2011 Automobile Maintenance Advanced Course for the

Industrial Technical Instructors

No.: AcP\ ----------Name: \-'\~ 1:. \~~

Instructor: Lin

W (illuto

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

w (lluto

W (lluto

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

~~!

22

W Yitllto

W Yituto

PM filter CDPF)

= Particulate matter/Partikel

Active DPF regeneration

W (jl{uto

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.

o

w 0{lltO

W 0{uto

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

19

w Ylluto

W Ylluto

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)

18

11 .2

10.2

Land Cruiser Hilux Surf Prado (Diesel)

(Diesel)

W (illuto

W (illlltO

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

17

W (jl{lltO

w

Split Injection • Timing : low temperature starting

Split injection

Aim of pilot-injection

• Reduction in :

• Combustion noise

• HC Emissions

• Fuel consumption (late injection start)

16

W Ylluto The Effect of Pilot Injection on Injection

Rate and Heat Generation Rate

Injection rate control

Conventional

Injection rate

W Ylluto

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

w -QilltO

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

W (illuto

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

14

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

W Q'luto

W Q'luto

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

13

W (j1[uto

W (j1[uto

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

12

w Cilluto

w Cilluto

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

11 22

W Muto

W (il{uto

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

W 9l11tO Denso ECD U2 system

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 __ -...,.--....

W 9luto

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.

9

W Ylluto

W Ylluto

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

8

W YlllltO

W YlllltO

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:

7

W Ylluto

W Ylluto

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

6

W 9illtO

W 9iuto

Unit Injector system CUIS)

Bosch Common Rail System

5

W Ylluto

W Ylluto

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

4

W Ylluto

W Ylluto

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

W <Yluto

w <Yluto

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