8/12/2019 4. Common Rail Direct Injection
1/60
COMMON RAIL DIRECT INJECTION
Dr. K. C. VoraHead, ARAI Academy
The Automotive Research Association of India, Pune
8/12/2019 4. Common Rail Direct Injection
2/60
CONTENTS
Introduction
System Types & Generation
Common Rail & Emission Strategy
System Validation & Tests
Project Milestones
8/12/2019 4. Common Rail Direct Injection
3/60
TECHNOLOGYDRIVERS
Emission regulations (Exhaust gas and Noise)
Further fuel economy improvements
Further improvements in
Reliability
Durability of engine/vehicles
Competitive costs and prices
INTRODUCTION
8/12/2019 4. Common Rail Direct Injection
4/60
FUEL INJECTION SYSTEM - FUNCTIONS
To meter the quantity of fuel to be injected.
To inject fuel at the right time in the cycle. This implies accurate timing
of injection as a function of engine speed and load.
To mix fuel with air effectively in the short period of time available. This
means that the fuel has to be introduced at very high energy levels
All the above have to happen consistently cycle by cycle, cylinder to
cylinder and over a period of time.
8/12/2019 4. Common Rail Direct Injection
5/60
5
Main Functionsof Diesel Fuel
Injection System
Injection Timing
Control
Atomization
and Penetration
Injection Quality
Control
FUEL INJECTIONSYSTEM - FUNCTIONS
8/12/2019 4. Common Rail Direct Injection
6/60
FUEL INJECTION SYSTEM - FUNCTIONS
Fuel Injection Pump Fuel quantity delivered
Injection Timing
Rate of Injection
Idle & Max speed Governing
Injector
Injection pressure
Spray pattern Filter
Removal of contamination from fuel Protect Fuel
Injection equipment
8/12/2019 4. Common Rail Direct Injection
7/60
Cam driven FIE
Pressure generation and injection are coupledCourtesy: Mico Bosch India.
CAM DRIVEN FIE
8/12/2019 4. Common Rail Direct Injection
8/60
Courtesy: Mico Bosch India.
DEVELOPMENT TRENDS IN CAM DRIVEN FIE
8/12/2019 4. Common Rail Direct Injection
9/60
COMMON RAIL & EDC FIP
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
10/60
PRESSURE GENERATION AND FIE
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
11/60
8/12/2019 4. Common Rail Direct Injection
12/60
TECHNOLOGY DRIVERS-EMISSION
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
13/60
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
8/12/2019 4. Common Rail Direct Injection
14/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
15/60
What is a Common Rail?
Common Rail is a1. Modular,
2. Electronic Controlled,
3. Diesel Fuel Injection System
COMMON RAIL SYSTEM
8/12/2019 4. Common Rail Direct Injection
16/60
COMMON RAIL SYSTEM
Special Characteristics
1. Injection Pressure is produced
and governed relatively.independent of the Engine
Speed and can be selected
freely within a wide range.
2. Injection begin and InjectionQuality can be freely selected
(EDC function).
8/12/2019 4. Common Rail Direct Injection
17/60
How are the main characteristics of CR
system achieved?
1. CR uses and intermediate HighPressure Accumulator (Rail)
2. Uses Electronic Control of Injectors
(use of Electro-magnetic valves)
COMMON RAIL SYSTEM
8/12/2019 4. Common Rail Direct Injection
18/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
19/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
20/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
21/60
COMPONENTS OF CRDI SYSTEM
CR
System
HP
Pump
Injectors(set of 4)
Rail
Sensors
ECU
Low
Pressure
Side
High
Pressure
Side
Electronics
Sedimenter
Priming Pump (Pear Type)
HP Pipes
(set of 5)
Filter
Low pressure pipes with quick fit couplers
8/12/2019 4. Common Rail Direct Injection
22/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
23/60
8/12/2019 4. Common Rail Direct Injection
24/60
ELECTRONIC DIESEL CONTROL
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
25/60
CRS- ELECTRONIC CONTROL UNIT (ECU)
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
26/60
8/12/2019 4. Common Rail Direct Injection
27/60
CRS- ELECTRONIC CONTROL UNIT (ECU)
ECU mounting Hints
Boundary condition influencing installation of ECU
Wiring harness: 150mm from ECU
Vibration: 4 plane screwing points
Temperature: < 60C
Humidity: Away from water splash
Chemical resistance: Away from battery
8/12/2019 4. Common Rail Direct Injection
28/60
SENSORS FOR CRDI ENGINE
Sensors
On CR
System
On
Engine
On
Vehicle
Fuel Temp
Rail Pressure
Engine Speed (Crankshaft)
Engine Phase (Cam Shaft)
Throttle Pedal
Knock Sensor
Water Temp
Intake Air Temp
and Boost
Pressure
Vehicle Speed
Air Mass Flow
Cruise Control
Water Sensor
Barometric Sensor
8/12/2019 4. Common Rail Direct Injection
29/60
SENSORS ON CRDI ENGINE
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
30/60
Courtesy: Mico Bosch India.
ORIENTATION ON CRS COMPONENT: COMMON RAIL
8/12/2019 4. Common Rail Direct Injection
31/60
ORIENTATION ON CRS COMPONENT: COMMON RAIL
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
32/60
HIGH PRESSURE PUMP OF COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
33/60
Servo valve principle
Solenoid actuator
200 - 1600 bar operatingpressure
pilot quantity 1-3 mm3
Extremely fast response
Low leakage system
Capable of multipleinjections
INJECTOR
8/12/2019 4. Common Rail Direct Injection
34/60
8/12/2019 4. Common Rail Direct Injection
35/60
CRS ADVANTAGES
Separation of pressure generation and injection allowing flexibilityin 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 emissioncontrol technologies as particulate filters, lean NOx catalysts, or NOx
adsorbers.
Fuel pump operates with low drive torque.
8/12/2019 4. Common Rail Direct Injection
36/60
8/12/2019 4. Common Rail Direct Injection
37/60
SYSTEM TYPES
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
38/60
SYSTEMTYPES
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
39/60
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
1600bar with CP1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
8/12/2019 4. Common Rail Direct Injection
40/60
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
1600bar with CP1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
8/12/2019 4. Common Rail Direct Injection
41/60
COMMON RAIL SYSTEM- COMMERCIAL VEHICLE (CRSN)
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
42/60
CRS SYSTEM FOR OFF HIGHWAY APPLICATIONS-
BASIC SYSTEM
8/12/2019 4. Common Rail Direct Injection
43/60
8/12/2019 4. Common Rail Direct Injection
44/60
SYSTEM COMPONENTS : CRS
Courtesy: Mico Bosch India.
8/12/2019 4. Common Rail Direct Injection
45/60
SYSTEM MANAGEMENT
8/12/2019 4. Common Rail Direct Injection
46/60
CONTENTS
Introduction completed
System Types & Generation completedCommon Rail & Emission Strategy
System Validation & Tests
Project Milestones
8/12/2019 4. Common Rail Direct Injection
47/60
COMMON RAIL SYSTEM & EMISSION
8/12/2019 4. Common Rail Direct Injection
48/60
COMMON RAIL SYSTEM & EMISSION
8/12/2019 4. Common Rail Direct Injection
49/60
SYSTEM VARIABILITY REDUCTION
Dispersion management is one of the great challenges.
Low variation and high precision are required during the entire
vehicle life
Euro 5Euro 6 Proposal
PM(
g/km)
NOx (g/km)
Euro 4
Future
dispersio
n
Enabling technologies:
Fast/Precise fuel
injection systems
Fuel injection control
strategies
Combustion sensors
Performing EGR
components
8/12/2019 4. Common Rail Direct Injection
50/60
CONTENTS
Introduction completed
System Types & Generation completedCommon Rail & Emission Strategy completed
System Validation & Tests
Project Milestones
8/12/2019 4. Common Rail Direct Injection
51/60
VALIDATION TESTS ON SYSTEM, ENGINE, VEHICLE
System endurance test on bench
Load collective measurement on vehicle
Low pressure circuit measurement on vehicle
Temperature measurement on vehicle
Vibration measurements on engine and vehicle
Fault monitoring and diagnostics on vehicle
Endurance test on engine
Mileage accumulation on vehicle Summer, winter, altitude test on vehicle
8/12/2019 4. Common Rail Direct Injection
52/60
OMMON RAIL SYSTEM LOAD COLLECTIVE MEASUREMENTS
8/12/2019 4. Common Rail Direct Injection
53/60
CONTENTS
Introduction completed
System Types & Generation completedCommon Rail & Emission Strategy completed
System Validation & Tests completed
Project Milestones
8/12/2019 4. Common Rail Direct Injection
54/60
PROJECT MILESTONES
8/12/2019 4. Common Rail Direct Injection
55/60
CUSTOMER PROJECTS : INTERFACE & INVOLMENTS
8/12/2019 4. Common Rail Direct Injection
56/60
COMMON RAIL SYSTEM & DIAGNOSIS
8/12/2019 4. Common Rail Direct Injection
57/60
PROJECT TEAMS
8/12/2019 4. Common Rail Direct Injection
58/60
COMMON RAIL SYSTEM & FUEL
8/12/2019 4. Common Rail Direct Injection
59/60
CONCLUSIONS
8/12/2019 4. Common Rail Direct Injection
60/60
Thank You!
Top Related