pressure
Provide option to automatically change rate shape according to
engine speed and load
Theory 2 - Introduction
17Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Theory 2 Common Rail System
CR Syllabus | June 2008 | Module 3 - Theory 5 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Common Rail
Function Design Operating concept
18Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Cam driven FIE
Pressure generation and injection are coupled
Theory 2 Common Rail System
19Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Development Trends in cam driven FIE
Pressure generation and injection are coupled
Theory 2 Common Rail System
20Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Common Rail : FIE with new concept
2. Ideal Engine
Begin of combustion
Time t
Start of Injection
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Start of delivery
Start of Injection
Pm
PsPeak pressure
Mean pressure
1. Conventional System 3. Common Rail System
Time t
Pilot injection
Main InjectionPm(PR)
PR Rail pressure
FIE : Fuel Injection Equipment
Theory 2 Common Rail System
21Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Common Rail : FIE with new concept
FIE : Fuel Injection Equipment
Accumulator
Fuel Tank
High pressure pump
Leakage & control qty
2/2-Solenoid valve
Valve control chamber
Nozzle
Theory 2 Common Rail System
22Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Common Rail System 1600 barTheory 2 Common Rail System
23Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Common Rail System
Theory 2 Common Rail System
24Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Multiple Injection Advantages
Exhaust aftertreatment management
Acoustics measure
Optimized combustion
Basic injection functions
25Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Engine with Common Rail System
Injector High pressure pipe
Pump
Rail
Low pressure pipes
Filter
Theory 2 Common Rail System
26Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | June 2008 | Module 3 - Theory 2 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Common Rail System - applications
Common rail system for Passenger car Fuel supply High pressure control System Diagrams
Common rail system for commercial vehicles Fuel supply High pressure control System Diagrams
Theory 2 Common Rail System
27Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | June 2008 | Module 3 - Theory 2 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Passenger Car Common Rail (PC-CRS)Common Rail System for passenger cars
28Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | June 2008 | Module 3 - Theory 2 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Common Rail System for Trucks with (CP3)
1 Fuel tank
2 Pre filter
3 Fuel filter
4 Gear pre supply pump
5 High pressure pump (CP3.4)
6 Metering unit
7 Rail pressure sensor
8 Fuel rail
9 Pressure relief valve
10 Injector
Common Rail System for Commercial vehicles
29Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.CR Syllabus | June 2008 | Module 3 - Theory 2 | Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Common Rail System for Trucks with (CPN2)
1 Fuel tank
2 Pre filter
3 Fuel filter
4 Gear pre supply pump
5 High pressure pump (CPN2.2)
6 Metering unit
7 Rail pressure sensor
8 Fuel rail
9 Pressure relief valve
10 Injector
Common Rail System for Commercial vehicles
30Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
CRS Advantages Separation of pressure generation and injection
allowing flexibility in controlling both the injection rates and timing.
Fuel pressure does not depend on the engine speed and load conditions (This feature differentiates the common rail from conventional injection systems)
High injection pressures and good spray preparations are possible even at low engine speeds and loads.
Capability to deliver stable, small pilot injections can be used for decreased NOx emissions and noise.
Option for post injections may be used together with such emission control technologies as particulate filters, lean NOxcatalysts, or NOx adsorbers.
Fuel pump operates with low drive torque.
Theory 2 Common Rail System
31Diesel Systems
Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it may not be reproduced or given to third parties.
Introduction to Common Rail Systems