4 Common_Rail_System_Naik L M

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


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


5Diesel Systems


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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


6Diesel Systems


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)


7Diesel Systems


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


Cam driven Fuel Injection Pump

Pressure generation and injection are coupled

Theory 1

9Diesel Systems


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

B

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Beyond B-B Electronic systems cheaper and better

ElectronicSystems

MechanicalSystems

Conventional fuel injection system vs Electronic Diesel Control

11Diesel Systems


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


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


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


Pressure Generation & FIEnozzle

pressure

2500

500

1000

1500

2000

bar

1980 20001990 19950

1975

Unit Injector

Distributor pump

Common Rail

1985E

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Indirect Injection

Direct Injection

Diesel engine and emission control

15Diesel Systems


By : L.M.NaikDeputy General ManagerEngineering Common Rail System Bosch Ltd, Bangalore

Theory 2:

Duration : 60 minutes

16Diesel Systems


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


17Diesel Systems


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


Cam driven FIE



19Diesel Systems


Development Trends in cam driven FIE



20Diesel Systems


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


21Diesel Systems


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


22Diesel Systems


Common Rail System 1600 barTheory 2 Common Rail System

23Diesel Systems


Common Rail System


24Diesel Systems


Multiple Injection Advantages

Exhaust aftertreatment management

Acoustics measure

Optimized combustion

Basic injection functions

25Diesel Systems


Engine with Common Rail System

Injector High pressure pipe

Pump

Rail

Low pressure pipes

Filter


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


27Diesel Systems


Passenger Car Common Rail (PC-CRS)Common Rail System for passenger cars

28Diesel Systems


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


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


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.


31Diesel Systems


Introduction to Common Rail Systems

4 Common_Rail_System_Naik L M

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