Theory 1:
Introduction to
Duration Dura tion : 60 minu tes
By : L.M.Naik Deputy General Manager Engineering Engine ering - Common Rail Rail System System Bosch Ltd, Bangalore Bangalore
Diesel Systems
1
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Theory 1
Contents
• Technol Technology ogy drivers drivers • Marke Markett dema demand nds s • Modern diesel diesel engine engine requirem requirements ents • Necessity Necessity of electro electronic nic diesel diesel control control
Diesel Systems
2
CR Syllabus | May 2008 | Module| 1-Theory | © Boschproperty Limitedy 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive propert of Bosch Limited (formerlyalso (formerly Motor Industries Ltd.) Without Wi thout their consent, it editing, distribution , as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
Theory 1
Contents
• Technol Technology ogy drivers drivers • Marke Markett dema demand nds s • Modern diesel diesel engine engine requirem requirements ents • Necessity Necessity of electro electronic nic diesel diesel control control
Diesel Systems
2
CR Syllabus | May 2008 | Module| 1-Theory | © Boschproperty Limitedy 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive propert of Bosch Limited (formerlyalso (formerly Motor Industries Ltd.) Without Wi thout their consent, it editing, distribution , as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
Theory The ory 1 - Intr Introduc oductio tion n
Technology Drivers Electronic diesel control Emission regulations(Exhaust gas and Noise) Further fuel economy improvements Further improvements in - Re Relia liabil bility ity - Du Dura rabi bilility ty of engine/vehicles Competitive costs and prices
Diesel Systems
3
CR Syllabus | May 2008 | Module| 1-Theory | © Boschproperty Limitedy 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive propert of Bosch Limited (formerlyalso (formerly Motor Industries Ltd.) Without Wi thout their consent, it editing, distribution , as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
Theory 1 - Introduction
Market Demands in Diesel sector Costs
Fuel Consumption Fuel Price
Power
Competitor Gasoline
Emissions
Comfort
4
Legislation Limits
Driveability Noise
DI Combustion System
Turbo charged-Inter cooled Higher injection Pressure Injection Pressure Electronic Diesel Control EDC with essential factors Pilot Injection
CR Syllabus | May 2008 | Module 1-Theory | ©exclusive Bosch Limited 2008. All rights reserved, also Motor regarding any disposal, exploitation, reproduction, Internal | Department | dd/mm/yyyy | This is 1the property of Bosch Limited (formerly Industries Co. Ltd.) Without their consent, editing, distribution, as well in the of applications for industrial property rights. it may not be reproduced oras given to event third parties.
Theory 1 - Introduction
Specific Power Output Naturally Aspirated Engine
Turbo Engine
Turbo Engine with Intercooling
80 ] l / W70 k [ t u 60 p t u O 50 r e w 40 o P c 30 i f i c 20 e p s 10 0 1940
1950
1960
1970 1980 Year of Intro du cti on
1990
Diesel Systems
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2000
2010
Theory 1 - Introduction
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)
Diesel Systems
6
CR Syllabus | May 2008 | Module| 2-Theory | © Boschproperty Limited 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive of Bosch Limited (formerlyalso Motor Industries Ltd.) Without their consent, it editing, as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
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 injection
Injection
characteristics (injection duration and rate of injection)
Injection
pressure
Injection
direction and
The
number of injection jets
Diesel Systems
7
CR Syllabus | May 2008 | Module| 2-Theory | © Boschproperty Limited 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive of Bosch Limited (formerlyalso Motor Industries Ltd.) Without their consent, it editing, as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
Theory 1
Cam driven Fuel Injection Pump
Pressur e generation and inj ection are coupled
Diesel Systems
8
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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 Diesel Systems
9
CR Syllabus | May 2008 | Module| 2-Theory | © Boschproperty Limited 2008. All rights reserved, regarding anyCo. disposal, exploitation, reproduction, Internal | DS/EAS-IN 03/06/2008 This is the1 exclusive of Bosch Limited (formerlyalso Motor Industries Ltd.) Without their consent, it editing, as well as in to thethird event of applications for industrial property rights. may notdistribution, be reproduced or given parties.
Conventional fuel injection system vs Electronic Diesel Control
Break even point Mechanical Systems s t n ) e t s n s o o p C m o ( C
Electronic B
B’
Functions • Beyond B-B’ Electronic systems cheaper and better
10
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Systems
Conventional fuel injection system
Mechanical (Diesel) Fuel Injection System: Fuel Injection Pump+Governor+Timer Driver’s demand
Engine
Mechanical coupling Gear lever
Wheels Gear box
Diesel Systems
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Role of electronics in fuel injection
Motivation for Electronic Control: Improve the Fuel Metering Accuracy Improve the Fuel Injection Timing Optimize the Combustion Process Provide Safety Mechanisms Improve the Driver Comfort Level
“Electronic Control does not replace Mechanical Control completely. It aids the Mechanical Control in improving overall performance”
Diesel Systems
12
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Electronic Diesel Control
Electronic (Diesel) Fuel Injection System: Electronic Diesel Control (EDC) Fuel Injection Pump Driver’s demand
Engine
Mechanical Coupling
Electrical Coupling
Gear Lever
Transmission Controller (TC)
Wheels Gear Box
Diesel Systems
13
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Diesel engine and emission control
Pressure Generation & FIE nozzle pressure bar 2500
Unit Injector 2000
Common Rail
1500
Direct Injection
Distributor pum p
1000
Indirect Injection
500
I o r u E
0 o r u E
0 1975
1980
1985
1990
I I o r u E
1995
Diesel Systems
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I I I o r u E
2000
Theory 2:
Duration : 60 minu tes
By : L.M.Naik Deputy General Manager Engineering Common Rail System Bosch L td, Bangalore
Diesel Systems
15
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Theory 2 - Introduction
Technology Demands on FIE • High pressure potential (> 2000 bars)
• Realisation of the “ ideal” rate of injection via pressure modulation alone • Capability of realising s taged (boot) as well as pilot i njection where pilot is separated from the main injection • Flexibili ty of selecting start of injection as well as end of injection • Moderate init ial rise of main in jection • Sharp cut off of the injection end flexibility of selecting peak in jection pressure • Provide optio n to automatically ch ange rate shape according to engine speed and load
Diesel Systems
16
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Theory 2 – Common Rail System
Common Rail • Function • Design • Operating concept
Diesel Systems
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CR Syllabus | June 2008 | Module| This 3 - Theory 5 | © Bosch Limited rights reserved, also regarding any exploitation, Internal | DS/EAS-IN 03/06/2008 is the exclusive property of2008. BoschAllLimited (formerly Motor Industries Co.disposal, Ltd.) Without their consent, it reproduction, editing, distribution, wellparties. as in the event of applications for industrial property rights. may not be reproduced or given toas third
Theory 2 – Common Rail System
Cam driven FIE
Pressur e generation and inj ection are coupled
Diesel Systems
18
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Theory 2 – Common Rail System
Development Trends in cam driven FIE
Pressur e generation and inj ection are coupled
Diesel Systems
19
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Theory 2 – Common Rail System
Common Rail : FIE with new concept 2. Ideal Engine p
1. Conventional Syst em
Start of d elivery p e r u s s e r p n o i t c e j n I
Peak pressu re
Ps
Start of Injectio n
e r u s s e r p n o i t c e j n I
Start of Injectio n
3. Common Rail System
Begin of combustion PR Rail pressure
Pilot injection Time t
Mean pressure Pm
Main Injection Pm (PR)
Time t FIE : Fuel Injection Equipment
Diesel Systems
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Time t
Theory 2 – Common Rail System
Common Rail : FIE with new concept Accumulator
Leakage & control qty 2/2-Solenoid valve Valve control chamber
High pressure pump
Fuel Tank
Nozzle
FIE : Fuel Injection Equipment
Diesel Systems
21
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Theory 2 – Common Rail System
Common Rail System – 1600 bar
Diesel Systems
22
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Theory 2 – Common Rail System
Common Rail System
Diesel Systems
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Basic injection functions
Multiple Injection Advantages
Exhaust aftertreatment management Optimized combustion Acoustics measure
Diesel Systems
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Theory 2 – Common Rail System
Engine with Common Rail System Injector High pressure pipe Rail Low pressure pipes
Pump
Filter
Diesel Systems
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Theory 2 – Common Rail System
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
Diesel Systems
26
CR Syllabus | June 2008 | Module| This 3 - Theory 2 | © Bosch Limited rights reserved, also regarding any exploitation, Internal | DS/EAS-IN 03/06/2008 is the exclusive property of2008. BoschAllLimited (formerly Motor Industries Co.disposal, Ltd.) Without their consent, it reproduction, editing, distribution, wellparties. as in the event of applications for industrial property rights. may not be reproduced or given toas third
Common Rail System for passenger cars
Passenger Car – Common Rail (PC-CRS)
Diesel Systems
27
CR Syllabus | June 2008 | Module| This 3 - Theory 2 | © Bosch Limited rights reserved, also regarding any exploitation, Internal | DS/EAS-IN 03/06/2008 is the exclusive property of2008. BoschAllLimited (formerly Motor Industries Co.disposal, Ltd.) Without their consent, it reproduction, editing, distribution, wellparties. as in the event of applications for industrial property rights. may not be reproduced or given toas third
Common Rail System for Commercial vehicles
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
Diesel Systems
28
CR Syllabus | June 2008 | Module| This 3 - Theory 2 | © Bosch Limited rights reserved, also regarding any exploitation, Internal | DS/EAS-IN 03/06/2008 is the exclusive property of2008. BoschAllLimited (formerly Motor Industries Co.disposal, Ltd.) Without their consent, it reproduction, editing, distribution, wellparties. as in the event of applications for industrial property rights. may not be reproduced or given toas third
Common Rail System for Commercial vehicles
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
Diesel Systems
29
CR Syllabus | June 2008 | Module| This 3 - Theory 2 | © Bosch Limited rights reserved, also regarding any exploitation, Internal | DS/EAS-IN 03/06/2008 is the exclusive property of2008. BoschAllLimited (formerly Motor Industries Co.disposal, Ltd.) Without their consent, it reproduction, editing, distribution, wellparties. as in the event of applications for industrial property rights. may not be reproduced or given toas third
Theory 2 – Common Rail System
CRS Advantages • Separation
of pressure generation and injection allowing flexibility in controlling both the injection rates and timing.
• Fuel pressure does not depend on t he 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 NO x catalysts, or NO x adsorbers. • Fuel pump operates with low drive torque. Diesel Systems
30
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