Common Rail System & Functions

Overview

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 Common Rail System & Functions

Common Rail system overview

System & Components
Application Sequence
Common Rail functions
Field Issues

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Common Rail System & Functions

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Common Rail System & Functions

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Common Rail System & Functions

System & Components

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 Common Rail System & Functions

Features:
CP1
h - Radial Piston Pump
- 3 Pumping Elements
- 3 Hole Mounting
- In built ‘Electric
Metering Unit’
Key data:

- Maximum system / nozzle sided pressure

: 1600 bar
- Max delivery quantity: 120 l/h at 3500
pump rpm
- Direction of rotation Right : clock-wise
- Required average low torque : 24 N-m
- Required transmission ratio : 0.678
- Life time : 300,000 km @Autogurukul
 Common Rail System & Functions

Rail
Features:

- 1600 bar maximum

operating pressure
- Rail Pressure RDS 4
mounted

Key data:

- Rail nominal volume :

19cm3
- Nominal Pressure:
1600bar @Autogurukul
 Common Rail System & Functions

Injectors : CRI 2.2

Features:

- 2nd generation 1600 bar Common Rail

Injector
- Fully software quantity controlled high
precision injector is actuated by a
solenoid valve.
- Capability of 3 injections per cycle with
an option of 4th injection for DPF and
with software quantity functions
- Min time gap : Pilot to Main 600 µs

Key data:

- Pressure range nozzle side: Up to 1600

bar @Autogurukul

- Nozzle Mini-sack-hole type

- Guide diameter : 19 mm
Common Rail System & Functions
- EDC 16 C with application friendly
torque based software structure
- Water proof version with
atmospheric pressure sensor
- 32 bit, Rated voltage 12 V, 56MHz
clock
- 2Mbyte external flash
- 8Kbyte EEPROM
- 154 pin , 2 chamber
- 17 digital inputs, 20 analog inputs
- ISO9141/KWP2000 diagnostic
interface
- 3 CAN interfaces possible

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Common Rail System & Functions

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Common Rail System & Functions

Application Sequence

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Common Rail System & Functions

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Common Rail System & Functions

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Common Rail System & Functions

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Common Rail System & Functions

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Common Rail System & Functions M&M 2.6l
Environmental Trials - Winter
Winter trials
Start Behaviour

White Smoke, Misfiring

Drive away , Drivability in cold
Governor stability

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Common Rail System & Functions M&M 2.6l
Environmental Trials - Altitude
High Altitude trials
Starting behavior
Smoke limitation
Turbo protection
Drivability in hot
Governor stability

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Common Rail System & Functions M&M 2.6l
Environmental Trials - Altitude

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Common Rail System & Functions M&M 2.6l
Environmental Trials - Altitude
Summer trials
Starting behavior
Smoke
Drive away , drivability in hot
Governor stability

Over heat protection

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Common Rail system & Functions

Common Rail Functions

Main Injection

Pilot Injections

Post Injection

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 Common Rail system & Functions
Common Rail Functions

InjCrv_phiPiIMax
OT

tiPiI2Bas tiPiI2BtiPasiI2t=iBPaiIs2B=as = tiPiI1Bas tiPiI1tBiPaisI1t=iBPaiIs1B=as =

=Ende/Begin BeginB/B eg eigB
nie
/nBgeing/iB
negi=
nEnde/Begin BeginB/BegeigBnie/nBgeing/iBnegin

PiI2 PiI2PiI2PiI2 PiI1 PiI1PiI1PiI1

MI

ET ET ET ET ET ET ET ET
phiMI1Des
tiPiI2Bas tiPiI1Bas
EnvCor EnvCor
AddCor AddCor
InjCrv_tiPiI1Des InjCrv_phiPiI1Des

InjCrv_tiPiI2Des InjCrv_phiPiI2Des

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 Common Rail Functions

IQA

Injector-
Quntity-
Adjustment
Compensation
of Production
Tolerance
FBC
Fuel-
Balance-
ZFC
Control
Zero-
Fuel- Equalization of
Calibration Cylinder Specific
Injection Quantity
PiIot Quantity
Regulation

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 Common Rail System & Functions
Common Rail Functions

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 Common Rail System & Functions
Common Rail Functions

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 Common Rail System & Functions
Common Rail Functions

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 Common Rail System & Functions
Common Rail Functions

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 Common Rail System & Functions

Zero Fuel Quantity Calibration

Features
Quantity

high noise
emissions

Energizing Time

ZFC Calibration
Correction Map Customer Benefit

ZFC Correction

Energizing Time Map

DS/ESK2, 03zf171e
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 Common Rail System & Functions

Common Rail Functions

Injector current € Detection of minimum PiIot quantity

during overrun mode
I € Continuous extension of energizing
time on each single Injector
€ evaluation of the effect of this
extension on engine speed

ET

n
1 2 3 4 Cylinder No.

t
Engine speed sensor

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Common Rail System & Functions

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Common Rail System & Functions

€ Compensation of differences in injected fuel quantity of each

single injector in a wide operation range of the engine
€ Improvement of NVH (noise vibration harshness) behaviour
Evaluation of cylinder individual
differences in engine speed by Quantity too large
engine speed sensor FBC correction
n of single injectors

Quantity too
small

1 2 3 4
Cylinder No.
Engine speed
sensor t

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Common Rail System & Functions

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 Common Rail System & Functions

Cruise control

Vehicle speed is maintained

at driver set value(through key module) Switch

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 Common Rail System & Functions

Field Issues

Scorpio CRDe Field issues

➢ Vehicle not starting after over night soaking

➢ Water entry in to ECU connector

➢ Phase sensor failure

➢ Wiring harness defects

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 Common Rail System & Functions
Field Issues

➢ Vehicle not starting after over night soaking

Cause
– Design of fuel tank and return line
– Fuel tank w/o strainer
– Fuel filter w/o non return valve

Effect
– Fuel does not stay in the fuel line
and goes back to tank

– Large particles will come to fuel filter

– Flap remains open because of
particles trap

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 Common Rail System & Functions
Field Issues

➢ Water entry at ECU end connector

Cause / possible reason ECU

– Water entry via wiring harness

– ECU mounting orientation
–No proper water proof sealing
Effect

– Pin K72 damaged, No supply to ECU Connector

– Engine / Vehicle does not start

Action
– Change orientation of ECU mounting
– Improve sealing

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 Common Rail System & Functions
Field Issues

➢ Phase sensor failure

Cause / possible reason
Old Location
– Coolant entry in to sensor side
after engine testing
– No protective cap put after
engine testing

Effect
New Location
– Cam Sensor failure
Action taken
– New Location for sensor
– Proposal for protection cap

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 Common Rail System & Functions

Troubleshooting at Plant

If RailCD_pPeak falls below falls below engine speed threshold Rail_pMeUnPeakMin_mp

generated an error due to which the engine was not starting.

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Common Rail System & Functions

Thank You !

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