Common Rail Direct Injection h5r2h
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COMMON RAIL DIRECT INJECTION Dr. K. C. Vora Head, ARAI Academy The Automotive Research Association of India, Pune
CONTENTS
•Introduction •System Types & Generation
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
INTRODUCTION TECHNOLOGY DRIVERS • Emission regulations (Exhaust gas and Noise) • Further fuel economy improvements
• Further improvements in • Reliability • Durability of engine/vehicles • Competitive costs and prices
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.
FUEL INJECTION SYSTEM - FUNCTIONS
Main Functions of Diesel Fuel Injection System
Injection Timing Control
5
Atomization and Penetration
Injection Quality Control
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
CAM DRIVEN FIE
Cam driven FIE
Courtesy: Mico Bosch India.
Pressure generation and injection are coupled
DEVELOPMENT TRENDS IN CAM DRIVEN FIE
Courtesy: Mico Bosch India.
COMMON RAIL & EDC FIP
Courtesy: Mico Bosch India.
PRESSURE GENERATION AND FIE
Courtesy: Mico Bosch India.
INJECTION PRESSURES 1600 - 2000 BAR
TECHNOLOGY DRIVERS-EMISSION
Courtesy: Mico Bosch India.
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
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
What is a Common Rail? Common Rail is a 1. Modular, 2. Electronic Controlled, 3. Diesel Fuel Injection System
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 Injection Quality can be freely selected (EDC function).
COMMON RAIL SYSTEM How are the main characteristics of CR system achieved?
1. CR uses and intermediate High Pressure Accumulator (Rail) 2. Uses Electronic Control of Injectors (use of Electro-magnetic valves)
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMPONENTS OF CRDI SYSTEM Filter Sedimenter Low Pressure Side
Priming Pump (Pear Type) Low pressure pipes with quick fit couplers
HP Pump CR System
High Pressure Side
Rail
Injectors (set of 4) HP Pipes (set of 5)
ECU Electronics Sensors
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
ELECTRONIC DIESEL CONTROL
Courtesy: Mico Bosch India.
CRS- ELECTRONIC CONTROL UNIT (ECU)
Courtesy: Mico Bosch India.
CRS- ELECTRONIC CONTROL UNIT (ECU)
Courtesy: Mico Bosch India.
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
SENSORS FOR CRDI ENGINE Fuel Temp On CR System
Rail Pressure Water Sensor Barometric Sensor Engine Speed (Crankshaft) Engine Phase (Cam Shaft) Knock Sensor
Sensors
On Engine
Water Temp Intake Air Temp and Boost Pressure Air Mass Flow Cruise Control
On Vehicle
Vehicle Speed Throttle Pedal
SENSORS ON CRDI ENGINE
Courtesy: Mico Bosch India.
ORIENTATION ON CRS COMPONENT: COMMON RAIL
Courtesy: Mico Bosch India.
ORIENTATION ON CRS COMPONENT: COMMON RAIL
Courtesy: Mico Bosch India.
HIGH PRESSURE PUMP OF COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
INJECTOR
Servo valve principle
Solenoid actuator
200 - 1600 bar operating pressure
pilot quantity 1-3 mm3
Extremely fast response
Low leakage system
Capable of multiple injections
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
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 NOx catalysts, or NOx adsorbers. Fuel pump operates with low drive torque.
CONTENTS
•Introduction completed •System Types & Generation
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
SYSTEM TYPES
Courtesy: Mico Bosch India.
SYSTEM TYPES
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM 1600bar with 1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM 1600bar with 1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM- COMMERCIAL VEHICLE (CRSN)
Courtesy: Mico Bosch India.
CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM
CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM
Courtesy: Mico Bosch India.
SYSTEM COMPONENTS : CRS
Courtesy: Mico Bosch India.
SYSTEM MANAGEMENT
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
COMMON RAIL SYSTEM & EMISSION
COMMON RAIL SYSTEM & EMISSION
SYSTEM VARIABILITY REDUCTION •Dispersion management is one of the great challenges. •Low variation and high precision are required during the entire vehicle life Euro 4
Enabling technologies:
PM (g/km)
• Fast/Precise fuel injection systems • Fuel injection control strategies • Combustion sensors Euro 6 Proposal
Euro 5
Future dispersio n
NOx (g/km)
• Performing EGR components
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy completed •System Validation & Tests •Project Milestones
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
COMMON RAIL SYSTEM LOAD COLLECTIVE MEASUREMENTS
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy completed •System Validation & Tests completed •Project Milestones
PROJECT MILESTONES
CUSTOMER PROJECTS : INTERFACE & INVOLMENTS
COMMON RAIL SYSTEM & DIAGNOSIS
PROJECT TEAMS
COMMON RAIL SYSTEM & FUEL
CONCLUSIONS
Thank You!
60
CONTENTS
•Introduction •System Types & Generation
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
INTRODUCTION TECHNOLOGY DRIVERS • Emission regulations (Exhaust gas and Noise) • Further fuel economy improvements
• Further improvements in • Reliability • Durability of engine/vehicles • Competitive costs and prices
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.
FUEL INJECTION SYSTEM - FUNCTIONS
Main Functions of Diesel Fuel Injection System
Injection Timing Control
5
Atomization and Penetration
Injection Quality Control
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
CAM DRIVEN FIE
Cam driven FIE
Courtesy: Mico Bosch India.
Pressure generation and injection are coupled
DEVELOPMENT TRENDS IN CAM DRIVEN FIE
Courtesy: Mico Bosch India.
COMMON RAIL & EDC FIP
Courtesy: Mico Bosch India.
PRESSURE GENERATION AND FIE
Courtesy: Mico Bosch India.
INJECTION PRESSURES 1600 - 2000 BAR
TECHNOLOGY DRIVERS-EMISSION
Courtesy: Mico Bosch India.
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
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
What is a Common Rail? Common Rail is a 1. Modular, 2. Electronic Controlled, 3. Diesel Fuel Injection System
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 Injection Quality can be freely selected (EDC function).
COMMON RAIL SYSTEM How are the main characteristics of CR system achieved?
1. CR uses and intermediate High Pressure Accumulator (Rail) 2. Uses Electronic Control of Injectors (use of Electro-magnetic valves)
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMPONENTS OF CRDI SYSTEM Filter Sedimenter Low Pressure Side
Priming Pump (Pear Type) Low pressure pipes with quick fit couplers
HP Pump CR System
High Pressure Side
Rail
Injectors (set of 4) HP Pipes (set of 5)
ECU Electronics Sensors
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
ELECTRONIC DIESEL CONTROL
Courtesy: Mico Bosch India.
CRS- ELECTRONIC CONTROL UNIT (ECU)
Courtesy: Mico Bosch India.
CRS- ELECTRONIC CONTROL UNIT (ECU)
Courtesy: Mico Bosch India.
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
SENSORS FOR CRDI ENGINE Fuel Temp On CR System
Rail Pressure Water Sensor Barometric Sensor Engine Speed (Crankshaft) Engine Phase (Cam Shaft) Knock Sensor
Sensors
On Engine
Water Temp Intake Air Temp and Boost Pressure Air Mass Flow Cruise Control
On Vehicle
Vehicle Speed Throttle Pedal
SENSORS ON CRDI ENGINE
Courtesy: Mico Bosch India.
ORIENTATION ON CRS COMPONENT: COMMON RAIL
Courtesy: Mico Bosch India.
ORIENTATION ON CRS COMPONENT: COMMON RAIL
Courtesy: Mico Bosch India.
HIGH PRESSURE PUMP OF COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
INJECTOR
Servo valve principle
Solenoid actuator
200 - 1600 bar operating pressure
pilot quantity 1-3 mm3
Extremely fast response
Low leakage system
Capable of multiple injections
COMMON RAIL SYSTEM
Courtesy: Mico Bosch India.
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 NOx catalysts, or NOx adsorbers. Fuel pump operates with low drive torque.
CONTENTS
•Introduction completed •System Types & Generation
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
SYSTEM TYPES
Courtesy: Mico Bosch India.
SYSTEM TYPES
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM 1600bar with 1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM 1600bar with 1H, Gear pump (feed), Metering unit, Injector, Rail, ECU
Courtesy: Mico Bosch India.
COMMON RAIL SYSTEM- COMMERCIAL VEHICLE (CRSN)
Courtesy: Mico Bosch India.
CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM
CRS SYSTEM FOR OFF HIGHWAY APPLICATIONSBASIC SYSTEM
Courtesy: Mico Bosch India.
SYSTEM COMPONENTS : CRS
Courtesy: Mico Bosch India.
SYSTEM MANAGEMENT
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy •System Validation & Tests •Project Milestones
COMMON RAIL SYSTEM & EMISSION
COMMON RAIL SYSTEM & EMISSION
SYSTEM VARIABILITY REDUCTION •Dispersion management is one of the great challenges. •Low variation and high precision are required during the entire vehicle life Euro 4
Enabling technologies:
PM (g/km)
• Fast/Precise fuel injection systems • Fuel injection control strategies • Combustion sensors Euro 6 Proposal
Euro 5
Future dispersio n
NOx (g/km)
• Performing EGR components
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy completed •System Validation & Tests •Project Milestones
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
COMMON RAIL SYSTEM LOAD COLLECTIVE MEASUREMENTS
CONTENTS
•Introduction completed •System Types & Generation completed
•Common Rail & Emission Strategy completed •System Validation & Tests completed •Project Milestones
PROJECT MILESTONES
CUSTOMER PROJECTS : INTERFACE & INVOLMENTS
COMMON RAIL SYSTEM & DIAGNOSIS
PROJECT TEAMS
COMMON RAIL SYSTEM & FUEL
CONCLUSIONS
Thank You!
60
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