crs theory 1 by naik n
TRANSCRIPT
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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
This is the exclusive property of Motor Industries Co. Ltd.Without their consent, it may not be reproduced or given to third parties.
Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- 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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Introduction
Cam driven FIE
Pressure generation and injection are coupled
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Introduction
Development Trends in cam driven FIE
Pressure generation and injection are coupled
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Technology Drivers : Multiple Injection
Exhaust aftertreatment management
Acoustics measure
Optimized combustion
Introduction- CRS Concept
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Common Rail : System working concept
Introduction- CRS Concept
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
System Types
Passenger Car – Common Rail (PC-CRS)
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Engine with CRSN (Side feed injector)
Common Rail System – Commercial Vehicle (CRSN)
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
System Management
Common Rail System & Vehicle
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Theory 1: Introduction to Common Rail System
Common Rail & emission strategy
Project mile stones
System Validation & tests
System types & Generations
Introduction
CRS Customer seminar – 05.06.07
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Common Rail System
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
CRS Customer seminar – 02.05.06
Theory 1: Introduction to Common Rail System
Project mile stones
System Validation & tests
System types & Generations
Introduction
Common Rail & emission strategy
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
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
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Q&A Session
Introduction to CRS by Naik
Question and Answer session
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Division : MICO-NE/ECR/EASTheory 1- CRS Customer Seminar – 05.06.07
Introduction to Common Rail Systems