Common Rail Systems

Diesel Common Rail Fuel Inje!on s"stem Mo#ame$ Hes#am

A-part Plus/MH/28.01.2013

%#" Common Rail & '#e tra$i!onal s"stems ma$e a (reat impat )or t#e $e*elopmnet o) $iesel en(ines. +ut it #a$ some pro,lems #i# raise$ t#e nee$s )or t#e )olloin( parameters  o )uel onsump!ons  Re$ue$ e#aust (as emission  n(ines to ,e more uiet

A-part Plus/MH/28.01.2013

%#" Common Rail & '#ese parameters an ,e met ," an inje!on s"stem t#at atomi4es )uel at t#e no44le 5nel" an$ at a #i(# inje!on pressure. In t#e same !me t#e injete$ uan!t" s#oul$ ,e preisel" metere$. '#e onl" s"stem t#at meet t#ese reuirements is ommon rail s"stem. Common rail is t#e most ommon inje!on s"stem )or passen(er ars an$ #ea*" $ut" tru6s.

A-part Plus/MH/28.01.2013

%#at is t#e $i7erene ,eteen Common Rail an$ ol$ s"stems&

A-part Plus/MH/28.01.2013

%#at is t#e $i7erene ,eteen Common Rail an$ ol$ s"stems&

A-part Plus/MH/28.01.2013

Common Rail s"stem separate$ pressure (enera!on an$ )uel inje!on. '#e )uel pump is responsi,le )or pressure (enera!on an$ injetors are responsi,le )or t#e )uel inje!on. '#e DC ontrols ea# o) t#e omponents. '#e main a$*anta(e o) $oin( so is to #a*e t#e a,ilit" to *ar" inje!on pressure uan!t" an$ !min( o*er a ,roa$ sale.

A-part Plus/MH/28.01.2013

Common Rail injetors are 59e$ it# a solenoi$ *al*e #i# opens or loses t#e no44le. '#e )olloin( sli$es ill s#o us #o t#e injetors a7ete$ t#e en(ine per)ormane.

A-part Plus/MH/28.01.2013

Common Rail #as ,eoe t#e most ommonl" use$ )uel inje!on s"stem )or passen(er ars li(#t $ut" tru6s  #ea*" $ut" tru6s an$ e*en loomo!*es $iesel en(ines. MA: is one o) +os# ustomers #i# is usin( +os# ommon rail s"stem on its ne tru6s an$ ,uses. '#e )olloin( *i$eo s#os #o it is installe$ in MA: ';M en(ine

A-part Plus/MH/28.01.2013

Operatng Concep: '#e t#ree opera!n( onepts o) ommon rail s"stem are  Pressure (enera!on Pressure ontrol an$ )uel inje!on.

'#e ommon rail pump is responsi,le )or pressure (enera!on. '#e pump is on!nousl" opera!n( an$ pro*i$in( pressure to t#e rail irrespe!*e to en(ine spee$ or t#e )uel uan!t" injete$. Rail pressure ontrol an ,e a#ie*e$ ," t#e pressure ontrol *al*e on t#e rail t#e meterin( unit on t#e CR pump inlet or om,inin( ,ot# o) t#em. '#e )olloin( sli$es ill s#o t#e a$*anta(es o) usin( ea# o) t#ese ontrols.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common Rail s"stem onsists o) to si$es '#e lo pressure si$e an$ t#e #i(# pressure si$e.  '#e lo pressure si$e omponents are  Fuel tan6 )uel 5lter an$ t#e presuppl" pump. '#e #i(# pressure si$e onsists o)  CR Pump CR injetors an$ t#e rail. 1.

Pressure re(ula!n( *al*e

2.

Fuel rail

3.

Hi(#-pressure pump

.

Fuel pre#ea!n(

?.

Fuel pre-$eli*er" pump

8.

@#ut-o7 *al*e

.

Injetor

10.

Rail pressure sensor

A-part Plus/MH/28.01.2013

Common Rail sysem componens: '#ere are to t"pes o) )uel suppl" pump letri suppl" pump an$ (ear pump. '#e eletri )uel pump is eit#er part o) t#e in-tan6 unit or is 59e$ in t#e )uel line. '#e main a$*anta(e is t#at t#e pump starts or6in( as soon as t#e $ri*er sit#es on t#e i(ni!on 6e". '#is ,uil$s up t#e neessar" pressure in t#e lo pressure iruit #en t#e en(ine starts an$ ma6es star!n( )aster. 1.

letri )uel pump

2.

B*ero *al*e

3.

Fuel 5lter

.

Hi(#-pressure re(ula!n( *al*e

?.

Return mani)ol$

8.

Fuel temperature sensor

.

Rail pressure sensor RD@E

10.

Rail )uel railE

11.

Injetors

12.

DC 1= C ontrol unit

A-part Plus/MH/28.01.2013

Common Rail sysem componens: '#e (ear pump is an(e$ to t#e #i(# pressure pump an$ is $ri*en ," its input s#a. In t#is a" t#e (ear pump ill start onl" aer t#e en(ine starts an$ t#e $eli*er" is $epen$ent on t#e en(ine spee$.

'#ere are some applia!ons #ere t#e to pump t"pes are use$. '#e eletri )uel pump impro*es star!n( response at lo pumps spee$s an$ #en t#e )uel is #ot.

A-part Plus/MH/28.01.2013

High Pressure Pump: '#e #i(#-pressure pump is t#e inter)ae ,eteen t#e lo-pressure an$ #i(#-pressure sta(es. Its )un!on is to ma6e sure t#ere is ala"s suGient )uel un$er pressure a*aila,le in all en(ine opera!n( on$i!ons. At t#e same !me it must operate )or t#e en!re ser*ie li)e o) t#e *e#ile. '#is inlu$es pro*i$in( a )uel reser*e t#at is reuire$ )or ui6 en(ine star!n( an$ rapi$ pressure rise in t#e )uel rail.

A-part Plus/MH/28.01.2013

High Pressure Pumps generatons: Bosch CP1: CP1 is t#e 5rst (enera!on o) +os# ommon rail pumps. It an (enerate pressures up to 13=0 ,ars. Mainl" it is 59e$ it# an eletri )uel suppl" pump an$ t#e pressure ontrol is on t#e rail.

A-part Plus/MH/28.01.2013

High Pressure Pumps generatons: Bosch CP2: CP2 is t#e seon$ (enera!on o) +os# ommon rail pumps. It an (enerate pressures up to 100 ,ars. It $i7ers )rom t#e CP1 an$ CP3 it# t#e $esi(n #i# onsists o) to a$jaent plun(ers an$ t#e pump is lu,riate$ it# oil.

A-part Plus/MH/28.01.2013

High Pressure Pumps generatons: Bosch CP3: CP3 is t#e t#ir$ (enera!on o) +os# ommon rail pumps. It an (enerate pressures up to1>00 ,ars. '#e CP3 is a #i(# pressure pump it# su!on si$e )uel-$eli*er" ontrol ," means o) a meterin( unit ME. '#is ontrol as 5rst use$ on t#e CP3 an$ as assume$ later on t#e CP1H.

A-part Plus/MH/28.01.2013

High Pressure Pumps generatons: Bosch CP1H: +os# CP1H is a mo$i5a!on on CP1 to ma6e it (enerate #i(#er pressures up to 1>00 ,ars. Fuel oin( into t#e pump element is metere$ ," an in5nitel" *aria,le solenoi$ *al*e M.

A-part Plus/MH/28.01.2013

High Pressure Pump componens:

A-part Plus/MH/28.01.2013

High Pressure Pump componens:

A-part Plus/MH/28.01.2013

High Pressure Pump componens:

A-part Plus/MH/28.01.2013

High Pressure Pump componens:

A-part Plus/MH/28.01.2013

High Pressure Pump componens: Pressure Regulaor:

A-part Plus/MH/28.01.2013

High Pressure sysem componens: Fuel Rail: Fuel is supplie$ to t#e rail )rom t#e #i(# pressure pump. '#e rail stores t#e )uel an$ $istri,utes it to in$i*i$ual injetors. It also $amps pressure *i,ra!ons ause$ ," #i(# pressure pump an$ inje!on proesses.

A-part Plus/MH/28.01.2013

High Pressure sysem componens: Rail Pressure sensor: '#e pressure sensor is monitorin( t#e pressure insi$e t#e rail. It is t"piall" a resis!*e sensor it# t#ree ires  = *olt suppl" )rom en(ine DC  @ensor (roun$ *ia en(ine DC  inear si(nal *olta(e output to DC

A-part Plus/MH/28.01.2013

High Pressure sysem componens: Rail Pressure sensor: '#e n(ine DC @upplies = *olts to t#e si(nal ire o) t#e )uel pressure sensor. '#e resis!*e *alue o) t#e sensor reates a #an(e in t#e *olta(e on t#e si(nal ire rela!*e to t#e )uel pressure in t#e rail.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol: Bn 5rst (enera!on ommon rail s"stems rail pressure is ontrolle$ ," t#e pressure ontrol *al*e. '#e pump (enerates ma $eli*er" uan!t" irrespe!*e to en(ine $eman$. Pressure ontrol *al*e installe$ on t#e rail returns eess )uel to t#e )uel tan6. '#e a$*anta(e o) t#e s"stem is t#e rail pressure an at rapi$l" to loa$ #an(es. Anot#er a$*anta(e is at star!n(.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol: '#e )olloin( (enera!ons o) CP pumps  CP3 CP1H E #as a pressure ontrol on t#e pump itsel) on t#e lo pressure si$e. A meterin( unit is installe$ on t#e pump inlet ma6es t#e pump onl" $eli*er t#e )uel uan!t" t#e t#e en(ine reall" nee$s. '#is re$ues t#e )uel onsum,!on. In )ault situa!on t#e pressure relie) *al*e pre*ents rail pressure )rom eee$in( a maimum.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: High Pressure conrol: A$jus!n( pressure on t#e lo pressure si$e ta6es too lon( to loer t#e pressure in t#e )uel rail #en rapi$ ne(a!*e loa$ #an(e ours. @o it ats slol". @o ne s"stems om,ines ,ot# ontrols on t#e #i(# pressure an$ lo pressure si$es. '#is om,ines t#e a$*anta(es o) ,ot# ontrols.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common rail injecor: Common rail injetors are t#e main omponent in t#e s"stem. '#e" #a*e t#e $iret rela!on it# t#e om,us!on #am,er. '#e start o) inje!on an$ t#e )uel uan!t" are ontrolle$ ," t#e eletrial tri((ere$ solenoi$ #i# ta6e si(nal )rom t#e DC.

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common rail injecor consructon:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common rail injecor consructon:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common rail injecor woring:

A-part Plus/MH/28.01.2013

Common Rail sysem componens: Common rail injecor woring:

A-part Plus/MH/28.01.2013

IMA Co$e Most injetors #a*e a o$e t#at must ,e pro(ramme$ to t#e en(ine C. '#e o$e relates to t#e ali,rate$ o rate o) t#e injetor. It ena,les t#e DC to orret t#e inje!on uan!t" to ompensate )or manu)aturin( tolerane.

A-part Plus/MH/28.01.2013

Bn-*e#ile tes!n( o) ommon rail s"stem '#e t#ree main onepts o) ommon rail opera!on are pressure (enera!on )uel inje!on an$ pressure ontrol. %e an test t#ese t#ree onepts on t#e *e#ile it#out ta6in( out an" o) t#e omponents. For $oin( so e #a*e +os# speial tools )or e*er" onept.

A-part Plus/MH/28.01.2013

Bn-*e#ile tes!n( o) ommon rail s"stem For tes!n( t#e injetors e #a*e t#is tool #i# ollets t#e return $uel )rom t#e injetors. '#e amount ollete$ is an in$iate i) t#e injetors are o6 or not.

A-part Plus/MH/28.01.2013

Bn-*e#ile tes!n( o) ommon rail s"stem

Return )uel uan!t" )or i$lin( spee$ no BJ

Return )uel uan!t" at starter spee$ no BJ

Return )uel uan!t" )or i$lin( spee$ o6

Return )uel uan!t" at starter spee$ o6

A-part Plus/MH/28.01.2013

Bn-*e#ile tes!n( o) ommon rail s"stem

Pressure sensor mo$ule

'#e pressure sensor mo$ule is onnete$ $iretl" to t#e HP onne!on port o) t#e HP pumpK )or t#is in a$$i!on t#e #i(# pressure line ,eteen t#e pump an$ rail is $eta#e$ t#e en(ine is not starta,le in t#is stateE. %#en t#e starter motor is a!*ate$ t#e reuire$ uan!t" is ollete$ in t#e pressure aumulatorK aer rea#in( t#e release pressure aroun$ =00 ,arE t#e o*ero *al*e opens pressure limi!n(E. '#e o*ero uan!t" os into a olle!on ontainer. '#e pressure *alue is $ispla"e$ on t#e $i(ital instrument. '#e pressure le*el a9aine$ is a measure )or t#e pressure ,uil$-up apa,ilit" o) t#e pump un$er en(ine start on$i!ons.

Di(ital pressure $ispla"

A-part Plus/MH/28.01.2013

Bn-*e#ile tes!n( o) ommon rail s"stem

Pressure sensor

J'@ atual *alues o) rail pressure !oring principle:

'#e pressure sensor is $iretl" onnete$ to t#e #i(# pressure onne!on o) t#e railK in a$$i!on t#e #i(# pressure line ,eteen rail an$ a easil" aessi,leE injetor is $eta#e$. '#e en(ine is operate$ in t#e i$lin( state en(ine runs on n-1 "lin$ersE spee$ *aria!on is possi,le it# re(ar$ to t#e rail pressure *aria!on priniple in ompliane it# t#e spei5a!ons o) t#e en(ine manu)aturersEK ," inreasin( t#e en(ine spee$ pressures !ll t #e maimum ran(e are onei*a,le.

Di(ital pressure $ispla"

'#e rail pressure *alue $ispla"e$ on t#e $i(ital pressure $ispla" is ompare$ it# t#e atual *alue )rom t#e $ia(nos! tester an$ t#us t#e aura" o) t#e RD@ is #e6e$.

A-part Plus/MH/28.01.2013