CRS Theory 1 by Naik n

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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07

CRS Customer seminar - 05.06.07

By : L.M.NaikDept. HeadMICO/EASSystem Engineering (EDC & CRS)MICO-Bangalore

Theory 1:

Duration : 90 minutes

Introduction to



System Engineering - CRS & VE EDC

EAS2System Development/Validation

Common Rail

George Anthony P

EAS2System Development/Validation

Common Rail

George Anthony P

EAS3System Electronics

(VE-EDC & Common Rail)

Srikantha Hande H

EAS3System Electronics

(VE-EDC & Common Rail)

Srikantha Hande H

EAS1Fuel investigations

and legislation

Fredrick A

EAS1Fuel investigations

and legislation

Fredrick A

EASDevelopment Application SystemVE EDC & Common Rail System

Naik L M

EASDevelopment Application SystemVE EDC & Common Rail System

Naik L M

Common Rail System Development – HydraulicsPlatform & Customer Projects. Hydraulic System validation for Common Rail

(Passenger car & CV application) .Basic Testing (Test Bench Hydraulics)

Fuel quality, analysis & co-ordination for customer failure analysis

Budget co-ordination, DBE & Training co-ordination

Co-ordination with DS for fuel and alternate fuel issues

RBIN Co-ordination

Indian Customer projects

System Engineering -Common Rail & VE EDC

RBIN Co-ordination

Sensors & EGR ECU

System Electronics -Common Rail & VE EDC

Mico - EAS organization

783001_S_Lmn



Theory 1: Introduction to Common Rail System

Project mile stones

System Validation & tests

System types & Generations

Introduction

Common Rail & emission strategy

CRS Customer seminar – 05.06.07



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



Introduction

Cam driven FIE

Pressure generation and injection are coupled



Introduction

Development Trends in cam driven FIE

Pressure generation and injection are coupled



Introduction

Pressure Generation & FIE

nozzlepressure

2500

500

1000

1500

2000

bar

1980 20001990 19950

1975

Unit Injector

Distributor pump

Common Rail

1985

Euro

I

Euro

II

Euro

III

Euro

0

Indirect Injection

Direct Injection



Introduction

Technology Drivers-Emission

Base Line Turbocharged

Direct Injection Diesel Engine

Intercooling

CombustionHigh Pressure Injection

Variable Turbo Geometry

Lub oilConsumption

OxidationCatalyst

De NOx Cat

Turbo ompounding

EGR

Part

icul

ate

trap



Introduction

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



Introduction- CRS Concept

Common Rail : FIE with new concept

2. Ideal Engine

Begin of combustion

Time t

Start of Injection

Inje

ctio

n pr

essu

rep

Time t

Inje

ctio

n pr

essu

rep

Start of delivery

Start of Injection

Pm

PsPeak pressure

Mean pressure

1. Conventional System 3. Common Rail System

Time t

Pilot injection

Main InjectionPm(PR)

PR Rail pressure

FIE : Fuel Injection Equipment



Technology Drivers : Multiple Injection

Exhaust aftertreatment management

Acoustics measure

Optimized combustion




Introduction : Electronic Diesel Control

Sensors ECU Actuators

Camshaft Position

Crankshaft Speed

Brake Switch

Clutch Switch

Air-conditioning

Air Mass Flow

Coolant Temp.

Air Temp.

Battery

Accelerator Pedal Position

Boost Pressure

Fuel Injectors

Boost Pressure ActuatorEGR ActuatorRadiator Fan ControlGlow Plug ControlVehicle Speed InfoFuel Consumption Info

Service Tester

IMMO ABS ESR AIRBAG

ProgramMemory(EPROM)

CentralProcessingUnit

Non-volatileMemory

(E2PROM)

PowerStage

DigitalSignal

Conditioner

AnalogSignal

ConditionerPowerStage

Diagnostic&

Alarms

ControllerAreaNetwork



Common Rail : System working concept




System Requirements

Engine modifications to suit CRS components

ECU + Sensors+ Wiring harness

Gear drive change (0.6→1)FIP mounting (pilot dia)Shaft dia and cone angleHigh pressure pumpDrive arrangementDrive ratio

Low pressure systemPre filter and typeFeed pump (Electrical or Gear)Low pressure pipesMain filter with water separator

Rail location/ clampingHPP (Rail to Inj) layout

Cylinder headClamp type injectorsNozzle locationSpray patternPiston bowlArrangement of glow plugWater temperature sensor location

Engine speed sensorTone wheel for speed sensor

Camshaft phase sensor



CRS Advantages• Separation of pressure generation and injectionallowing 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 NOxcatalysts, or NOx adsorbers.

• Fuel pump operates with low drive torque.

Introduction- CRS




Project mile stones



Introduction





System Types

Major Common Rail System Applications

For Com. Vehicles

For Off High way

For Pass. Cars

For LPV *

System components will differ w.r.t. following major points

• Engine spec. • Emission legislation• Vehicle functions, Elect voltage (12/24V)• Safety & Comfort• Application • Durability w.r.t environment • Diagnosis

LPV :* 3 & 4 Wheelers with 1& 2 Cylinders

And PF based FIP

Low Priced (micro) Vehicles



System Types

Passenger Car – Common Rail (PC-CRS)



Engine with CRSN (Side feed injector)

Common Rail System – Commercial Vehicle (CRSN)



Pump: CP1H-OHW with Anti-wear Package

Injector: CRI2.0-OHW with Anti-wear Package

Rail: LWR2 with RDS4, DBV4 and throttle

ECU: EDC16C39(12 V), optional EDC16UC40 (24V)

optional EDC7 for engine mounting

System: 1.100 bar

1-controller-concept

max. 3 injectionsin accordance to the injection-map

low-pressure circuit: Gear Pump at CP1H-OHW

suction side fuel filter for severe conditions and

water seperation

CRS System for off highway applications- Basic system

Source :DS/CRS 2.0 OHW



CRS System for off highway applications- Basic system

Electronic control unit EDC16

Rail with Pressurelimiting valve

HP-pump CP1H-OHWwith metering unit and (integrated) gear pump

Sensors

InjectorCRI2.0-OHW

Rail pressure sensor

Source :DS/CRS 2.0 OHW



PF -Pump

Common RailInjector

EDC17COM4

LWR2PressureControl Valve

High pressure

Low pressure

Rail

Rail Pressure Sensor

EDC17Cx

Other sensors

AcceleratorPedal sensor

Speed sensor(Crank)

Phase sensor(Cam)

Other actuators

System Components : CRS 1.1

CRS 1.1

689009_S_Lmn



System Management

Common Rail System & Vehicle




Project mile stones



Introduction





Common Rail System & emission

Strategies to reach Euro5 – Passenger Cars

Diesel Systems

0

5

10

15

20

25

30

0 0.05 0.10 0.15 0.20 0.25 0.30NOx [g/km]

PM [m

g/km

]

Euro4Euro5*

1

2

* Expected Scenario** new EU commission proposal*** Half Useful Life: 5 yrs. / 50 kmi

Euro4

Euro5,T2 B8

• switchable EGR, optimized Cooling and Distribution • optimized Turbocharger• High-end Injection Systems • reduced ε, optim. Injection and Glow Strategies, low T

2

Diesel Particulate Filter1

NOx Storage Catalyst /Selective Catalytic Reduction3

3

T2B5***Useful LifeHalf \ Full

T2B8***Useful LifeHalf \ Full

Euro5**dependingon vehicle



g/kWh

0.04

0.06

0.02

0.10

02 60 4

PM

8

0.08EU 3

EU 3 Standard

without EGRwith EGR

for EU 4, EU 5 and US 10

g/kWh

NOx

DeNOx

Advanced high-pressure injection+EGR+DPF

High-pressure injection +EGR+DPF

Optimized combustion +advanced timing

US 10

EU 5 EU 4

Common Rail System & emission

Strategies to reach Euro4,5 – Commercial vehicles





Project mile stones



Introduction




Common Rail System





Project mile stones



Introduction




Project mile stones

Important phases• Planning

Customer requirement, Application schedule, Order procedure

• System definition

System description, Project sheet, Customer specification,

Design Layout -High Pressure and Low Pressure circuit,

ECU, Software, Wiring Harness, Sensors, Actuators

• Engine and Vehicle Application

• System Validation

• Error management and service concepts

• Release for Production

• Start of Production



Customer Projects : Interface & involvements

System

Engineering

System Definition

SupportFirst Engine & Vehicle build

Systemdevelopment

SystemValidation & testing

SystemRelease& Field support

System Engineering – Common Rail

System Componentsto suitCustomerRequirements

High & low pressure circuit

EnvironmentalTests-Summer- Winter- High altitude- Sea level- City drive- Highway drive- Critical & local

conditions

In-house testing

SystemAssessment& release

End of lineData set

Diag.Tester InterfaceRamp up support

Field support for technicalIssues

Fuel issues

System Interface withengine

System Interface withvehicle



Common Rail System & Diagnosis

Diagnostic Layer Error memory, service information

Application Layer Datasets - Curves, Maps, Setpoints

Program Software Function sequencing

Flow of events

Firmware Chip level I/O interface

Bosch, RBIN

Bosch, RBINBosch, MICO

Bosch, MICO



Aftermarket & new service concept

Common Rail & EDC FIPField repair within qualified workshop ...Field repair within qualified workshop ...

CP1 CP3 EDCFIP

... all necessary requirements... all necessary requirements

Test dataParts

Repair instructionsCD-K

Spare partsTestequipment



Project teams

MEETING

C panel meeting : Frequent case to caseB panel meeting : Monthly or progressivelyA panel meeting : Quarterly /decision making phases

Proj

ect T

eam

B panel

Hig

h le

vel t

eam

A panel

• Engine devpt• Emission testing• Design (Eng,Veh)

• Vehicle engg• Proto type/testing• Production

• Electronics• Hardware• Wiring harness• Diagnosis • Tester/EOL

• Field trials • Service

• Purchase• Durability• Quality

C panel

Proj

ect T

eam

B panel

Hig

h le

vel t

eam

A panel

ENCRYPTED DATA TRANSFER

• Application-E• Combustion• Emission• Application-V• Component• Development

• Sales• Project Mgmt.• Hyd. System • Production

• Electronics• ECU -Software• ECU-Hardware• Elect. System• Sensors

• Service

• Testing• Durability• Quality

C panel

CRS Project teams



Common Rail System & Fuel

Important Parameters to remember ….!

Fuel filtration and Fuel Injection Equipment• Ensured reliability and efficiency• Long service life

Fuel contamination • Solid rust particles (from Fuel tanks)• Water ( 10 -12 micron rust can damage the...)• Injection Nozzles• Piston Cylinder head

High temperature in fuel tank • Variation in tank temperature and ambient temperature

Running vehicle with very less fuel in the tank• Can cause rust to enter the high pressure circuit• Air bubbles in fuel system can cause timer oscillation



Conclusion

Common Rail System• Common Rail is modular System

• Selection of component is very specific to end application

• System is defined considering engine & vehicle functions

• Design of Layout (High Pressure and Low Pressure) is important

• ECU, Software, Wiring Harness, Sensors, Actuators are new in this segment

• System Validation is must in actual operating condition/environment

• Error management

• Project management is essential

• New service concept

• Product awareness, trained personnel to handle electronics/tester



Q&A Session

Introduction to CRS by Naik

Question and Answer session



Introduction to Common Rail Systems

Documents

CRS Theory 1 by Naik n