Optimized Diesel System

Fuel injection system

– new generation
– injection rate shaping
– reduced tolerance
– optimized nozzle

Air management Exhaust emission-management

Throttle- /swirl valve Exhaust emission aftertreatment
Electric charger with sensors
Combustion -control
process

Tolerance reduction
– inj. quantity adaptation
– pressure wave correction
– zero fuel quantity calibr.
– fuel quantity balancing

* Source ; Bosch HD_FIE_DILEE-25

Ideal Fuel Injection System

HD_FIE_DILEE-26
 Requirements for Fuel Injection system

* Emission Reduction. (NOx , Smoke)

* Higher Power & Better Fuel Consumption.
* Noise Reduction.
* Better Driveability

Inj.
Smoke Inj Press Inj. Rate Timing

Load

E/G speed
Inj.Press Crank angle
E/G speed
Inj.Timing Control
High Inj. Press Inj. Press Control Inj. Rate Flexibility
F

HD_FIE_DILEE-27
Effect of Injection Pressure
Mean Drop Size & Smoke

HD_FIE_DILEE-28
Future Demands on Fuel Injection Sytem

Î High pressure injection

Î Tolerance reduction

Î Injection rate Exhaust aftertreatment management

Optimized combustion

Acoustics measure

* Source ; Bosch HD_FIE_DILEE-29

 Multiple Injection Passenger Car
Injection Requirements
Combustion without exhaust gas treatment system

Injection
quantity
mm3
TDC stroke TDC
Engine start
and low idle

TDC
Emission Engine speed rpm
area
TDC

* Source ; Bosch HD_FIE_DILEE-30

 Common Rail System for Commercial Vehicles

* Source ; Bosch HD_FIE_DILEE-31

 Common Rail System in Car

* Source ; Bosch HD_FIE_DILEE-32

 Common Rail System for Commercial Vehicles
Concept for Heavy-duty Truck

Pressure Rail pressure

High limiter valve sensor
pressure
Rail
pump
CP3
Gear Flow limiter
pump Filter

Metering
unit ZME

Other actuators Other sensors

Injector

Accelerator
pedal
Control unit
Engine
speed
(crank)

Tank Engine
Prefilter High pressure
speed
(cam) Low pressure

* Source ; Bosch HD_FIE_DILEE-33

 Common Rail System for Commercial Vehicles
Concept with el. Feed Pump for Light Truck

Pressure Rail pressure

High limiter valve sensor
pressure Rail
pump
CP3 Gear
pump

Metering
unit ZME

Other actuators Other sensors

Injector
Filter
Accelerator
Electric pedal
fuel pump Control unit
Engine
speed
(crank)
Tank Engine High pressure
Prefilter speed Low pressure
(cam)

* Source ; Bosch HD_FIE_DILEE-34

 High Pressure Pump
(Bosch CP 3.4)

High Press
Low Press

* Source ; Bosch HD_FIE_DILEE-35

 CommonRail Injector

* Source ; Bosch HD_FIE_DILEE-36

 CRIP2-Piezo
back flow connector

Multiple Injection
plug
actuator module
high pressure
valve plate connector
filter
valve

nozzle

hydraulic amplifier
throttle plate

* Source ; Bosch HD_FIE_DILEE-37

Common Rail System for Commercial Vehicles
Generation 4

* Source ; Bosch HD_FIE_DILEE-38

 System and functionality

* Source ; Bosch HD_FIE_DILEE-39

 ECU Function (1)

■ FIE
- Injector Drive ; Fuel quantity & timing
- Pilot & Post Injection
- Cylinder balancing & shut-off

■ Engine Management
- Starter motor control, starter lock-out
- Starting aids control
- Idle control/validation, idle timer
- Fan clutch control
- Engine brake & exhaust brake control
- Engine monitoring & protection
- Turbo/EGR control [opt]

HD_FIE_DILEE-40
 ECU Function (2)

■ Vehicle Management
- Cruise control, Road speed limit control
- Progressive shifting & Multiple torque limit control
- PTO control
- Throttle inhibit, Anti-theft protection (Immobilizer)
- Pressure governing for fire truck [opt]
■ Diagnostics
- Failure detection, Fault Storage
- Limp home
- Data/history recording
- Service modes/testing
■ Communications
- High speed ; CAN / SAE J1939
- Low speed ; ISO 9141
HD_FIE_DILEE-41
 EDC - Contol Unit for Commercial Vehicles

*
Development of Complexity Target
**
Limited due to size of wiring harness
*** Calibration data, residual is fault storage

Type M7 MS5 MS6 EDC7 EDC17*

Width of word bit 8 16 16 32 32

Computing Power MIPS <1 1 4 40 300
Transistors Mio <1 <1 <1 7 25
Memory kByte 64 128 512 500-1500 4000
Data memory (RAM) 160 1900 5000 6000 8000
~1500*** ~1600***
Connector-pins 35 55 70-86 89 -141 < 160* *
1988 1993 1997 2001 2008

* Source ; Bosch HD_FIE_DILEE-42

 EDC7 - Technology
Technology and Performance
Housing
ƒ cast cover/ cast plate
ƒ heat dissipation via base plate
Technology:
ƒ Standard+ PCB
- 6 layers
ƒ Electronical components:
- BGA pitch 1,0 mm
- DPAK
Characteristical features of performance:
ƒ Tambient ≤ 105°C
ƒ power dissipation up to 30 W (Theatsink: 85°C)
(depending on specific project conditions)
ƒ Vibration load: aeff = 4,4 g
ƒ Degree of Protection: IP6K9K

* Source ; Bosch HD_FIE_DILEE-43

 Electronic Control Unit EDC7C1

* Source ; Bosch HD_FIE_DILEE-44

 Electronic Diesel Control EDC

Exhaust Gas
Transmission Vehicle Engine Injection CRT SCR

EDC DCU
TCU *

EDC DCU
TCU VCU *

DLN* EDC
TCU Coordinator

ICU
PCU Powertrain Control Unit
e.g. PSG/VP44

*DLN = Drive Line Node *DCU = Dosing Control Unit

ECU Partitioning and Integration for Trucks

* Source ; Bosch HD_FIE_DILEE-45
 Common Rail System Roadmap
for Commercial Vehicles
Pressure Amplified CRS
•1800 bars
Injection Rate Shaping
• Solenoid / Piezo
• Pressure-/Needle-lift-control
CRSN4 2000 bar
• New ECU-generation
(Microhybrid / PCB) SOP
• Closed loop fuel control

•1600 bars, Solenoid CRSN3 1800 bar

• Top-Head Injector
• Multiple Injection SOP Conventional CRS
• New high pressure pump
• Fuel balancing control
• EDC 7 CRSN2 1600 bar
SOP

CRSN1 1400 bar

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

* Source ; Bosch HD_FIE_DILEE-46

 Euro4 - Corrective Functions

IQA PWC FMA

Injector- Pressure- Fuel-
Quantity- Wave- Mean-Value-
Adaptation Correction nt Adaptation
me
Compensation nag e Long term
o n-Ma
i
of production Inject drift compen-
tolerances sation via λ
FBC
Fuel-
ZFC Balancing-
Zero- Control
Fuel-Quantity- Torque control
Calibration for cylinder-
Closed-loop cylinder
pilot quantity deviations
control

* Source ; Bosch HD_FIE_DILEE-47

 Euro4 Corrective Functions
effective operation range of corrective functions
4 cylinder calibration example - schematic
load
*) Colored functions are
drift-compensating

IQA
FBC*

PWC

FMA*

ZFC*

engine rpm

* Source ; Bosch HD_FIE_DILEE-48