10_16_2007_Cummins_CRS3.3i(2)

1

Diesel Systems

CRS3.3i

needle… the 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.

Diesel Systems

CRI3.3i CR Piezo Injector – Direct Needle Actuation

HP 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.

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)

Metering unitZME

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 für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CRS3.3i Function Schematic

nozzle (pressure chamber)sackholeinjector (actuator chamber)coupler chamber

pres

sure

[bar

]

U

[V]

2000

1500

1000

500

0

coupler volumebefore nozzlesack hole

Voltage at Piezo actuator200V

0 V

before nozzle

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.

CRI3.3i - Results

CRI3.xCRI3.3i

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

P_E

VI [

bar]

-5

0

5

10

15

20

1000 bar / 40.0 mm³

CRI3.3i Hydraulic Results – Injection Rate

crank angle (°)

inje

ctio

n ra

te s

igna

l (-)

Advantage CRI3.3i:• fast needle opening/closing• increased steepness• minimized throtteling effects• square shaped injection rate

Strictly confidential | DS/EIP2 | 01.05.2007 | © 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.

7

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]

Men

ge H

E [m

m³/H

ub]

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 (m

m3/

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

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 KennfeldlinearitätSehr gute Voraussetzung für Korrelationsfunktionen (IMA,…)

AD (MI) [ms]

quan

tity

(MI)

[mm

3 /H]

0

1

2

3

4

5

50 75 100 125 150 175 200

Small PI quantitiy delivery possibleHigh steepness of PI quantity map, energizing concept has to be optimized

200V

0V

ca. 0,13mm³/µs(ca. 0,05mm³/µs CRI3.3)


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 1200Ansteuerdauer [µs]

Hub

/Hub

-Str

euun

g [m

m³/H

]

1600bar CRI3.3 1200bar CRI3.3300bar CRI3.3 1600bar Inj.CRI-PDN A1.21200bar Inj.CRI-PDN A1.2 300bar Inj.CRI-PDN A1.2

H/H (300bar)= H/H-1mm³/H.

H/H (1200bar)= H/H-3mm³/H.

H/H (1600bar)= H/H-3mm³/H.

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

s/s-

devi

atio

n[m

m³/s

]

energizing time [µs]

stroke/stroke-deviation independent of energizing time


10

CRS3.3i

Hydraulic Results – Characteristic Map EDC17

0

1

2

3

4

5

6

7

8

9

10

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

Hub

/Hub

-Str

euun

g [m

m³/H

]

2000 bar

1800 bar

1600 bar

1400 bar

1200 bar

1000 bar

800 bar

600 bar

400 bar

200 bar

200bar (Offset = +0 mm³)










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

*

*

*

*

*

*

*

*

*

*

**

**

**

**

**

**

**

**

**

**

S/S

spr

ead

(mm

3/S

)

ET (µs)


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

Prüfpunkt [Nr.]

Eins

pritz

men

ge [m

m³/H

]

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

Hub

/Hub

-Str

euun

g [m

m³/H

]

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

20m

m³/H

.@80

0bar

2mm

³/H.@

1200

bar

7mm

³/H.@

250b

ar

50m

m³/H

.@20

00ba

r

2mm

³/H.@

2000

bar

1,5m

m³/H

.@80

0bar

80m

m³/H

.@14

00ba

r

Q (m

m3/

S)

Test Points

S/S

spr

ead

(mm

3/S

)


Diesel Systems

1000 bar /

CRI3.3i

CRI3.0

Advantage CRS3.3i:strongly reduced pressure wave amplitudes

free applicable injection distances, no PWChighest 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 für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CRI3.3i

NVC

fuel

mas

s

ISA

voltage

fuel

mas

s

voltage

pola

rizat

ion

ETrp

mp

init-/ starting-time

stro

ke

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


14

CRI3.3i - Results

CRI3.3i – needle sensor feasibility

0

10

20

30

40

50

60

70

100 300 500 700 900 1100

Ansteuerdauer [µs]

Eins

pritz

men

ge [m

m³/H

]

2000bar

1500bar

1000bar

500bar

with governor

ca. <1mm³

With active governoralmost no quantity difference

0

10

20

30

40

50

60

70

100 300 500 700 900 1100Ansteuerdauer [µs]

Eins

pritz

men

ge [m

m³/H

]

2000bar

1500bar

1000bar

500bar

ca. 3mm³

without governor

78µm86µm

Aktorhub:

U [V

]

time [s]


Common Rail System CRS3.3i

Status 09/07

A6-sample

Project

Internal A-sample successfully testedCRI Test Bench: > up to 2000h reachedEngine Test: > up to 400h cumulated

☺☺

☺

☺Technology

Functional Concept

Actuator Module Design

ECU control functions

applicable Q-Hyd range > 880ccmOptimisation 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.

CRI3.3i at one sight

Summary of hydraulic results:

CRI3.3iCRI3.x

EM VE LL VL

S/S

CRI3.3iCRI3.x

extreme linear injection mapsmall sample deviationvery small shot to shotspread

962_01962_03962_05962_06962_11962_12962_13962_14962_15962_16

energizing time

quan

tity

step injection rateclosed couple PIreduced pressure wave oscillations

-1000

-800

-600

-400

-200

0

200

400

600

800

1000

1200

inje

ctio

n ra

te

inje

ctio

n ra

te

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

Diesel Systems

distance PI-MI

quan

tity

reduced quantity wave amplitudeimproved accuracy(at free distance: +/- 0,5 mm3/S)no rail throttles and PWC„closed PI“ possible

inje

ctio

n ra

te

CRS3.3iCRS3.0

time scale

CRS3.3i

Costumer benefit with CRS3.3i:slightly reduced fuel consumption:

a) reduced pump torque due to lack of fuel returnb) 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.

21

CRI3.3i

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Conclusion• CRS3.3i technically feasible; though fuel-resistant piezo stack is

a 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)

22

CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD<6tHigh Pressure CR System

* Safety margin 50 µs

** Typical values 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

CRS3.2 1800 barCRS3.0 1600 bar

CRS2.5 1800 barCRS2.2 1600 bar, CRS2.0 1450 bar

CRS3.3 2000 bar

Solenoid Valve CR System

Piezo Valve CR SystemCRS Premium line

CRS Top line

CRS High line

CRS Mid line

CRS Base line

0 ms*

Adv. Multiple Injection: 0 ms*

0,2 ms**

CRS1.x 1400 / 1450 barCRS for LPV / EME0,8 ms**

CRS2.6 2000 bar

0 ms*

CRS2.7 2200 bar

CRS-HP > 2200bar

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Documents

10_16_2007_Cummins_CRS3.3i(2)