Post on 01-Jan-2017
2011 Automobile Maintenance Advanced Course for the
Industrial Technical Instructors
No.: AcP\ ----------Name: \-'\~ 1:. \~~
Instructor: Lin
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Emissions legislation • Emissions legislation for Diesel passenger cars
% 100
50
o
State-of-the~art technology 2004
100 - --___ --t---------
50
USA Japan EPA CARS
. __ ~.Q~t4__ .~.9P~ .. . __ BinS ULEV
0014
o .. _ij!~~~~~~~~~~~~~~~~~-~~&L~-~O~1~7~ -100 -~~2-1.~2 ~·----------------
EGER 50- 15/04
CO 0 -······ ··· · 1990
Figures = emissions limits in glkm
Source: Bosch 1
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Conclusions
1. Comparison with traditional pumptype diesel injection system
2. Development trend of common rail injection technology
3. Problems generated following the development of common rail fuel injection technology
Thank you
~~!
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PM filter CDPF)
= Particulate matter/Partikel
Active DPF regeneration
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Piezo inline injector
Source: Bosch
Post-processing System of Exhaust Emissions
Engine control :co:m:p:u~te~rJ~~~~~~~~~~~:S~;=!!!!===ll··='l"""'"--""'----"'"l
Air-fuel ratio sensor
Source: Bosch
Temperature
Temperature sensor
Air-fuel ratio sensor
To collect the final PM residues
Suck up NOx temporary, and through the control and management
of engine to reduce it into N2 under the absence of 02
Use oxidation to remove CO, HC and a portion of catalyst with PM constitution.
Convert them into harmless C02, H20 and other substances, and convert NO into N02.
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How to Pass EURO 4 Certification • 1. Use low-sulfur diesel • 2. Adopt post-processing system
(recommend to use low-ash engine oil: E4 rv E6 grade)
• DOC . SCR • DPF (CR-DPF) • High volume of EGR
• 3. Use 3rd generation common rail system with piezoelectric injection nozzle • Capable of passing EURO 4 certification without
using DPF
3RD generation CRS
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Post-injection --------------,==,="='''''=
• What is the post-injection: • A small certain amount of fuel injection
after main injection
• Advantages: • Reduction in NOx-emisissions
• Disadvantage • Slightly increased fuel consumption
Fuel efficiency comparison with conventional models
(km/L)
15~--------------~ Old model 14.0
14 f--- --------------1 If ill New model
11
10
9
8
7
6
5 Caldina (2.0L)
Test mode: 10-15 mode
Alphard (3.0L)
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11 .2
10.2
Land Cruiser Hilux Surf Prado (Diesel)
(Diesel)
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Consequences of pilot-injection
• Pre-conditioning of the combustion space for the main injection process both in terms of pressure and temperature.
• Ignition delay for main injection is shortened
• Noise advantages (reduced peak combustion pressure)
• Optimum combustion
Injection Activation possibility
• Pilot injection): From 900 before Toe to 100 after TOe
• Main-injection: From 200 before Toe to 100 after TOe
• Post-injection: From TOe to 2000
after TOe
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Split Injection • Timing : low temperature starting
Split injection
Aim of pilot-injection
• Reduction in :
• Combustion noise
• HC Emissions
• Fuel consumption (late injection start)
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Rate and Heat Generation Rate
Injection rate control
Conventional
Injection rate
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Heat generation
rate
Big pre-mixed combustion
(NOx, noise)
-20 TOC 20 40
Crack angle (deg)
Pilot Injection Before TDC After
25° 20° 15° 10° 5° 0° -50 _100 -15° -20°-25°
' / ~ (!) ~T :f" I~ b1) ro
V '\ .... ~ /
IJ/ . ."" :~ , " 1- 2---I Voltage waveform f--- I--'- Jf
,.,
"" r
.-~ ~, .-r-: . ~
1 .•.. .. L ,~ A. ... .. h .. ~
""" 1... ......... :. i\ . .L •
1 = Pre-injection la = Combustion pressure with pre-injection
2 = Main injection 2a = Combustion pressure without pre-injection 15
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Ideal Injection Timing and Injection Volume (Rate)
Pilot
Pilot injection
The fuel injection in hope of generating an easy combustible mixed air in the combustion chamber beforehand.
t Reduced PM
Source: Bosch
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Pre-injection
The fuel injection in hope of generating a seed fire in the combustion chamber.
Retced NOx
Reduced noise
Main
Main injection
After
After injection
A supplemental fuel injection in hope of enhancing complete combustion of residue fuel.
t Reduced PM
Pilot Injection
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Post
Post-injection
There is no such injection in original fuel injection control system. It is the fuel injection in hope of enhancing postprocessing effect of exhaust emissions.
ReducJd NOx
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Magnetic injector
Source: Bosch
Basic Injection Rate Control • Main injection
• Pilot injection or Pre-injection • Small amount of fuel injection before main
injection
• Spl it injection • Small amount of fuel injection before main
injection while starting • Small amount of fuel injection, no need pre
heating
• Post-injection • Small amount of fuel injection after main injection
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System Composition of CRS
[c----:-:- I ----------------1 ~~P?~ lt l?~~~~~?~ r-· Engine control
, ........................................................... -.-.... --i computer ! Crank position sensor ~--.. '
[~y?~~-.~?_~~nsors J--_ I~::::::::::::::::::::::::::::::::::::::::::::::::::::~
Rail pressure sensor
Orifice
/
t I I , i I
Intake regulation valve (MPROP)
- - - + ---+
Common rail
Fuel tank '-------'
Fuel System
PCV control
Supply Pump
Pressure signal
Common Rail -
- High pressure area
Low pressure area
Injection
control
~
Injector ~
-------1J----------------~~~~~-----------jJ;~y-Pre-
Filter p
Fuel Tank
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Classification (cant.) • Classified by common rail installation position
Located in engine cylinder Located outside of engine head (bottom fuel intake) cylinder head (top fuel intake)
• VW TDI - UIS • BOSCH CRS • HEUI • DELPHI CRS
• DENSO CRS
Main Features of Electronic Control Type CRS
• Uses high-pressure injection throughout the operation range • Lower exhaust emissions • More consistent engine power performance
• Injection rate (volume) control • Reduced exhaust volume • Reduced engine noise
• Injection timing can be set flexibly • Improved performance
• Control injection pressure solely according to engine revolution and load changes • Injection pressure will no longer increase following an
increase in engine revolution • Able to maintain high pressure even in low speed
• Improved starting performance, reduced white exhaust smoke
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VW TDI - UIS
Classification • Classified by common rail fuel pressure
Low-pressure common rail High-pressure common rail
• VW TDI - UIS • BOSCH CRS
• HEUI • DELPHI CRS
• DENSO CRS
• Classified by fuel injection control method
Mechanical + Electronic Electronic Control Control
• VW TDI - UIS • BOSCH CRS
• DELPHI CRS
• DENSO CRS
• HEUI ~u
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Car System Diagram
IJ_' ________ ~_~~~=2 ... 'C
Flow regulator
r 1 ·.; ->I~ject:ns:~n:::~~;fdiV=d x, . ':tP- - - - - - - - - -:- - - - - - - - - - - - - - - - - -- - --I .. _'M'~.;~ !!l.l!~"~'/".;;;; ~~,;,,;:~, ~.:~.:;;: :-'y;.lt.'M*(Ijj~S:lJ!. Common rail pressure sensor d d d' d ... · . .. ..... ... ... d .....
I • Injection volume control Injector I I ~m.ljdl\J fifi<.ii I I • Injection timing control I I I I I I I I I I I I I I I j
• Injection pressure control ~; - ~.!;,-t. -:'i1 :J "t \Ll:;q.l~
~ . Il,:'·alatl r. f~Hp};f!1iJ :; _ r Engine, Car !Hl ~ '.: .. ~ . .
." _ Arr ECU :i!!!' communication
,- ABS/ASR ECU iilH;; - INOMAT ECU litH,:;'
I Communication L __ -...,.--....
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NE sensor (Crank position sensor)
:- , NE !t~jlllffi ~~.~ (,tMill (I:jJl:t!\B Accelerator pedal sensor
Pressure sensor
Water 'temperature sensor ."---ir---flIt= '1 Fuel temperature sensor
~---f---d1t:l1 .< Car speed sensor
r I .1. I I I I
~illit.K&JJ[!~~:rlH:~ .. 1 ()iliMi?Tl<'~
Supply pump
G sensor (Cylinder differential sensor)
G F5);nH:~ (~tu:.~}1jjjU }.;.1i(fn;'}fi ) Fuel injection rate co
;W.k~[4ni't.H, hk< blithl } ;' I .. '~'~. ' .-' ~: Fuel injection volume
" I
~!!'iIj. '='di*. .. ,~.~= ..• :....~~:p .. . ;;;.;; ..... ;;;;;; .... ;.;;;; .... ~,.,=~.~ I -......... _:'d ',' Fuel injection timing
fJ(~1~~j.I!tj}.}J 1~ \J'JVj1:'tOl jJ~ i · d. dd "dd d 'd ... ............... _ ......... '. _ .... " -, I
~~~~/-I~C: Fuel injection pressure
CPAV (common rail pressure
- , ::::.:~~--.::.,,:.::.,·:.::...·:..... · ...::.:··::.:.:,·.....:~~i
Caterpillar HEUI fuel system .3. High Pressure Oil Pump 4.lniector Actuation
Pressure ConlrDI Valve 1. Inlectots
Four basic components work together to bring precision, reliability and simplified maintenance to the HEUI fuel system.
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The Main CRS Types • Bosch • Denso
• Market mainstream
• BMW, RENAULT, BENZ, VW, VOLVO, Hyundai, KIA ...
• Delphi • GM
• Hyundai, KIA, Ssangyong
• Japanese mainstream
• Code: ECD-U2 • Mitsubishi FUSO
• Isuzu (6H Kl-TC)
• Hino(K13-C)
• Other makers • Caterpillar
• Code: HEUI
• ISUZU ( 4JX1-TC)
• Siemens
Bosch CRS for passenger cars ' • Bosch Common Rail System for passenger cars
(j) Air mass meter
® EngineECU @ High pressure pump @ Common rail E~;C·::. :~.c:,O' ..
(g) Injectors
@ Engine speed sensor
(J) Coolant temp. sensor
@ Filter
@ Accelerator pedal sensor
Source: Bosch
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What is a Common Rail system
• Diesel accumulator fuel-injection system
• A accumulator named Common Rail is a fuel distribution pipe
• Electronic engine management for direct injection diesel engines • Electronic diesel control (EDC) • Start-assist system • Emission control
• DI + Turbo = TDI
Common Rail System Addressed by Different Car Makers
• FORD : TDCi (Turbo Diesel Common-rail direct Injection)
• Benz: CDi (Common-rail direct Injection) • BMW: 320"D", 530"D" (An added D at the
rear of car model) • Bosch: CRS • Land Rover: TdV5 , TdV8 • VWj Audij Skodaj Seat: TDi • Hyundaij KIA: CRDi • SSangyyong: XDi • Renault:
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High-Pressure Injection System (01) - Passenger Car Market
High-pressure injection systems from Bosch: Installation in passenger-car diesel engines
DCRS . VP44 100% --
80% ---l
60% ---l 80 66.1
40% --l
20% --
21,2
0% ,----
2002 2006
Source: Bosch
High-Pressure Injection System (01) - Total Market
The market for Bosch diesel injection systems: breakdown by product groups
9.5 Mio. Plan: 11 Mio.
100% systems systems
,----"'- ,,"> '''''~-'"-~-"
UIS/UPS
80%
60%
40%
Inline- and distributor pumps
20%
0% 2002 2006
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Unit Injector system CUIS)
Bosch Common Rail System
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Bosch VP44 Radial-piston Distributor Pump
CD Radial-piston distributor pump with integrated engine/pump control unit
® Glow control unit
@ Injection nozzles
@AirMmass meter
@ Pedal-travel sensor
CP) Crankshaft speed sensor
(J) Sheathed-element glow plugs
(,6) Engine-temperature sensor
® Fuel filter
Source: Bosch
VP44 Radial-piston Distributor Pump
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Countermeasure 2 • The higher the injection pressure, the
higher the thermodynamic efficiency.
• The higher the injection pressure, the injection duration will be shorten.
• This makes the direct injection (01) diesel engine become the most thermodynamically efficient of all the internal combustion alternatives.
Diesel DI systems by Bosch VP44 eRS Radial-Piston Common-Rail-Distributor System Pump
Accumulator/Rail
High pressure Pump
3
UIS Unit-I njectorSystem
UPS Unit-PumpSystem
Source: Bosch
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Clean diesel Emission
,---. Common roil M1 injectfon system
I ; t f i ! expanded I' vliew
(DPNR: Diesel Particulate and NOx Reduction System)
Source: Toyota
Countermeasure 1 • Diesel management system