10_16_2007_Cummins_CRS3.3i(2)

Diesel Systems

CRS3.3i

… the direct needle

1

Strictly confidential | 0281_Ze DS_PC/PJ-ECI| 07.08.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel Systems

CRI3.3i CR Piezo Injector – Direct Needle Actuation CRI3.3i (2000 bar): RB-SOP not decided yet Customer Benefit: Emissions Ð • direct actuated nozzle needle ⇒ highest needle dynamics • hydraulic buffer volume ⇒ highest multiple injection flexibility • minimum PI quantity (0.5 – 0.8 mm3/S) • closed loop control Fuel consumption Ð • close couple combustion concept • no fuel return

HP connector

Electrical connection

Power & Torque Ï • more injected fuel quantity in less time • maximum engine power + torque output Internal | DS-PC/PJ-ECI | 25.07./2007 | 0277_Ze | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel Systems – CRS3.3i Systemlayout Metering unit ZME

Pressure regulating valve DRV3.3

Rail pressure sensor RDS4.3

Rail (LWR3.3)

High pressure pump CP4.1

PiezoInjector CRI 3.3i (1...n)

Fuel filter

Tank

Electrical presupply pump EKP

Tank

New

Prefilter EKP pressure

high pressure

backflow pressure

Diesel Systems Vertraulich | DS/ECP2-Kc | 21.11.2005 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Control unit EDC 17

U [V]

CRS3.3i Function Schematic 200V

Voltage at Piezo actuator

0V

pressure [bar]

2000

coupler volume before nozzle sack hole

1500

1000

nozzle (pressure chamber) sackhole coupler volume injector (actuator chamber) before nozzle coupler chamber

500

sack hole 0

time scale

Diesel Systems Strictly confidential | DS/PJ-EII | 0071e_Pa_583 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3.3i - Results

CRI3.3i Hydraulic Results – Injection Rate CRI3.x

1000 bar / 40.0 mm³

injectionP_EVI rate signal (-) [bar]

CRI3.3i

20

15

10

5

0

-5 0

1

2

Advantage CRI3.3i: • fast needle opening/closing • increased steepness • minimized throtteling effects • square shaped injection rate

3

4

5 6 Kurbelwinkel [Grad]

7

8

crank angle (°)

Strictly confidential | DS/EIP2 | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

9

10

CRS3.3i

Hydraulic Results – Characteristic Injection Map 120

180V 2000 bar

0V

100

Q (mm3/S)

Menge HE [mm³/Hub]

1600 bar 80

1200 bar

800 bar

60

40

200 bar 20

0 0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

1,1

1,2

1,3

1,4

1,5

ET (ms)

Dauer HE [ms]

7

1.Q=f(AD)_7461_0003A.xls

1.Q=f(AD)_7461_0004.xls

1.Q=f(AD)_7461_0005A.xls

1.Q=f(AD)_7461_0006A.xls

1.Q=f(AD)_7461_0007A.xls

1.Q=f(AD)_7461_0008A.xls

1.Q=f(AD)_7461_0010A.xls

1.Q=f(AD)_7461_0011A.xls

1.Q=f(AD)_7461_0012A.xls

1.Q=f(AD)_7461_0013A.xls

Strictly confidential | DS/PJ-ECI 0208_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3.3i - Results 100

5 2000 bar 1800 bar

90

1600 bar 80

1400 bar

3

1200 bar

quantity (MI) [mm3/H]

200V

4

70

0V

1000 bar 800 bar

60

ca. 0,13mm³/µs

2

(ca. 0,05mm³/µs CRI3.3)

600 bar 400 bar

50

1

250 bar 200 bar

40

0 50

30

75

100

125

150

175

200

20 10 0 0,0

0,5

1,0

1,5

2,0

2,5

AD (MI) [ms] Î Î

Î PI Sehr gute Kennfeldlinearität Small quantitiy delivery possible Sehr guteofVoraussetzung fürenergizing Korrelationsfunktionen (IMA,…) HighÎsteepness PI quantity map, concept has to be optimized

Strictly confidential | DS/EIP2 | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3.3i - Results Comparison stroke/stroke-deviation Vergleich H/H-Streuung CRI3.3 zu CRI3.x-CRI3.3i CRI3.3i 7 6,5 6

1600bar CRI3.3

1200bar CRI3.3

300bar CRI3.3

1600bar Inj.CRI-PDN A1.2

1200bar Inj.CRI-PDN A1.2

300bar Inj.CRI-PDN A1.2

s/s-deviation [mm³/s]

Hub/Hub-Streuung [mm³/H]

5,5 5 4,5

H/H (1600bar)= H/H-3mm³/H.

4 3,5 3 H/H (1200bar)= H/H-3mm³/H. 2,5 2

H/H (300bar)= H/H-1mm³/H.

1,5 1

Î stroke/stroke-deviation independent of energizing time

0,5 0 0

200

400

600

energizing time [µs] Ansteuerdauer [µs]

800

Strictly confidential | DS/EIP2 | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

1000

1200

CRS3.3i

Hydraulic Results – Characteristic Map EDC17 10

9

S/S spread (mm3/S) Hub/Hub-Streuung [mm³/H]

7

*

1400bar (Offset = +6 mm³)

6

*

1200bar (Offset = +5 mm³)

5

800bar (Offset = +3 mm³)

1600 bar

**

1400 bar

**

1200 bar

* **

1000bar (Offset = +4 mm³) 4

1800 bar

**

*

1600bar (Offset = +7 mm³)

2000 bar

**

*

1800bar (Offset = +8 mm³)

8

**

*

2000bar (Offset = +9 mm³)

1000 bar

* **

800 bar

3

* **

600bar (Offset = +2 mm³)

600 bar

2 400bar (Offset = +1 mm³)

* 1

400 bar

200bar (Offset = +0 mm³) 200 bar

* **

0 0

*Teilhub

10

**

100

200

Schrittweite 1µs

300

400

**Vollhub

500

600

Schrittweite 10µs

700

800 900 Ansteuerdauer [µs]

1000

1100

ET (µs)

Strictly confidential | DS/PJ-ECI 0208_Ze | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

1200

1300

1400

1500

50Hub-Messung EMI

CRS3.3i

Hydraulic Results – Inj/ Inj + S/S Spread

0,6

0,5

40

0,4

30

0,3

20

0,2

10

0,1

0

Hub/Hub-Streuung [mm³/H]

0,7

S/S spread (mm3/S)

50

0,8

80mm³/H.@1400bar

1,5mm³/H.@800bar

2mm³/H.@2000bar

60

7mm³/H.@250bar

Q (mm3/S)

Einspritzmenge [mm³/H]

70

20mm³/H.@800bar

80

50mm³/H.@2000bar

0,9 2mm³/H.@1200bar

90

0 1

2

3

4

5

6

7

Prüfpunkt [Nr.] Test Points

11

Q 7461_0003A

Q 7461_0004A

Q 7461_0005A

Q 7461_0006A

Q 7461_0007A

Q 7461_0008A

Q 7461_0010A

Q 7461_0011A

Q 7461_0012A

Q 7461_0013A

3s H/H 7461_0003A

3s H/H 7461_0004A

3s H/H 7461_0005A

3s H/H 7461_0006A

3s H/H 7461_0007A

3s H/H 7461_0008A

3s H/H 7461_0010A

3s H/H 7461_0011A

3s H/H 7461_0012A

3s H/H 7461_0013A

Strictly confidential | DS/PJ-ECI 0208_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel Systems

CRI3.3i Hydraulic Results – Pressure Waves CRI3.3i CRI3.0

Advantage CRS3.3i: Î strongly reduced pressure wave amplitudes Æ free applicable injection distances, no PWC Æ highest flexibility Î Less SW function efforts 1000 bar /

Streng vertraulich | Department | 03.2007 | 783d_0596_Sk | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CRI3.3i

initial classification

fuel mass

lifetime

NVC

.x 3 I CR

temperature stroke

fuel mass

voltage

U

ISA voltage

cold start

• They finally can enable to be used as „on-board sensor“ in a closed-loop control structure.

ET rpm p

• Piezo injectors require precise activation/charging as a function of rail pressure, temperature, lifetime, etc.

Strictly confidential | DS/EIP2 | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

polarization

temp.

init-/ starting-time

CRI3.3i - Results

CRI3.3i – needle sensor feasibility 70

Aktorhub: 78µm 86µm

Einspritzmenge [mm³/H]

50

2000bar

ca. 3mm³

1500bar

U [V]

60

1000bar 40

70 30

time [s]

500bar

2000bar

60 20

ca. up to 2000h reached Engine Test: > up to 400h cumulated

z z z

A6-sample

Technology Î

Functional Concept

☺

Î

Actuator Module Design

☺

Î

ECU control functions

☺

Î

applicable Q-Hyd range > 880ccm

☺

Optimisation Step: Improvement of CRI Hydraulics and Actuator

Strictly confidential | DS/PJ-ECI 0228_Ze, 0185_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3.3i at one sight

Î

Î Î Î

step injection rate closed couple PI reduced pressure wave oscillations

962_01 962_03 962_05 962_06 962_11 962_12 962_13 962_14 962_15 962_16

CRI3.3i CRI3.x

S/S

CRI3.3i CRI3.x

EM

energizing time

VE

LL

1200 1000 800 600 400 200 0 -200 -400 -600 -800

injection rate

Î

extreme linear injection map small sample deviation very small shot to shot spread

injection rate

Î

quantity

Summary of hydraulic results:

-1000

time scale

Î Î

injection rate

Î

reduced quantity wave amplitude improved accuracy (at free distance: +/- 0,5 mm3/S) no rail throttles and PWC „closed PI“ possible

quantity

Î

time scale

CRS3.3i CRS3.0

distance PI-MI

Diesel Systems Strictly confidential | DS/PJ-EII | 0096_Pa_587 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

time scale

VL

CRS3.3i

Costumer benefit with CRS3.3i: Î

slightly reduced fuel consumption: a) reduced pump torque due to lack of fuel return b) possibility of closed PI-strategy

Î

optimized multiple injection capability

Î

reduced quantity drift Æ means smaller tolerances Æ means slightly reduced engineering target concerning emissions

Î

Potential of no PWC due to reduced pressure wave oscillations

Î

potential to omit fuel cooler in critical applications

Î

no fuel return lines from injectors

do the benefits justify the add-on costs ? Diesel Systems Strictly confidential | DS/PJ-EII | 0214_Ze; 0096_Pa_587 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

CRI3.3i

Conclusion • CRS3.3i technically feasible; though fuel-resistant piezo stack is • • •

a challenge long piezo stack is driving costs of system (stack and ECU) higher compared to CRS3.x, but market demands lower costs reducing piezo length would require higher transition ratio • either hydraulically (coupler) • or mechanically higher transition ratio means • less stiffness (reduced performance) • system more sensitive toward tolerances

• higher tolerance sensitivity means • more critical over lifetime • more critical injector/injector • Bosch conclusion: • CRI3.3i is the right approach to get the best injector performance • CRI piezo direct is no favorable business case for customer / Bosch • Bosch is developing advanced solenoid CR systems (CRS2.5,6,7) 21

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD 2200bar

0 ms*

Piezo Valve CR System

CRS3.3 2000 bar CRS3.2 1800 bar

CRS Top line

0 ms*

CRS3.0 1600 bar CRS2.7 2200 bar

Solenoid Valve CR System

CRS2.6 2000 bar

CRS High line

Adv. Multiple Injection: 0 ms*

CRS Mid line

CRS2.5 1800 bar

CRS2.2 1600 bar, CRS2.0 1450 bar 0,2 ms**

CRS Base line 0,8 ms**

* **

22

Safety margin 50 µs Typical values

CRS1.x 1400 / 1450 bar CRS for LPV / EME 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.