83245790-10-16-2007-Cummins-CRS3-3i-2.pdf

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1

Diesel Systems

CRS3.3i

needle

t he direct

Strictly confidential | 0281_Ze DS_PC/PJ-ECI| 07.08.2007 | Robert Bosch GmbH reserves all rights even in the event of industrial property

rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Diesel Systems

CRI3.3i CR Piezo Injector Direct Needle ActuationHP connector

Electricalconnection

CRI3.3i (2000 bar): RB-SOP not decided yet

Customer Benefit:

Emissions

direct actuated nozzle needle

highest needle dynamics

hydraulic buffer volume

highest multiple injection flexibility minimum PI quantity (0.5 0.8 mm3/S) closed loop control

Fuel consumption

close couple combustion concept no fuel return

Power & Torque

more injected fuel quantity in less time maximum engine power + torque output

Internal | DS-PC/PJ-ECI | 25.07./2007 | 0277_Ze | Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We

reserve all rights of disposal such as copying and passing on to third parties.

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Diesel Systems CRS3.3i Systemlayout

Tank

Control unit EDC 17

Prefilter

Fuel filter

high pressure backflowpressure

Pressure regulating valveDRV3.3

Tank

ElectricalpresupplypumpEKP

Piezo-InjectorCRI 3.3i(1...n)

MeteringunitZME

Rail pressuresensor RDS4.3

EKP pressure

Rail (LWR3.3)

Highpressure

pumpCP4.1

New

Diesel SystemsVertraulich | DS/ECP2-Kc | 21.11.2005 | Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von Schutzrechtsanmeldungen. Jede

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CRS3.3i Function Schematic

nozzle (pressure chamber)

sackhole

injector (actuator chamber)

coupler chamber

pressure[bar]

U[V

]

2000

1500

1000

500

0

coupler volume

before nozzle

sack hole

Voltage at Piezo actuator200V

0 V

beforenozzle

sack hole

couplervolume

time scale

Diesel SystemsStrictly confidential | DS/PJ-EII | 0071e_Pa_583 | Robert Bosch GmbH reserves all rights even in the event of industrial property rights.

We reserve all rights of disposal such as copying and passing on to third parties.

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CRI3.3i - Results

CRI3.x

CRI3.3i

0 1 2 3 4 5 6 7 8 9 10Kurbelwinkel [Grad]

P_

EV

I[bar]

-5

0

5

10

15

20

1000 bar / 40.0 mm

CRI3.3i Hydraulic Results Injection Rate

crank angle ()

injectionratesignal(-)

Advantage CRI3.3i: fast needle opening/closing increased steepness minimized throtteling effects

square shaped injection rate

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all rights of disposal such as copying and passing on to third parties.

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CRS3.3i

Hydraulic Results Characteristic Injection Map

0

20

40

60

80

100

120

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5

Dauer HE [ms]

MengeHE[mm/Hub]

1.Q=f(AD)_7461_0003A.xls 1.Q=f(AD)_7461_0004.xls 1.Q=f(AD)_7461_0005A.xls 1.Q=f(AD)_7461_0006A.xls 1.Q=f(AD)_7461_0007A.xls

1.Q=f(AD)_7461_0008A.xls 1.Q=f(AD)_7461_0010A.xls 1.Q=f(AD)_7461_0011A.xls 1.Q=f(AD)_7461_0012A.xls 1.Q=f(AD)_7461_0013A.xls

2000 bar

1600 bar

1200 bar

800 bar

200 bar

180V

0V

Q(

mm3/S)

ET (ms)

Strictly confidential | DS/PJ-ECI 0208_Ze | 08.04.2007 | Robert Bosch GmbH reserves all rights even in the event of industrial property rights.


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CRI3.3i - Results

0

10

20

30

40

50

60

70

80

90

100

0,0 0,5 1,0 1,5 2,0 2,5

2000 bar

1800 bar

1600 bar

1400 bar

1200 bar

1000 bar

800 bar

600 bar

400 bar

250 bar

200 bar

Sehr gute Kennfeldlinearitt

Sehr gute Voraussetzung fr Korrelationsfunktionen (IMA,)

AD (MI) [ms]

quantity(MI)[mm3/H]

0

1

2

3

4

5

50 75 100 125 150 175 20

Small PI quantitiy delivery possible

High steepness of PI quantity map, energizing concept has to be optimized

200V

0V

ca. 0,13mm/s(ca. 0,05mm/s CRI3.3)



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CRI3.3i - Results

Vergleich H/H-Streuung CRI3.3 zu CRI3.3i

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

5,5

6

6,5

7

0 200 400 600 800 1000 1200

Ansteuerdauer [s]

Hub/Hub-Streuung[mm/H]

1600bar CRI3.3 1200bar CRI3.3

300bar CRI3.3 1600bar Inj.CRI-PDN A1.2

1200bar Inj.CRI-PDN A1.2 300bar Inj.CRI-PDN A1.2

H/H (300bar)= H/H-1mm/H.



Comparison stroke/stroke-deviation CRI3.x-CRI3.3i

s/s-devia

tion[mm/s]

energizing time [s]

stroke/stroke-deviation independent of energizing time



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CRS3.3i

Hydraulic Results Characteristic Map EDC17

0

1

2

3

4

5

6

7

8

9

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

Ansteuerdauer [s]


2000 bar

1800 bar

1600 bar

1400 bar

1200 bar

1000 bar

800 bar

600 bar

400 bar

200 bar

200bar (Offset = +0 mm)










50Hub-Messung EMI*Teilhub Schrittweite 1s **Vollhub Schrittweite 10s

*

*

*

*

*

*

*

*

*

*

**

**

**

**

**

**

**

**

**

**

S/Ssprea

d(mm3/S)

ET (s)



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11

CRS3.3i

Hydraulic Results Inj/ Inj + S/S Spread

0

10

20

30

40

50

60

70

80

90

1 2 3 4 5 6 7

Prfpunkt [Nr.]

Einsp

ritzmenge[mm/H]

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9


Q 7461_0003A Q 7461_0004A Q 7461_0005A Q 7461_0006A Q 7461_0007A Q 7461_0008A Q 7461_0010A Q 7461_0011A Q 7461_0012A Q 7461_0013A

3s H/H 7461_0003A 3s H/H 7461_0004A 3s H/H 7461_0005A 3s H/H 7461_0006A 3s H/H 7461_0007A 3s H/H 7461_0008A 3s H/H 7461_0010A 3s H/H 7461_0011A 3s H/H 7461_0012A 3s H/H 7461_0013A

20mm/H.@800bar

2mm

/H.@

1200bar

7mm/H.@250bar

50mm/H.@

2000bar

2mm/H.@

2000bar

1,5mm/H.@8

00bar

80mm/H.@

1400bar

Q(

mm3/S)

Test Points

S/Sspread(mm3/S)



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Diesel Systems

1000 bar /

CRI3.3i

CRI3.0

Advantage CRS3.3i:

strongly reduced pressure wave amplitudes free applicable injection distances, no PWC

highest flexibility Less SW function efforts

CRI3.3i Hydraulic Results Pressure Waves

Streng vertraulich | Department | 03.2007 | 783d_0596_Sk | Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von

Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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CRI3.3i

NVC

fuelmass

ISA

voltage

fuelmass

voltage

polarization

ET

rpmp

init-/ starting-time

stroke

temp.

U

CRI3.

x

Piezo injectors require precise activation/chargingas a function of rail pressure, temperature, lifetime, etc.

They finally can enable to be used as

on-board sensor in a closed-loop control structure.

initial classification

lifetime

temperature

cold start



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14

CRI3.3i - Results

CRI3.3i needle sensor feasibility

0

10

20

30

40

50

60

70

100 300 500 700 900 1100

Ansteuerdauer [s]

Einspritzmenge[mm/H]

2000bar

1500bar

1000bar

500bar

with governor

ca.

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Common Rail System CRS3.3i

Status 09/07

A6-sample

Project

Internal A-sample successfully tested

CRI Test Bench: > up to 2000h reached

Engine Test: > up to 400h cumulated

Technology

Functional Concept

Actuator Module Design

ECU control functions

applicable Q-Hyd range > 880ccm

Optimisation Step: Improvement of CRI Hydraulics

and Actuator

Strictly confidential | DS/PJ-ECI 0228_Ze, 0185_Ze | 08.04.2007 | Robert Bosch GmbH reserves all rights even in the event of industrial

property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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CRI3.3i at one sight

Summary of hydraulic results:

CRI3.3i

CRI3.x

EM VE LL VL

S/S

CRI3.3i

CRI3.x

extreme linear injection map

small sample deviation

very small shot to shot

spread

962_01

962_03

962_05

962_06

962_11

962_12

962_13

962_14

962_15

962_16

energizing time

quantity

step injection rate

closed couple PI

reduced pressure waveoscillations

-1000

-800

-600

-400

-200

0

200

400

600

800

1000

1200

injectionrate

injectionrate

time scale time scale

Strictly confidential | DS/PJ-EII | 0096_Pa_587 | Robert Bosch GmbH reserves all rights even in the event of industrial property rights.


Diesel Systems

distance PI-MI

quantity

reduced quantity wave amplitude

improved accuracy

(at free distance: +/- 0,5 mm3/S)

no rail throttles and PWC

closed PI possible

injectionrate

CRS3.3iCRS3.0

time scale

CRS3 3i

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CRS3.3i

Costumer benefit with CRS3.3i:

slightly reduced fuel consumption:

a) reduced pump torque due to lack of fuel return

b) possibility of closed PI-strategy

optimized multiple injection capability

reduced quantity drift

means smaller tolerances

means slightly reduced engineering target concerning emissions

Potential of no PWC due to reduced pressure wave oscillations

potential to omit fuel cooler in critical applications

no fuel return lines from injectors

do the benefits justify the add-on costs ?

Diesel SystemsStrictly confidential | DS/PJ-EII | 0214_Ze; 0096_Pa_587 | Robert Bosch GmbH reserves all rights even in the event of industrial property

rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3 3i

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21

CRI3.3i

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von


Conclusion

CRS3.3i technically feasible; though fuel-resistant piezo stack isa challenge

long piezo stack is driving costs of system (stack and ECU)higher compared to CRS3.x, but market demands lower costs

reducing piezo length would require higher transition ratio either hydraulically (coupler) or mechanically

higher transition ratio means less stiffness (reduced performance) system more sensitive toward tolerances

higher tolerance sensitivity means

more critical over lifetime more critical injector/injector Bosch conclusion:

CRI3.3i is the right approach to get the best injector performance

CRI piezo direct is no favorable business case for customer / Bosch Bosch is developing advanced solenoid CR systems (CRS2.5,6,7)CRI piezo direct is no favorable business case for customer / Bosch

Bosch is developing advanced solenoid CR systems (CRS2.5,6,7)

CRS R d

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22

CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD 2200bar

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83245790-10-16-2007-Cummins-CRS3-3i-2.pdf

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