08. deutz common rail
TRANSCRIPT
Challenges in the Future Answered by Deutz CR
• New emission legislations
- On-road Euro 4 (10/2005) incl. exhaust aftertreatment
- Off-road Stage 3 (01/2006 ... 01/2008)
• Cost reduction
- DEUTZ‘s Medium Duty FIE (el. UPS) has a cost penalty against
the main C&I competitors‘ option for Stage 3
(el. distributor pump)
• Customer requirements
- Noise reduction ~ 3 dB(A) until 2006
- Torque increase 10...20 % (low end and max. torque)
- Main customer RVI is “Common Rail – minded“
Deutz FIE Strategy for the Future
• New electronic FIE to be developed for the Medium
duty engine families (SOP‘s: mid 2005)
• 2015 FIE (el. UPS) is attractive for the future
• 2011, 914: Product concept/strategy under work
(SOP‘s > 2006)
Einspritzleitung
Nockenwelle
Rollenstößel
Ausgleichscheibe
Kurbelgehäuse
Einspritzpum pe
Medium Duty families: Situation today
Deutz UPS Best in class (Common Rail)
System cost Fuel consumption Low end torque Engine noise Up to 1600 bar
Emission EU3
Deutz mech. UPS Best in class (el. distr. pump)
System cost Fuel consumption Cold start Electronic functions (EMR variant)
Up to 1350 barEmission EU2, C&I stage 2Electronics on demand
Options for the future
Unit Injector System Volvo, Iveco, DDC, CAT VW passenger car
Unit Pump Systems DaimlerChrysler, Mack, DAF DEUTZ liquid cooled
•High peak pressure•Favourable injection rate
Common-Rail Almost every
passenger car RVI, JohnDeere,
Cummins, CAT
•Pressure flexibility•Multiple injection•Silent gear train
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DCR - System
ECU
Thermostaticvalve
Prefilter withwater separator
Hand-primer
Supplypump
Mainfilter
HP-pump
Injector
DBV
Rail
FCU
Pressuresensor
11 22
33
11
22
33
Heater (optional)
Pressure sensor
MProp
pback, max < 1,2 bar
pSystem = 300 ÷ 1600 bar
pmin > 0,5 ÷ 1,0 bar
pmax < 10,5 ÷ 13 bar
ECU: Electronic Control Unit FCU: Fuel Control UnitDBV: Pressure limiter valve
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CR-Injector / FunctionCross Section of a BOSCH-CRIN 2nd Generation Injector
Features:• Injector just opens when current is on• A leakage occurs during opening which is systematically caused (dependend on rail pressure and
injection duration)• Spring is just applied to keep the injector closed against compression pressure in combustion chamber• Exchange of nozzles is not permitted ! The whole injector has to be removed !• Service concept is in progress
Magnet coil
Magnet core Armature Control chamber High pressure channel Pressure piece
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Rail
• High pressure storage of injection system
• Rail contains pressure relieve valve (DBV) and rail pressure sensor (RDS)
Pressure relieve valve (integrated)
Pressure sensor
• The system is adjusted that after each injection a corresponding fuel quantity is delivered by the pump always before the next injection occure
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Pressure Relieve Valve (DBV)
Features:
• Pressure relieve valve is a mechaninical safety device, which opens at 1950(-100) bar and protects the system concerning over pressure caused by any malfunction
• If opened the rail pressure remains in the range of 650 - 850 bar (dependend on speed and load). The engine keeps running but if necessary with decreased performance (limp home mode)
• Under usual conditions the DBV will not open during engine operation
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Rail Pressure Sensor (RDS)
• Input variable for rail pressure controller
• If any malfunction is detected the ECU may force the DBV to open by putting over pressure onto the system
0 V
5 V
4,5 V
0,5 V
0 bar 1800 bar
Pressure
Signal voltage
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High Pressure Pump (PF 45)HD-connector
ND-connector
I/O-Ventil keeps two functions:
• Hydraulic separation of high pressure side during suctioning
• Filling of pumps is just possible at a minimum pressure of approx. 1.7 bar
I/O-Valve (integrated)
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High Pressure Pump (PF 45)
• Pump housing is common for all engines
• Roller tappet is common for all engines
• Spring cup seat differs between engines
- short seat: TCD 2012
- long seat/1 TCD 2013 L4/6 2V
- long seat/2 TCD 2013 L4/6 4V
TCD 2013 TCD 2012
02.1
2.02
TK-
TM1
02.1
2.02
TK-
TM1
FCU (Fuel Control Unit):
To high pressure pump
From feed pump
back to tank
Fuel Control Unit (FCU)
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Fuel Control Unit (FCU)
• FCU controlles filling of high pressure pumps
• It is just delivered as much as needed to reach or keep the rail pressure setpoint
Inlet
to PF 45
Outlet
M-Prop
0
0,5
1
1,5
2
2,5
3
3,5
4
300 500 700 900 1100 1300 1500
Current [mA]
Fu
el
flo
w [
l/m
in]
• Supplier: BOSCH
• FCU for all DCR systems usable
• Tested Part from Supplier
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Characteristic of Overflow Valve
4
4,5
5
5,5
6
6,5
7
7,5
8
0 500 1000 1500 2000 2500 3000
Engine speed [rpm]
Pre
ssu
re [
bar
, ab
solu
te]
Low Pressure vs. Engine Speed
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Gear Pump - New Requirements
pgegen [bar] nMotor [1/min] Q [L/min]3 100 0,333
10 1000 1,8310 2300 2,92
Specifications: 2014 pumpgear driven
Suction pressure: p = 0,5 – 1.0 bar abs
4-7L Tier III belt driven
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Prefilter Requirements
• Prefiltration of Particle 30 m
• Water seperation of > 98 %
• Fuel preheating by means of a thermostatic valve
• Water storage with water level sensor
• Mechanical water draining (optional magnetic valve)
• integrated primer pump
• 1000 h exchange interval