Theory 1:

Introduction to

Duration : 60 minutes

By :
L.M.Naik
Deputy General Manager
Engineering - Common Rail System
Bosch Ltd, Bangalore

Diesel Systems

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 1

Contents

Technology drivers
Market demands
Modern diesel engine requirements
Necessity of electronic diesel control

Diesel Systems

CR
Syllabus
| May 2008
| Module| 1-Theory
| Boschproperty
Limited 2008.
All rights
reserved,
regarding
anyCo.
disposal,
exploitation,
reproduction,
Internal
| DS/EAS-IN
03/06/2008
This is the1 exclusive
of Bosch
Limited
(formerlyalso
Motor
Industries
Ltd.) Without
their consent,
it
editing,
as well
as in to
thethird
event
of applications for industrial property rights.
may notdistribution,
be reproduced
or given
parties.

Theory 1 - Introduction

Technology Drivers
Electronic diesel control
Emission regulations(Exhaust gas and Noise)
Further fuel economy improvements
Further improvements in
- Reliability
- Durability
of engine/vehicles
Competitive costs and prices

Diesel Systems

CR
Syllabus
| May 2008
| Module| 1-Theory
| Boschproperty
Limited 2008.
All rights
reserved,
regarding
anyCo.
disposal,
exploitation,
reproduction,
Internal
| DS/EAS-IN
03/06/2008
This is the1 exclusive
of Bosch
Limited
(formerlyalso
Motor
Industries
Ltd.) Without
their consent,
it
editing,
as well
as in to
thethird
event
of applications for industrial property rights.
may notdistribution,
be reproduced
or given
parties.

Theory 1 - Introduction

Market Demands in Diesel sector

Costs

Fuel Consumption
Fuel Price

Power

Competitor
Gasoline

Emissions

Comfort

Legislation Limits

Driveability
Noise

DI Combustion System

Turbo charged-Inter cooled

Higher injection Pressure
Injection Pressure
Electronic Diesel Control
EDC with essential factors
Pilot Injection

CR
Syllabus
| May 2008
| Module 1-Theory
| exclusive
Bosch Limited
2008.
All rights
reserved,
also Motor
regarding
any disposal,
reproduction,
Internal
| Department
| dd/mm/yyyy
| This is 1the
property
of Bosch
Limited
(formerly
Industries
Co. Ltd.)exploitation,
Without their
consent,
editing,
distribution,
as well
in the
of applications for industrial property rights.
it may not
be reproduced
oras
given
to event
third parties.

Theory 1 - Introduction

Specific Power Output

specific Power Output [kW/l]

Naturally Aspirated Engine

Turbo Engine

Turbo Engine with Intercooling

80
70
60
50
40
30
20
10
0
1940

1950

1960

1970

1980

1990

Year of Introduction
Diesel Systems

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

2000

2010

Theory 1 - Introduction

Diesel Fuel Injection System

An Overview
Inline injection pumps; standard, control sleeve
Distributor injection pump; Axial and Radial, VE EDC
Single plunger injection pump; PF,UIS,UPS
Accumulator injector system (CRS)

Diesel Systems

CR
Syllabus
| May 2008
| Module| 2-Theory
| Boschproperty
Limited 2008.
All rights
reserved,
regarding
anyCo.
disposal,
exploitation,
reproduction,
Internal
| DS/EAS-IN
03/06/2008
This is the1 exclusive
of Bosch
Limited
(formerlyalso
Motor
Industries
Ltd.) Without
their consent,
it
editing,
as well
as in to
thethird
event
of applications for industrial property rights.
may notdistribution,
be reproduced
or given
parties.

Diesel fuel injection system

Overview:
The combustion process that take place inside a diesel engine are
essentially dependent on the way in which the fuel is injected into the
combustion chamber.
The most important criteria are the timing and duration of injection,
degree of atomization and the distribution of fuel inside the combustion
chamber.
The various factors which affect the mixture formation:
Start of injection
Injection characteristics (injection duration and rate of injection)
Injection pressure
Injection direction and
The number of injection jets
Diesel Systems

CR
Syllabus
| May 2008
| Module| 2-Theory
| Boschproperty
Limited 2008.
All rights
reserved,
regarding
anyCo.
disposal,
exploitation,
reproduction,
Internal
| DS/EAS-IN
03/06/2008
This is the1 exclusive
of Bosch
Limited
(formerlyalso
Motor
Industries
Ltd.) Without
their consent,
it
editing,
as well
as in to
thethird
event
of applications for industrial property rights.
may notdistribution,
be reproduced
or given
parties.

Theory 1

Cam driven Fuel Injection Pump

Pressure generation and injection are coupled

Diesel Systems

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Inline (PE) fuel injection pump

PE Standard in-line injection pumps

1 Pump barrel
2 Inlet port
3 Helix
4 Pump plunger
5 Plunger return spring
6 Rotational travel due to action of
control rack (Injected fuel
quantity)
7 Camshaft
Diesel Systems

CR
Syllabus
| May 2008
| Module| 2-Theory
| Boschproperty
Limited 2008.
All rights
reserved,
regarding
anyCo.
disposal,
exploitation,
reproduction,
Internal
| DS/EAS-IN
03/06/2008
This is the1 exclusive
of Bosch
Limited
(formerlyalso
Motor
Industries
Ltd.) Without
their consent,
it
editing,
as well
as in to
thethird
event
of applications for industrial property rights.
may notdistribution,
be reproduced
or given
parties.

Conventional fuel injection system vs Electronic Diesel Control

Break even point

Components
( Costs)

Mechanical
Systems

Electronic
B

Functions
Beyond B-B Electronic systems cheaper and better

10

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it may not be reproduced or given to third parties.

Systems

Conventional fuel injection system

Mechanical (Diesel) Fuel Injection System:

Fuel Injection
Pump+Governor+Timer
Drivers demand

Engine

Mechanical
coupling
Gear lever

Wheels
Gear box

Diesel Systems

11

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Role of electronics in fuel injection

Motivation for Electronic Control:

Improve the Fuel Metering Accuracy

Improve the Fuel Injection Timing

Optimize the Combustion Process
Provide Safety Mechanisms
Improve the Driver Comfort Level

Electronic Control does not replace Mechanical Control completely.

It aids the Mechanical Control in improving overall performance

Diesel Systems

12

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Electronic Diesel Control

Electronic (Diesel) Fuel Injection System:

Electronic Diesel Control (EDC)
Fuel Injection Pump
Drivers
demand

Engine

Mechanical
Coupling

Electrical
Coupling

Gear
Lever
Transmission Controller (TC)

Wheels
Gear Box

Diesel Systems

13

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Diesel engine and emission control

Pressure Generation & FIE

nozzle
pressure
bar
2500

Unit Injector
2000

Common Rail

1500

Direct Injection

Distributor pump

1000

1975

1980

1985

1990

1995

Diesel Systems

14

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Euro III

Euro I

Euro 0

Euro II

Indirect Injection

500

2000

Theory 2:

Duration : 60 minutes

By :
L.M.Naik
Deputy General Manager
Engineering Common Rail System
Bosch Ltd, Bangalore

Diesel Systems

15

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 2 - 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

Diesel Systems

16

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 2 Common Rail System

Common Rail
Function
Design
Operating concept

Diesel Systems

17

CR
Syllabus
| June 2008
| Module| This
3 - Theory
5 | Bosch
Limitedof2008.
rights reserved,
also regarding
exploitation,
Internal
| DS/EAS-IN
03/06/2008
is the exclusive
property
BoschAllLimited
(formerly Motor
Industriesany
Co.disposal,
Ltd.) Without
their consent, it
reproduction,
editing, distribution,
wellparties.
as in the event of applications for industrial property rights.
may not be reproduced
or given toas
third

Theory 2 Common Rail System

Cam driven FIE

Pressure generation and injection are coupled

Diesel Systems

18

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 2 Common Rail System

Development Trends in cam driven FIE

Pressure generation and injection are coupled

Diesel Systems

19

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may not be reproduced or given to third parties.

Theory 2 Common Rail System

Common Rail : FIE with new concept

1. Conventional System

Injection pressure p

Start of delivery
Peak pressure

Ps

Start of Injection

Injection pressure p

2. Ideal Engine
Start of Injection

3. Common Rail System

Begin of combustion
PR Rail pressure

Pilot injection
Time t

Mean pressure Pm

Main Injection
Pm
(PR)

Time t
FIE : Fuel Injection Equipment

Diesel Systems

20

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may not be reproduced or given to third parties.

Time t

Theory 2 Common Rail System

Common Rail : FIE with new concept

Accumulator

Leakage & control qty

2/2-Solenoid valve
Valve control chamber

High pressure pump

Fuel Tank

Nozzle

FIE : Fuel Injection Equipment

Diesel Systems

21

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may not be reproduced or given to third parties.

Theory 2 Common Rail System

Common Rail System 1600 bar

Diesel Systems

22

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 2 Common Rail System

Common Rail System

Diesel Systems

23

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may not be reproduced or given to third parties.

Basic injection functions

Multiple Injection Advantages

Exhaust aftertreatment management

Optimized combustion
Acoustics measure

Diesel Systems

24

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may not be reproduced or given to third parties.

Theory 2 Common Rail System

Engine with Common Rail System

Injector
High pressure pipe
Rail
Low pressure pipes

Pump

Filter

Diesel Systems

25

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Theory 2 Common Rail System

Common Rail System - applications

Common rail system for Passenger car
Fuel supply
High pressure control
System Diagrams
Common rail system for commercial vehicles
Fuel supply
High pressure control
System Diagrams

Diesel Systems

26

CR
Syllabus
| June 2008
| Module| This
3 - Theory
2 | Bosch
Limitedof2008.
rights reserved,
also regarding
exploitation,
Internal
| DS/EAS-IN
03/06/2008
is the exclusive
property
BoschAllLimited
(formerly Motor
Industriesany
Co.disposal,
Ltd.) Without
their consent, it
reproduction,
editing, distribution,
wellparties.
as in the event of applications for industrial property rights.
may not be reproduced
or given toas
third

Common Rail System for passenger cars

Passenger Car Common Rail (PC-CRS)

Diesel Systems

27

CR
Syllabus
| June 2008
| Module| This
3 - Theory
2 | Bosch
Limitedof2008.
rights reserved,
also regarding
exploitation,
Internal
| DS/EAS-IN
03/06/2008
is the exclusive
property
BoschAllLimited
(formerly Motor
Industriesany
Co.disposal,
Ltd.) Without
their consent, it
reproduction,
editing, distribution,
wellparties.
as in the event of applications for industrial property rights.
may not be reproduced
or given toas
third

Common Rail System for Commercial vehicles

Common Rail System for Trucks with (CP3)

1 Fuel tank
2 Pre filter
3 Fuel filter
4 Gear pre supply pump
5 High pressure pump
(CP3.4)
6 Metering unit
7 Rail pressure sensor
8 Fuel rail
9 Pressure relief valve
10 Injector

Diesel Systems

28

CR
Syllabus
| June 2008
| Module| This
3 - Theory
2 | Bosch
Limitedof2008.
rights reserved,
also regarding
exploitation,
Internal
| DS/EAS-IN
03/06/2008
is the exclusive
property
BoschAllLimited
(formerly Motor
Industriesany
Co.disposal,
Ltd.) Without
their consent, it
reproduction,
editing, distribution,
wellparties.
as in the event of applications for industrial property rights.
may not be reproduced
or given toas
third

Common Rail System for Commercial vehicles

Common Rail System for Trucks with (CPN2)

1 Fuel tank
2 Pre filter
3 Fuel filter
4 Gear pre supply pump
5 High pressure pump
(CPN2.2)
6 Metering unit
7 Rail pressure sensor
8 Fuel rail
9 Pressure relief valve
10 Injector

Diesel Systems

29

CR
Syllabus
| June 2008
| Module| This
3 - Theory
2 | Bosch
Limitedof2008.
rights reserved,
also regarding
exploitation,
Internal
| DS/EAS-IN
03/06/2008
is the exclusive
property
BoschAllLimited
(formerly Motor
Industriesany
Co.disposal,
Ltd.) Without
their consent, it
reproduction,
editing, distribution,
wellparties.
as in the event of applications for industrial property rights.
may not be reproduced
or given toas
third

Theory 2 Common Rail System

CRS Advantages
Separation

of pressure generation and injection

allowing 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 NOx
catalysts, or NOx adsorbers.
Fuel pump operates with low drive torque.
Diesel Systems

30

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.

Introduction to Common Rail Systems

Diesel Systems

31

Internal | DS/EAS-IN 03/06/2008 | This is the exclusive property of Bosch Limited (formerly Motor Industries Co. Ltd.) Without their consent, it
may not be reproduced or given to third parties.