SYSTEM SOLUTIONS FOR MODERN

DIESEL ENGINE CONCEPTS

* Written by Robert Bosch GmbH in conjunction with Jack Holstein, National Service
Manager, Australia - Special thanks go out to the people of the Association of Australian
Diesel Specialists Inc. for sending me a copy of their Magazine (Diesel Torque) that had
this article included in it...Great job with the magazine...keep up the good work.

Quality and expertise in automotive equipment

Since Robert Bosch introduced the low-voltage magneto for motor vehicles as it's first
product in 1897, the company has been growing steadily and developed into the Bosch
Group operating on an international scale. In the area of automotive equipment, the Bosch
name is synonymous with quality, performance and precision. Some examples are ABS,
suspension and safety systems, lighting equipment, engine management systems,
electrical and electronic automotive body equipment, semiconductors and electronic control
units as well as starters and alternators.

Through innovative development work, precision in production and high quality standards,
Bosch will continue to help make motor vehicles even safer, cleaner and more fuel efficient.

Within the Bosch Automotive Equipment Sector, the K5 product division is responsible for
diesel injection systems.

The story of the diesel engine

In 1887, after a development time of five years, Rudolf Diesel
presented his third and first working diesel engine. However,
because of it's weight and size this engine could only be used for
stationary purposes for three decades. In particular, what was
lacking was a compact, light and at the same time efficient
injection pump. In 1922 Robert Bosch decided to develop diesel
injection systems. In 1927 the first mass-produced injection
pumps left the plant. This created the prerequisites for the high
speed diesel engine used in motor vehicles. The first diesel car
went into production in 1936.

This was the beginning of a partnership-like cooperation between

manufacturers of diesel engines and Bosch which repeatedly resulted in major
developments. For example, after the introduction of distributor pumps on 1964, diesel
engines became increasingly common in cars. Since 1983 Bosch electronics have been
used to optimize diesel injection controls. Because of developments such as these, today's
diesel engines are regarded as a reliable, economical and durable power plant in all types
of vehicles.

For a long time, diesel engines were associated with low with low power, a sacrifice in
convenience and a difficult to control exhaust behavior. Typical characteristics such as
surging and idle vibration were eliminated by refining the mechanical portion of the injection
equipment and by utilizing electronic control systems.
 These measures improved the driveability and stability of the idle speed and contributed
significantly to a reduction to fuel consumption and emissions.

The electronically controlled Bosch injection systems assume numerous additional

functions such as the control of the injected fuel quantity as a function of ambient
temperature and the air quantity drawn in, the control of exhaust gas recirculation as well
as cruise control.

Current new developments for the diesel engine of

tomorrow
In addition to the continuous improvement of
existing products and systems, Bosch is
constantly working on new developments.
Solenoid valve technology for distributor pumps
and single cylinder pumps (unit injector, unit
pump), common rail as well as the cross section
controlled nozzles are current examples.

Continuous development
work enhances the environmental compatibility of diesel
engines
During the first decades, diesel technology was concerned with improving performance and
reducing fuel consumption. Today the focus is on stricter requirements regarding
environmental compatibility. Engines - and thus also the injection equipment must meet
increasingly stricter standards regarding emission levels as well as particulate and noise
emissions.

More efficient electronic control systems with exhaust-

gas recirculation
The more flexibility parameters such as the start of injection, injection rate, direction of
injection, injection pressure and the air-fuel ratio can be adapted to given engine
requirements, the lower the pollutant emissions of diesel engines. Electronically controlled
injection systems allow the flexible matching of these values by means of electronically
stored maps.

The control of the start of injection and the air quantity keeps emissions stable throughout
the entire engine life. This is supplemented by electronically controlled exhaust-gas
recirculation.

High pressure and precise injection

Clean exhaust from diesel engines is not only achieved through the electronic control of
injection but also through the continued development of all mechanical components. Bosch
 developed various concepts together with engine design engineers. All concepts are
suitable for high pressure and work with an electronic control:

* Control sleeve in-line pump

* High pressure distributor pump
* Unit injector
* Unit pump system
* Common rail

The direct path to maximum fuel efficiency

Diesel engines have always been regarded as fuel efficient. They have the best thermal
efficiency and thus the lowest fuel consumption of all
internal combustion engines. If we take advantage of the
principle of direct injection, fuel consumption can be
reduced by another 15% compared to conventional pre-
and swirl chamber engines.

Direct injection also for cars

Having been widely used in heavy commercial vehicles
for a long time, DI engines are now being installed more
often in smaller delivery trucks and cars. In the past
combustion noise of DI engines was inherently louder than that of pre- or swirl chamber
engines. Today, DI engines have become so quiet through continued development of the
injection systems that even luxury cars benefit from their typical advantages.

Injection systems for the most diverse areas of

application
Bosch offers it's partners in the engine industry a wide range of injection components.
Whether dealing with passenger cars, small pick-up trucks, commercial vehicles, machines,
ships, agricultural machinery - there is an injection system precisely tailored to the
particular requirements of each application. Modern injection systems can contain a host of
functions among them the electronic control of the start of injection.

Diesel engines run even more economically with

electronic control
On diesel engines the injection system makes sure fuel is injected into the combustion
chamber at the right moment with the required pressure and the correct amount. Systems
such as the proven in-line pump or newly developed control sleeve pump meet these
requirements with a high degree of reliability.

The injection system precisely meters the fuel during the injection process at a high
pressure and with the accuracy of a fraction of a thousandth of a second. Fuel is injected
up to 250 times per second at speeds over 2,000 km/h. Today, the combination of precision
and high flexibility is being achieved more often through electronic injection controls.
 Electronic control systems for diesel injection
Diesel injection systems have achieved a high degree of technical maturity. Mechanical
control systems have proven their reliability and precision for many years. The first
electronic diesel control (EDC) has been a standard feature of distributor pumps since
1983. With the use of electronics it was possible to adjust the start of injection and exhaust-
gas recirculation more accurately and flexibly to the engine requirements. Electronic
systems improve fuel economy and reduce the amount of pollutants in the exhaust. In
addition, a significant improvement of the performance characteristics was achieved with
the introduction of electronic fuel quantity control in 1986. Among other things the EDC
carries out the following functions:

* Start quantity control

* Cylinder balancing
* Idle speed control
* Active surge damper
* Cruise control
* Protection against overheating
* Start of injection control
* Glow time control
* Exhaust gas recirculation
* Boost pressure control
* A/C compressor control
* Engine brake control
* Self diagnostics
* Anti-theft protection

The electronic diesel control is able to collect different data from the engine and operating
conditions with sensors. It flexibly processes the data with characteristic curves or maps
with two- or multi- dimensional representation in the control unit.

Data exchange between electronic control units

Since all data are available in uniform, digitalised form, the diesel injection system can be
easily interconnected with other vehicle systems. For example:

* Data exchange with the anti lock braking system (ABS) and traction control (ASR)
* Data exchange between the engine and the automatic transmission
* Driver information

Universally applicable in-line pumps

In-line pumps have been used for years in car, commercial vehicle, tractor, industrial and
stationary engines. Together with governors, timing devices and various add-on modules
from the Bosch module system, these injection pumps offer a wide range of possible
applications.
 Electronics for in-line pumps
For in-line pumps Bosch offers system solutions in the form of electronic add-on modules
or fully electronic controls. Idle control and driveability can be optimized with add-on
modules. There are also solutions for future emission standards. The electronic start of
injection control influences the mixture formation and combustion. Emissions of nitrogen
oxides and unburned hydrocarbons are significantly reduced.

Electronically controlled control sleeve pump with

proven sizes
To meet stricter emission standards, commercial vehicle diesel engines require a high
injection pressure and a precise start of injection. With the newly developed control sleeve
pump, the start of injection and the delivered fuel quantity can be freely selected by means
of maps on commercial vehicle diesel engines. Linear solenoids electronically control the
injected fuel quantity and the start of injection. Within a predetermined range, the sleeve
riding on the plunger can be adjusted to vary the start of injection.

The control sleeve pump can be mounted on engines without any difficulty. The classical
in-line pump can be easily replaced by the new control sleeve pump which in addition to
injection pressures of up to 1400 bar at the nozzle offers precise start of injection control.

This new system also opens up the possibility of integrating diesel injection into a network
of electronic controls. The combination of electronically controlled control sleeve pump with
traction control (ASR) - an important feature for heavy commercial vehicles - is especially
useful and advisable.

The VP 44 Piston Distributor diesel injection pump or

Solenoid Valve controlled pump
The new electronically controlled VP 44 high pressure radial piston distributor pump
generates pump pressures of more than 1000 bar and nozzle pressures of over 1500 bar.
The high atomization energy thus produced at the nozzles, plus the variable delivery rate
and pre-injection lead to a very clean burning engine with a smooth and consequently quiet
combustion process. The fast-response adjustment of injection timing and high precision
metering of the fuel by fast acting solenoid valves form the basis for the high power output
and low fuel consumption of modern diesel engines.

SVC Radial Piston Distributor Pump

Operating Principle

Features:

* Radial-piston configuration for pump pressures up to 100 bar.

* Efficiency-optimized fuel-injection system for high atomization energy at the nozzle.
* Immediate fuel-quantity response and rapid spill through fast high-pressure solenoid
valve.
* Extended durability die to multi-point calibration in ECU.
* Close tolerances due to multi-point calibration in pump ECU.
* Significantly reduced drift during complete service life.
* Possibility of cylinder cut-out and cylinder balancing up to n/max.
* Start-of-delivery control without needle movement sensor.
* Possibility of delivery rate variation and pilot injection in relevant speed range (2nd
generation)