2004 deer busch
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10th Diesel Emission Reduction Conference
Advanced Diesel Common Rail Injection System
for Future Emission Legislation
Roger Busch
Common Rail System Engineering for PC
Diesel Systems
Robert Bosch GmbH
© 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
Outlook
• Drivers and Challenges for PC and LDT - Diesel
• Overall System Requirements for Advanced Common Rail
• BOSCH 4th Gen Common Rail Injection Systems
• Potential Evaluation of 4th Gen Common Rail Systems
© 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.
2
Diesel System Innovations
Diesel Progress - PC
© 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.
3
Diesel System Innovations
2003
149 Nm/l
51 Nm/l
48,4 kW/l
9,5 l/100km
Consumption
[l/100 km]
spec. Torque [Nm/l]
1936
33 kW
6,5 l/100km
130 kW
13,0 kW/l
spec. Power [kW/l]
eff. Power [kW]
© 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.
4
Approval Data for PC - Diesel at least Euro 3
source: KBA Germany
© 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 System Innovations
© 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.
6
DEER 2004
4th Gen Diesel Common Rail Injection System
Outlook
• Drivers and Challenges for PC and Truck - Diesel
• Overall System Requirements for Advanced Common Rail
• BOSCH 4th Gen Common Rail Injection Systems
ã Potential Evaluation of 4th Gen Common Rail Systems
â 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.
7
PC Common Rail System 4th Generation
FIE Requirements Evaluation
3 max. injection pressure
Pressure at the needle
Sensitivity analysis
of important
injection parameters
for the engine
performance
Needle lift
2b
4
1
2a
5
6a
6b
Time
Feature:
1
Pilot injection (number, time gap, quantity, tolerance)
2
Opening pressure, influence of pressure ramp, gradient
3
Max. injection pressure, influence of small nozzle holes
4
Pressure gradient during closing
5
Post injection (near, late, influence of pressure level)
6
Opening and closing speed of the needle
© 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.
8
FIE Requirement Evaluation - Summary
NOX [g/kg]
Particles / NOx = 1/10
Potential Analysis for PC an LDCombustion Process and FIE
7
Euro3
6
5
Euro4
4
3
2
1
0
A
z
F
E
D
C
B
G
I
H
L
K
series applications cept cept cept cept cept cept ept cept cept cept cept ept
c
c
n
on
on
on
on
on
on Co
on
on
on
on
on
C
z
n = 2000/min,
BMEP = 6,5 bar
C
C
C
C
C
C
C
fast needle opening velocity
but: injection rate during ignition delay
injection rate after start of combustion
C
C
C
„vario“ nozzle
ẻ rate shaping
ẻ
â 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.
M
Euro4/ 3
1400 kg
inertia weight
9
4th
Gen5"Diesel
Common Rail Injection System
"Euro
- Einspritzsystem
“Optimal” Shape for PC Engines
© 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.
10
DEER 2004
4th Gen Diesel Common Rail Injection System
CRS System Requirements for PC - Summary
Ö full flexible timing of multiple injection events
Ö full flexible choise of injection pressure in the engine map
stillquantities
valid and well - known
Ö small precise and stable injection
from series Common Rail
technology, gaining goals on
noise, power, Euro4 - emission and
maintaining EGT
© 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.
11
DEER 2004
4th Gen Diesel Common Rail Injection System
CRS System Requirements for PC - Summary
good spray
formation Ö
low Noise and
Ö
NOx - formation
very fast needle opening @ start of injection
limited quantity during ignition delay, but
Ö max. allowed injection rate to increase local air ratio
high spray
momentum Ö
Ö
increase EGR acceptance Ö
seperate
Ö
injection and
burning phase
strong increase of injection rate after start of combustion
high maximum of main injection rate
strong rate decrease and fast needle @ end of injection
© 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.
12
DEER 2004
4th Gen Diesel Common Rail Injection System
Outlook
• Drivers and Challenges for PC and Truck - Diesel
• Overall System Requirements for Advanced Common Rail
• BOSCH 4th Gen Common Rail Injection Systems
ã Potential Evaluation of 4th Gen Common Rail Systems
â 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.
13
PC Common Rail System 4th Generation
Piezo-Injector with Coaxial-Vario-Nozzle CRI4-PV
Injector -Charakteristics
z Basis: CRI3
z
Systempressure 1600/1800 bar
z
Space requirement as CRI3
z
One row for part load
z
Both rows for full load
© 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.
14
4th Generation Common Rail System for PC
Vario Nozzle Strategies
Combustion Noise [dB(A)]
NOx [g/kg]*
12
10
with PI
8
w/o PI
6
4
2
0
n=2000rpm,
BMEP=6,5bar
101
w/o PI
Avoidance of PI
(except for cold engine and idle)
Emission reduction
Reduction of QHYD
98
Noise reduction
95
92
Indepentantly switchable 2nd row
89
with PI
86
83
200
of spray holes
400
600
800 1000 1200 1400
hydraulic flow / cyl. displacement
[cm³/30s@100bar/dm³]
Current
Configuration
Potential Vario Nozzle
appropriate power output
© 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.
15
DEER 2004
4th Gen Diesel Common Rail Injection System
Advanced Common Rail Systems for PC
CRS 4 - Hydraulically Amplified Diesel Injection System
• Functions
Ö Rail Pressure up to 1350 bar
Ö HAD - Injector with hydraulic pressure amplification
Ö sophisticated closed loop fuel metering control
Ö innovative, delivery controlled high pressure pump platform
• Advantages
Ư small Qhyd and passive rate shaping to pull down
raw emissions and noise @ part load
Ö max pressure > 2200 bar @ spray hole to reach high power
and reduce raw emissions @ full load (US 06, e.g. LD in EU)
© 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.
16
PC Common Rail System 4th Generation
Hydraulically Amplified Diesel Injector (HADI)
Injector-Characteristics
z System pressure up to 1.350bar
z Pressure amplification ≈1:2
z Pressure at the nozzle up to 2.200bar
z Pressure/lift controlled needle
z Ramp rate shape
z Space requirements as CRI2
z Conventional nozzle
© 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.
17
CRS - Roadmap Pkw und Light Duty < 6t
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copying and passing on to third parties.
18
Advanced Control Functions
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copying and passing on to third parties.
19
Advanced Control Functions
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copying and passing on to third parties.
20
