Classe de Injetor - Bosch

IQA - Injector Quantity Adjustment

! ! ! ! ! ! !

Why IQA? What does IQA do? Operating principles IQA Adjustment Map EOL programming IQA accuracy Perspective

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IQA - Injector Quantity Adjustment

Why IQA? 0,12 Euro 2

Particle [g/km]

0,10

Euro 2 - Application

0,08 Euro 4 - Application

0,06

+/- 1 mm³/Str

Euro 3

0,04 Euro 4

+ 0,5 mm³/Str (PI)

0,02 +/- 1 mm³/Str (MI)

0,00

- 0,5 mm³/Str (PI)

0

0,2

0,4

0,6 NOx + HC [g/km]

0,8

1,0

1,2

•The actual fuel quantity must be as exact as possible to reach the emission limit values •High technical effort to reduce the production line tolerances DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Advantage of IQA is ! ! !

To reach the emission limit values of the future Equal injection fuel quantity for each cylinder To increase the injector first pass yield (FPY) by widening the production tolerances

What is IQA not able to do? ! ! !

Correction of the PI within the „plateau“ (i.e. CRI2) Correction of the start of the injection Correction of the drift of the injector (no closed-loop control)

DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Operating principle IQA Characteristics !

Correction of the fuel quantity of new injectors

!

Individual correction of tolerances at each point in the characteristic map for each cylinder (injector)

!

Influence on the fuel quantity by adjusting the energizing time (ET)

px MV characteristic

desired fuel quantity inj.tolerance for correction Q (mm³)

actual fuel quantity of inj.

p2 p1

ET (µs) DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Quantity [mm³]

The energizing time map in the ECU characterises the behaviour of mean value injectors in the engine.

P = const.

QCRI(ET)

QMV(ET)

Test Point QTP QMV

∆QIMA = QMV - QTP

Precondition: ∆QIMA

dQCRI dQMV = d ET d ET

∆ET ETIQA ETTP DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

ET [µs] 5

IQA - Determination of the adjustment map ! Definition of the 4 inspection points ID, PI, EP, FL in agreement with the

customer and the injector development ! Definition of a control duration map from the average of a batch of 25 injectors - Additional pressure lines may be required ! Definition of the additional measuring points for the available quantity values 80

Example

Inspection Points

70

Fuel Quantity [mm³/stroke]

1600 bar

Additional Points

60

1200 bar

800 bar

FL

50 400 bar

40 30

250 bar

EP

20 10

ID

PI

0 0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

DS/P-IMA (EAC) 382 9973d_Wh IQA training ET [ms] © 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.

1

1,1

1,2

1,3

1,4

1,5

6

IQA - Injector Quantity Adjustment ! Selection of the most suitable matching points between inspection points and additional points 80

PP VL 1600bar/900µs - 250bar/1280µs

1600 bar

Inspection Points FL

PP LL 250bar/810µs _ 250bar/1280µs 3,00

y = 1,9841x R2 = 0,9576

50 40 30

250 bar/1280 µs

Fuel Quantity [mm³/str.]

60

2,00

-2,00

-1,00

0,00 0,00

800 bar

0,5 -2

-1,5

-1

0 -0,5 0 -0,5

0,5

1

1,5

2

-1 -1,5

400 bar

-2 1,00

2,00

PP VL

3,00

-1,00 -2,00

20

PI

250 bar

EP

-3,00 PP LL

10

1

1,00

-3,00

1200 bar 2

1,5

Additional Points

250bar / 1280µs

70

y = 0,4248x R2 = 0,1663

ID ID

Chosen inspection point ID 0 0,1 quantity 0,2 0,3 tolerance 0,4 0,5 at0,6 0,7 0,8measuring 0,9 1 point 1,1 1.98 1,2 * 1,3 1,4 1,5 •Fuel additional correction ET [ms] value ID DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Operating principle IQA Adjustment Map

Fuel Quantity [mm3]

IQA Adjustment Map 0

250

400

800

0

0

0

0

0

0

PI

0

0,42*∆ID

0,42*∆ID

0

0

ID

0

∆ID

0,83*∆ID

EP

0

1,98 *∆ID

1,65 *∆ID

PL

0

1,98*∆ID

1,65*∆ID

0,84*∆EP 1,2*∆EP

FL

0

1,98*∆ID

1,65*∆ID

0,4*∆FL

Weighting Factors

1600

Rail Pressure [bar]

0,45*∆EP 0,9*∆EP ∆EP

1,3 *∆EP ∆FL

Inspection Points

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IQA - Injector Quantity Adjustment

Operating principle in ECU Dynamic Interrupt ∆q

q_desired p_Rail

Mengenwert der Prüfpunkte [mm3]

250

0

1600 Raildruck [bar]

400

800

0

0

0

0

0

0

PI

0

ID

0

0,83*∆ID

0,45*∆EP

0,9*∆EP

EP

0

1,99*∆ID

1,65*∆ID

∆EP

1,3*∆EP

x*FL

0

1,99*∆ID

1,65*∆ID

0,84*∆EP

1,2*∆EP

FL

0

1,99*∆ID

1,65*∆ID

0,4*∆FL

∆FL

0 0,42*∆ID ∆ID

0,42*∆ID

shared for one type of injector

Calculation of ET 1600 bar

90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0

Flash PROM InjVlv_stQntAdj_Map 0

+

800 bar 600 bar

t ET

250 bar

0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5

Control duration map

*

E²PROM

Correction Value ∆ EP / ∆ID / ∆FL / ∆ PI /QS

individual for each injector DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Operating Principle

Quantity [mm³]

Quantity energizing time map - without IQA 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0

1600

1200

VL FL +- 2,1 mm³

800

400

EP EM +- 3,0 mm³

250

ID LL +- 1,0 mm³

ET [µs] Ansteuerdauer [µs] DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Operating Principle Quantity energizing time map - with IQA

Quantity [mm³]

64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0

1600

1200

VL FL +- 1,1 mm³

800

400

EM EP +- 1,25 mm³ 250

LL ID +- 0,5 mm³

ET [µs] Ansteuerdauer [µs] DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Influences on IQA accuracy !

!

!

accuracy of measuring process " reproducibility of measurement (RM) " accuracy of measuring device " stability of injector: i.e. sensitivity to backflow config., temperature, test sequence, clamping ... " differences between test stations within one production line and between different production lines (DTS) accuracy of injector " quantity stability over lifetime " slope variation in the Quantity-ET map (DQ CRI ≠ DQMV) (SV) " maximum required correction value (RCV max) compatibility of the production quantity deviation to the engine quantity deviation

DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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IQA - Injector Quantity Adjustment

Implemented process for EOL-Programming IQA - Coding Labeling of injectors with alphanumeric and Data-Matrix-Code

Mounting of injectors and reading of the IQA Code

Transmission of IQA Code into ECU

Reduction of emission dispersion in the engine

Bosch Customer

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Code - Input

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IQA - Injector Quantity Adjustment

Perspective !

IQA will be introduced in passenger cars in all future projects

!

The inspection points will be determinated by IQA (requirement for high correlation to additional points)

!

Further optimisation of the IQA algorithm " correction of the slope variation " multi linear IQA coding

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IQA - Injector Quantity Adjustment

Summary !

The IQA functionality is assigned to correct the injector quantity of each injector of a Common-Rail-System individually and across the complete range of the Q(ET) - map.

!

The input of the function are the ECU correction values. They represent the difference to the nominal values of the respective test point and will be encoded and labeled on top of each injector.

!

At the end of the automobile manufactur line, the ECU adjustment values of the mounted injectors and the allocated cylinders are programmed into the ECU.

DS/P-IMA (EAC) 382 9973d_Wh IQA training © 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.

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(Responsibility in Europe, to be defined at RBAJ)

IQA - Flow Chart for an application First application with IMA for this customer Flow Chart for IMA applications

Presentation IMA Handling Service, EOL programming and after market D: 1 day; R:DS/VXY, DS/P-IMA; 1 1/2 year before customer SOP

EMI reference map of CRI in digital form to DS/EAC, DS/P-IMA R:DS/EIM, DS/EIP

Information about the relevant working range of the engine to DS/P-IMA and DS/EAC2 R:DS/Vxy

Preparation Determination of IMA addtional measuring points for the IMA adjustment map R:DS/P-IMA, DS/EAC2

Determination of check sequence with addtional measuring points R:DS/ECR-Ba Measurement of CRIs R:DS/ECR-Ba

Measurement data to DS/P-IMA R:DS/EIM, DS/EIP

C- & D-sample lot R:BaW,HoW,RBTR

Selection of 100 CRIs to measure the quantity at the additional points R:DS/P-IMA, DS/EAC2

Measurement data to DS/P-IMA D: 1 w.; R:DS/ECR-Ba

EMI curves of 5 nominal injector with high pressure config. of customer R: DS/EAC4

Calculation of the IMA adjustement map R:DS/EAC2, DS/P-IMA

Determination of average value R:DS/EIM, DS/EIP Delivery of nominal injector to customer R:DS/Vxy, DS/EIM, DS/EIP

Customer

Determination of ET map R:customer

Calibration of map

Validation Check of the IMA adjustement map with 25 extrem CRIs R:DS/EAC4, DS/EAC2

Comparison ET map with EMI reference map R:EAC2, DS/P-IMA

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Engine test with injector set R:customer, DS/EAC2, DS/Vxy

Time

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