Diesel Basic

Bosch Training Training Centre Diesel Engine

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Division : MICO/PDT(BTC)

Bosch Training Training Centre Principle of the reciprocating engine

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Division : MICO/PDT(BTC)

Bosch Training Training Centre Principle of the reciprocating engine

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Division : MICO/PDT(BTC)

Bosch Training Training Centre 4 stroke cycle diesel engine

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Division : MICO/PDT(BTC)

Bosch Training Training Centre Fuel layout on a diesel engine(o/f valve on FIP)

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Division : MICO/PDT(BTC)

Bosch Training Centre Sectional view of the injection pump PE .. A

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Division : MICO/PDT(BTC)

Common Rail System Gear Pump / Feed Pump

Bosch Training Centre Fuel Layout - With VE Pump

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Division : MICO/PDT(BTC)

Bosch Training Centre VE Pump - Features

The basic VE Pump contains the following functional groups: Vane type supply pump Distributor Head (High Pressure Pump) Mechanical Governor  Hydraulic Timer  Electric Shut off Device

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Division : MICO/PDT(BTC)

Bosch Training Centre Distributor Pumps - VE Mechanical (sleeve controlled)

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Division : MICO/PDT(BTC)

Bosch Training Centre Role of Electronics in FIE

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Division : MICO/PDT(BTC)

Bosch Training Centre EDC System blocks

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Division : MICO/PDT(BTC)

Bosch Training Centre VE EDC Pump Structure

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System

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Division : MICO/PDT(BTC)

Bosch Training Centre Demands & Basic parameters Emission Legislation Higher Power and Torque Fuel Efficient Smoother drivability Cost effective Injection Quantity Injection Begin Injection Pressure

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System

Degrees of Freedom in Common Rail :

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•

Injection Pressure

•

Injection Quantity

•

Injection Begin

Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System What is Common Rail? Common Rail is a

Modular , Electronic Controlled, Diesel Fuel Injection System.

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System

Special Characteristics : •

•

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Injection Pressure is produced and governed relatively independent of  the Engine Speed and can be selected freely within a wide range . Injection begin and Injection Quantity can be freely selected  (EDC function)

Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System

How are the main characteristics of CR system achieved ?

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•

CR uses an intermediate High Pressure Accumulator (Rail)

•

Uses Electronic Control of Injectors

Division : MICO/PDT(BTC)

(use of Electro-magnetic valves)

Bosch Training Centre Common Rail System Injection pressure [bar] 1800 1600 1400

Common Rail

1200 1000 other   port-controlled systems

800

Common Rail

600

Other port controlled Systems (Conventional)

400 200

1000

2000

3000

4000 Engine speed [RPM]

1

Division : MICO/PDT(BTC)

5000

Bosch Training Centre Common Rail System Driver demand

CP3

1

MPROP

Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System

1

Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System Layout

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Pump CP1 - Standard

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Pump CP1 - Standard

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Pump CP1 - Standard

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Pump CP1 - Standard

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Pump CP1 - Standard

1

Division : MICO/PDT(BTC)

Common Rail System CP3 - High Pressure Pump

Controller (MPROP) - Control at the Pump inlet Feed Pump (Gear Pump)

Common Rail System MPROP - Magnetic Proportional Valve Maximum delivery Q [l/h] Zero delivery

I [A]

Detail A

Fuel

Zero delivery

Maximum delivery

 A Fuel

Bosch Training Centre Common Rail System DRV  – Pressure Regulator Valve

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System DRV  – Pressure Regulator Valve    t   e   n   g   a    M

   t   e   n   g   a    M

   F

   F   g   n    i   r   p    S

   F

  e   r   u   s   s   e   r   p    h   g    i    H

   F

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Rail

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Division : MICO/PDT(BTC)

Bosch Training Centre Common Rail System High Pressure Rail

Factors determining the Rail Volume :

Rail Volume is a compromise based on the following two factors Volume to be kept as small as possible to keep the response time of the system short (i.e., the setpoint pressures to be achieved in as short a time as possible) Volume should be as large as possible to keep the Pressure oscillation to minimum possible value.

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Division : MICO/PDT(BTC)

Bosch Training Centre High Pressure Rail

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Division : MICO/PDT(BTC)

Bosch Training Centre Pressure Limiter Valve

From Rail

Return to Tank

High Pressure Fuel

Low Pressure Fuel

2000

   ] 1500   r   a    b    [   e   r 1000   u   s   s   e   r   p

500

0 0

4

time

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Division : MICO/PDT(BTC)

Bosch Training Centre Injector 

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Division : MICO/PDT(BTC)

Bosch Training Centre Injector 

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Division : MICO/PDT(BTC)

Bosch Training Centre Injector  Principle

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Division : MICO/PDT(BTC)

Bosch Training Centre Closed

Injector 2/2 Valve

Open p2



p2

0 Outlet Orifice

p1



0

p1

U

pst

I



p1

FV

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Division : MICO/PDT(BTC)



Control volume Vst

Inlet Orifice    t    f    i    L   e   v    l   a    V

p1  p st

F0

F0

p2

Bosch Training Centre Common Rail System Injector 

Current

Armature Lift

Nozzle end Pressure

Control Chamber Pressure

Needle Lift

Injection Rate

Time

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Division : MICO/PDT(BTC)

Bosch Training Centre Injector Characteristics 100

Full Load Area

90

   )  .   r    t   s70    /    3   m 60   m    (   y50    t    i    t   n40   a   u    Q30

1600bar  1500bar 

80

950bar 

Emission area

600bar 

Pilot Injection Area

300bar 

Low Idle Area

250bar  20

10

0 0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Energizing Time (ms)

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Division : MICO/PDT(BTC)

1.0

1.1

1.2

1.3

1.4

1.5

Bosch Training Centre Electronic Control Unit Input circuits (1)

analog signals

digital signals

sign.  process. unit

Output circuits (2)

D

A

sign.  process. unit

Signal D

A

 processing

digital correcting and output signals

(3) Interfaces (5): communication diagnosis

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Power supply (6)

Memory

12/24V

(4)

Division : MICO/PDT(BTC)

steady correcting varaibles

Bosch Training Centre Common Rail System Filter assembly

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Division : MICO/PDT(BTC)