Bosch Training Centre

Diesel Engine
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Principle of the reciprocating engine
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

4 stroke cycle diesel engine
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Fuel layout on a diesel engine(o/f valve on FIP)
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Sectional view of the injection pump PE .. A
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t, it may not be reproduced or given to third parties.

Common Rail System

Gear Pump / Feed Pump

Bosch Training Centre

Fuel Layout - With VE Pump
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t, it may not be reproduced or given to third parties.

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VE Pump - Features
The basic VE Pump contains the following functional groups: Vane type supply pum
p Distributor Head (High Pressure Pump) Mechanical Governor Hydraulic Timer Elec
tric Shut off Device
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t, it may not be reproduced or given to third parties.

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Distributor Pumps - VE Mechanical (sleeve controlled)
1
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t, it may not be reproduced or given to third parties.

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Role of Electronics in FIE
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t, it may not be reproduced or given to third parties.

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EDC System blocks
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

VE EDC Pump Structure
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
1
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t, it may not be reproduced or given to third parties.

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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Common Rail System
Degrees of Freedom in Common Rail : Injection Pressure Injection Quantity Inject
ion Begin
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t, it may not be reproduced or given to third parties.

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Common Rail System
What is Common Rail?
Common Rail is a
Modular, Electronic Controlled, Diesel Fuel Injection System.
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t, it may not be reproduced or given to third parties.

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Common Rail System
Special Characteristics :
Injection Pressure is produced and governed relatively independent of the Engine
Speed and can be selected freely within a wide range. Injection begin and Injec
tion Quantity can be freely selected (EDC function)
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t, it may not be reproduced or given to third parties.

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Common Rail System
How are the main characteristics of CR system achieved ?
CR uses an intermediate High Pressure Accumulator (Rail) Uses Electronic Control
of Injectors (use of Electro-magnetic valves)
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t, it may not be reproduced or given to third parties.

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Common Rail System
Injection pressure [bar] 1800 1600 1400 1200 1000 800 600 400 200 other port-con
trolled systems Common Rail
Common Rail Other port controlled Systems (Conventional)
1000
2000
3000
4000 5000 Engine speed [RPM]
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t, it may not be reproduced or given to third parties.

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Common Rail System
Driver demand
CP3
MPROP
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
1
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t, it may not be reproduced or given to third parties.

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Common Rail System Layout
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t, it may not be reproduced or given to third parties.

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Common Rail System
High Pressure Pump CP1 - Standard
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
High Pressure Pump CP1 - Standard
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t, it may not be reproduced or given to third parties.

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Common Rail System
High Pressure Pump CP1 - Standard
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
High Pressure Pump CP1 - Standard
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
High Pressure Pump CP1 - Standard
1
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t, it may not be reproduced or given to third parties.

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
A
Fuel
Maximum delivery

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Common Rail System
DRV Pressure Regulator Valve
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t, it may not be reproduced or given to third parties.

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Common Rail System
DRV Pressure Regulator Valve
F Magnet F Magnet F High pressure F Spring
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
High Pressure Rail
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t, it may not be reproduced or given to third parties.

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 s
hort (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 mini
mum possible value.
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

High Pressure Rail
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t, it may not be reproduced or given to third parties.

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Pressure Limiter Valve
From Rail High Pressure Fuel
Return to Tank Low Pressure Fuel
2000 1500 1000 500 0
0 4
pressure [bar]
time
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Injector
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Injector
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Injector Principle
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Bosch Training Centre

Injector 2/2 Valve
Closed p2
0 p1 Outlet Orifice p st
t p 2 Open p2
0

p1 Inlet Orifice Control volume Vst p1 p1

U I
FV
Valve Lift
F0
F0
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t, it may not be reproduced or given to third parties.

p s

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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Bosch Training Centre

Injector Characteristics
100
90
Full Load Area
1600bar
1500bar
80
Quantity (mm3/str.)
70
Emission area
60
950bar
50
600bar
40
Pilot Injection Area
30
Low Idle Area
300bar 250bar
20
10
0 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
Energizing Time (ms)
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Bosch Training Centre

Electronic Control Unit
Input circuits (1) sign. process. unit sign. process. unit Output circuits (2) s
teady correcting varaibles digital correcting and output signals Interfaces (5):
communication diagnosis
analog signals
A Signal D processing (3)
D A
digital signals
Power supply (6) 12/24V
Memory (4)
1
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Common Rail System
Filter assembly
1
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t, it may not be reproduced or given to third parties.

Bosch Training Centre

Common Rail System
Electric Fuel Pump
1
Division : MICO/PDT(BTC)
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t, it may not be reproduced or given to third parties.