Satz des Titelbilds an

andere COT-Prospekte
anpassen
Common Rail Systems
by Liebherr
High-Performance and Fuel-Efcient
2 Common Rail Systems by Liebherr
Since the establishment of the company, Liebherr has focused on concentrating its core compe-
tencies within the company in order to directly control decisive technologies. For the development
of diesel engines, fuel injection and engine management are becoming increasingly crucial due to
increasing emission and consumption requirements. Therefore it logically follows that Liebherr has
developed its own engine management system and its own Common Rail fuel injection system
in order to have all system expertise available in the area of engine development and production.
The fuel injection technology was developed in house and has been used successfully since the
beginning of 2012 in Liebherr diesel engines with 97/68 EC stage IIIB and USA EPA CARB Tier
4 interim emission levels. All engine series from 4-cylinder in-line engines up to 12-cylinder V
engines are supported. Starting in 2014, Liebherr will offer the fuel injection system for all engine
manufacturers. This applies to both road and non-road applications in the medium and heavy-
duty range as well as for stationary engines.
High quality fuel injection systems
by Liebherr
3 Common Rail Systems by Liebherr
High quality fuel injection systems
by Liebherr
The Common Rail System Page 4
Development Page 6
Manufacturing expertise Page 8
Quality and reliability Page 10
Engine management Page 12
Efcient pressure generation
and storage
Page 14
Fuel injection characteristics Page 16
Liebherr diesel engines with
Common Rail fuel injection
system
Page 18
VCV
PCV
p
p
4 Common Rail Systems by Liebherr
High-pressure pump
A 2-cylinder in-line pump with an oil lubri-
cated crankcase is used for engines with
a capacity of up to 2 litres per cylinder.
An active high-pressure valve provides
protection against overpressure by
absorbing undesired pressure peaks.
Liebherr
Engine Control Unit
Injector
Injector
Pressure Pipe
Connector
Pressure Pipe
Connector
High Pressure Pump
Pre-lter
Filter
PCV
VCV
High Pressure
Low Pressure
High pressure sensor
Pressure control valve
Volumetric control valve
Electric wiring
VCV
PCV
p
p
5 Common Rail Systems by Liebherr
The Common Rail System
Engine management
The engine control unit optimizes injection start
and duration in real-time. This makes the opti-
mum management of fuel combustion possible
in every operating point.
Injector
Injectors with solenoid-drive devel-
oped and manufactured in house
guarantee injection pressures of up to
2,000 bar and ensure extremely ne
fuel spray. The opening and closing
ank of the nozzle needle speed can
be independently adjusted.
Liebherrs modular Common Rail System consists of four main components:
high-pressure pump, pressure accumulator, injector and electronic control unit.
This innovative system supports compliance with applicable and future emission
standards for diesel engines and makes high performance possible with the low-
est possible fuel consumption. With precise multiple injection at pressures of up
to 2,000 bar, constant performance and low emission values are guaranteed over
the entire service life of the engine.
Reduced emissions The optimised injection process via a 3-way servo valve in
the Common Rail injector and the injection nozzle which
is perfectly matched to the cylinder, signicantly reduce
fuel consumption and the level of raw emissions
Efciency and
economy
Liebherr uses a 2-cylinder in-line pump with oil lubrication
for engines with a capacity of up to 2 litres per cylinder.
This delivers up to 300 litres of fuel per hour at a pres-
sure of 2,000 bar. In conjunction with the engine control
unit, the pressure is regulated exclusively by a volume
ow control valve which only supplies the pump with pre-
cisely the right amount of fuel that the combustion engine
requires. Injection only takes place when the solenoid
injector is energized by the Liebherr control unit for the
injection start calculated in real-time. During each cycle
of the injector, a volume of switching leakage, not greater
than 30 ml/min at full load, returns to the fuel tank. There
is no permanent high-pressure control leakage.
Reliability All components are specically designed for the highly
dynamic loads in off-highway applications. To ensure that
development is consistently focused on these require-
ments, a detailed product validation plan has been created
for the development process. In addition to endurance
testing with variable load proles, this also includes various
environmental tests.
Fuel Tank
Pre-lter
6 Common Rail Systems by Liebherr
Modular design
All components of the Common Rail System
are suitably dimensioned for the wide spec-
trum of use and are designed as a modular
system. For example, the injector is de-
signed so that it can be used with different
injection amounts both with 4 and 6 cylinder
in-line engines as well as in 8 and 12 cylin-
der v-engines.
7 Common Rail Systems by Liebherr
Research and development
The Liebherr fuel injection system was created after a development period of
only four years. A fundamental aspect for this was the use of the simultaneous
engineering concept. Selected components were completely newly developed in
order to create a reliable state-of-the-art complete system. Modern development
tools such as the Finite Element Method (FEM) and Computational Fluid Dynam-
ics analysis (CFD) contributed towards the constant optimisation of the system
and its modules.
Finite Element
Method
Many components of a fuel injection system are sub-
jected to cyclic loads. When testing with FEM, particular
emphasis is placed on determining and then optimising
fatigue resistance. Stress and deformation are, of course,
also inspected under operating and peak loads and the
component geometries are adapted accordingly.
CFD simulation Through CFD analysis, ow effects within the compo-
nents can be simulated. All ow-carrying components of
the Common Rail System were inspected intensively by
Liebherr calculation engineers using this method. In this
way, for example, the effect of cavitation erosion on the
nozzle needles and nozzles could be minimised, which
occurs due to the very high ow speeds.
Product validation Product validation is an integral part of the development
process of Common Rail Systems. The validation plan is
oriented towards excellent system reliability and availabil-
ity under demanding environmental conditions, as well
as towards a long product service life. It includes many
measurements and tests to be performed during develop-
ment, which are carried out by Liebherr on the numerous
hydraulic and engine test benches.
CFD simulation
CFD simulations were used, for example, to optimise
nozzle needle and nozzle geometry. In this way,
the areas of fuel recondensation are kept separate
from the nozzle walls.
Finite Element Method (FEM)
FEM calculations can be used to rep-
resent, for example, which areas of the
injector housing are decisive for fatigue
resistance. Production processes are
adjusted in order to maximise fatigue
resistance.
.
8 Common Rail Systems by Liebherr
Autofrettage
With autofrettage, the parts
of the Common Rail System
subjected to high pressure are
autofrettaged at up to 10,000
bar, which makes them fatigue-
endurable.
.
9 Common Rail Systems by Liebherr
Manufacturing expertise
Micro-precision manufacturing
Negative imprints of injection spray holes
of various injection nozzles, which are pro-
duced using the manufacturing processes
of Electro Discharge Machining (EDM) and
Hydro Erosive Grinding (HEG).
conic
laval
bottleneck
Injector assembly
The injectors assembled in the clean
room are subjected to various tests
as early as during assembly, for ex-
ample pneumatic tests, to check the
tted O-rings.
Liebherr Common Rail Systems are not only developed but also manufactured in
Bulle, Switzerland. The micro-precision parts for the injectors are manufactured
at an additional site in Germany. Large investments in modern production and
test facilities made fast start-up times for series production possible. The latest
knowledge about material ow and other process sequences were taken into
account when constructing the facilities.
Micro-precision
manufacturing
The geometry of the nozzle hole and its process-
reliable manufacturing are especially important for the
required ne fuel spray. Therefore Liebherr has introduced
Electro Discharge Machining (EDM) and Hydro Erosive
Grinding (HEG) manufacturing processes at its own
micro-precision manufacturing site.
Assembly in a
clean room
To ensure the functional capability of the high-precision
parts in the Common Rail System, extreme care is nec-
essary during assembly. The parts must be absolutely
dust and oil-free, therefore they are cleaned in four sepa-
rate washing cycles. High pressure pump, high pressure
connectors and injector parts are assembled in a class
7 clean room after acclimatization to ensure absolute
assembly precision.
Assembly
monitoring
On the assembly line, which is congured for series pro-
duction and largely automated, all manual process steps
are monitored by the system technology. Operating errors
are practically eliminated by the intelligent quality man-
agement system (Poka Yoke).
10 Common Rail Systems by Liebherr
Spray pattern test bench
With the aid of a camera, the test
bench measures the geometry
of the spray pattern of the injec-
tor/nozzle. Due to the very high
speed of the injection process,
this places high demands on the
measurement system as well as
on the synchronisation of the
measurement and control loop.
11 Common Rail Systems by Liebherr
Geometry measurements
Modern measurement instruments are used to
measure the geometry of the Liebherr Common
Rail System parts. The photo to the left shows
the evaluation of the round surfaces of the con-
trol valve.
Quality and reliability
Injector leak test
With the aid of a camera system, the
leak tightness of the nozzle/nozzle
needle is checked. In the process, the
camera records any drop formation on
the nozzle which is subjected to high
pressure.
Uncompromising quality assurance is decisive for the high reliability and availabil-
ity of the fuel injection systems. Liebherr uses an up-to-date computer-assisted
quality management system (CAQ system) that is implemented as early as the
production creation process and covers the entire product life cycle. Statistical
assessments, FMEA (failure mode and effects analyses) and CIP (Continuous
Improvement Processes) are examples of a consistent process philosophy. Many
efcient test benches that were specially developed for Liebherr are used to test
the highly precise components of the Common Rail System.
Comprehensive
controls on
incoming
material
In the incoming goods department, all purchased parts of the
Common Rail fuel injection system are already checked for
the highest quality with the aid of highly modern measurement
instruments. This includes 3D coordinate measuring devices,
roughness and contour measuring systems as well as an opti-
cal surface scanner.
Series testing Before delivering the fuel injection systems, the high pres-
sure pumps, injectors and high pressure connectors are
tested 100 % for functional and service life-relevant qual-
ity features, such as ow rate, torque or leakage. The Data
Matrix Code (DMC) is used to track the assembled parts and
assign them to the corresponding system components.
High-pressure
pump test
bench
The test schedule, according to which every pump is tested,
includes eleven test points with approx. 20 attributes. The pa-
rameters measured in the individual test points are evaluated
and stored in order to guarantee lasting traceability.
Leak test bench Injectors, pressure pipe connections and high pressure pumps
are subjected to a leak test on the leak test bench at multiple
stages up to 2,000 bar. This ensures that there is no leakage to
the outside or within the system on the high-pressure sealing
surfaces.
Highest quality
standards
Quality assurance at the Bulle site is certied according to
DIN EN ISO 9001/2008 and operates in accordance with VDA
standards (reliability control group).
12 Common Rail Systems by Liebherr
Solenoid drive
A solenoid drive opens and closes
the Common Rail injector nozzle.
It is controlled by the Liebherr
engine control unit.
13 Common Rail Systems by Liebherr
Engine management
Engine control unit
The engine control unit is developed
together with the Liebherr Compe-
tence Center for electronics in Lindau.
The circuit boards are assembled on
their own production equipment.
Application / diagnostics program
With the diagnostic software, which
is developed by Liebherr the engine
parameters can be optimally ad-
justed to the application and errors
can be read out and analysed. The
diagnostics software is efcient and
easy to use.
The Liebherr engine management system records numerous physical
engine variables for the optimal control of the fuel injection system. The engine data
is processed in the control unit using congurable mathematical models. In this
way, the control system can be easily adjusted to different numbers of cylinders
and capacities. In addition to the engine control unit, Liebherr also offers an
application and diagnostics program in order to provide both the implementer as
well as the service operator with optimal support.
Optimal control
and monitoring
Comprehensive functions and conguration possibilities
of the engine control unit ensure optimal control of the
fuel injection system for reliable engine operation. The fuel
injection timing and the fuel amount are calculated indi-
vidually for each cylinder, so that the injectors solenoid
valve can be correspondingly actuated. The control signal
and number of injections will be adapted to the require-
ments of the corresponding engine or the application.
Engine system
monitoring
The 97/68 EC and USA EPA CARB emissions standards
make engine system monitoring necessary. The Liebherr
engine management adopts permanently to monitoring
and controlling various exhaust gas after-treatment sys-
tems such as particulate lters or SCR catalytic convert-
ers and exhaust gas recycling.
Highest safety
standards
The Liebherr engine control unit was developed
according to the requirements of off-highway applications
as well as international standards such as ISO15998/
ISO13849 and ISO61508 SIL2. All electronic compo-
nents full high requirements for reliability, service life
and safety and are well suited for rough application
areas. For the specic requirements of mining devices,
the plugs correspond with degree of protection IP6k9k,
both in a connected and disconnected state.
0
100
200
50
150
250
300
350
400
1000 2000 3000 4000
400 bar
1200 bar
2000 bar
14 Common Rail Systems by Liebherr
Pressure generation
At maximum pump speed, 300 litres of fuel
are aspirated, condensed and delivered
through the high pressure connectors into
the injectors every hour.
Engine speed [rpm]
F
l
o
w

[
l
/
h
]
0
20
40
10
30
50
60
70
80
90
100
110
1000 2000 3000 4000
400 bar
1200 bar
2000 bar
15 Common Rail Systems by Liebherr
Flow curves
The high pressure pump for engines
with a capacity of up to a 2 litres per
cylinder supplies up to 300 l/h at a
pressure of 2,000 bar.
High degree of pump efciency
The hydraulic degree of efciency of the
CRS system high pressure pump for
engines with a capacity of up to 2 litres
per cylinder is above 80% at a pressure
of 2,000 bar.
Efcient pressure generation
and storage
To ensure good pressure stability between injection cycles, the pressure generat-
ed by the pump is stored temporarily in so-called high pressure connectors. In the
Liebherr Common Rail System, this pressure accumulator has a non-return valve
with a choke, which minimises the expansion of the pressure waves, increasing
injection performance. Depending on customer requirements and the conditions
of the engine installation space, Liebherr also offers a fuel injection system with a
conventional continuous rail.
Volume ow
regulating valve
A special feature of the Liebherr system is the volume ow
control valve that exclusively controls the pressure and
only supplies the pump with precisely the right amount
of fuel that the combustion engine requires. The systems
pressure sensor is tted in addition to an active control
valve directly on the pump.
System integration The link between the mechanics, electronics and com-
bustion is formed by system integration, which develops
all required injection and pressure control functions as
well as diagnostics and correction algorithms, equipping
them with a data set and validating them.
Engine speed [rpm]
E
f
f
i
c
i
e
n
c
y

[
%
]
16 Common Rail Systems by Liebherr
3-way servo valve
The injector has an additional
hydraulic intermediate valve with which
the nozzle needle can be closed
very quickly and, independently of that,
can be opened with adjustable speed.
17 Common Rail Systems by Liebherr
Injection rates
The diagram on the left shows the fuel supply
during the injection process at various opening
speeds of the servo valve depending on a set
pressure between 200 and 2,000 bar. Closing
takes place independently.
Quantity characteristic map
At pressures from 200 to 2,000 bar,
the quantity characteristic curves of
the Liebherr injectors are set apart by
a very high linearity, i.e. even injection
amounts, as shown in the diagram on
the left.
Fuel injection characteristics
With the Common Rail technique, multiple injections per combustion cycle are
possible. A stable multiple injection of the Liebherr system, together with
the high injection pressure of 2,000 bar, guarantees a highly efcient combus-
tion. Therefore, it is possible to minimise soot particles and NOx emissions
already inside the engine. The most complete fuel combustion possible ensures
maximum energy use, which thereby reduces fuel consumption.
Stable
multiple
injection
With multiple injection, pre-injection is very important for
quiet engine operation, the main injection is important for opti-
mal power development/maximum torque and post-injection is
important for reduction of emissions. Liebherr adapts the vari-
ous injection processes specically to every engine and appli-
cation. The 3-way servo valve ensures that the injection spray
is established moderately. Finally, the injection process is com-
pleted by closing the nozzle needle very quickly. This results in a
very clear boundary for the individual injections and a precisely
measured fuel amount - both of which are decisive factors for an
optimal combustion process.
High degree
of efciency
An efcient energy conversion from high pressure generation up
to the injection pressure is decisive for a high degree of efcien-
cy of the injection system. Liebherr uses many design measures
in order to connect the injector nozzles throttle-free, if possible,
to the high pressure pipe system, for example hole lters.
Minimum
switching
leakage
Liebherr injectors are set apart by their very small amount of
switching leakage. In the case of system injectors for engines
with a capacity of up to 2 litres per cylinder, at full load, it is a
maximum of 30 ml/min. This provides the following advantages.
higher degree of efciency and therefore lower fuel consumption
lower leakage temperatures, therefore lower cooling
requirements
good tolerance of various fuel qualities
optimal preconditions for start-stop operation as the
system pressure remains when the engine is shut off,
restarting is accelerated
18 Common Rail Systems by Liebherr
6-cylinder in-line engine D936/946 4-cylinder in-line engine D934/944
19 Common Rail Systems by Liebherr
Liebherr offers two versions of the Common Rail System. The fuel injection system
for engines with a capacity of up to 2 litres per cylinder is available for all engine
manufacturers starting in 2014. Starting in 2016, the program will be expanded
with a system for engines with a capacity of up to 5 litres per cylinder.
Liebherrs Common Rail fuel injection system is suitable for engines in road and
non-road applications in the medium and heavy-duty area as well as for stationary
engines.
Product range
8-cylinder V-engine D9508 12-cylinder V-engine D9512
Common Rail System for engines with a capacity of up to 2 litres per cylinder
System pressure 250-2,000 bar
Control leakage / injector 30 ml/min at 2,000 bar
Number of cylinders 4-12
Number of injection cycles 3
Pump delivery volume 300 l/h
Injection volume 5-300 mg
Nozzle ow rate 600-1,300 ml / 30 sec
Emission standards
97/68 EC stage IIIB and EPA CARB Tier 4i
97/68 EC stage IV and EPA CARB Tier 4f
EURO VI
Common Rail System for engines with a capacity of up to 5 litres per cylinder
System pressure 250-2,000 bar
Control leakage / injector 40 ml/min at 2,000 bar
Number of cylinders 8-20
Number of injection cycles 3
Pump delivery volume 900 l/h
Injection volume 10-1,000 mg
Nozzle ow rate 1,400-4,000 ml / 30 sec
Emission standards
USA EPA CARB Tier 2
97/68 EC stage III
Liebherr-Component Technologies
Liebherr-Component Technologies AG, based in Bulle, Switzerland, is responsible for all activities of the components
division of the Liebherr group. The companies and business areas belonging to this division are specialised in the
development, design, manufacture and reconditioning of high-performance components in the eld of mechanical,
hy draulic and electrical drives and control technology. The sale of components to customers outside the Liebherr
group of companies is managed centrally by Liebherr-Components AG in Nussbaumen, Switzerland.
Biberach: large diameter bearings, gearboxes, rope
winches, switchgear, electronics, electrical machines
Lindau: electronics, power electronics
Bulle: diesel engines, gas engines, splitter boxes,
axial piston units, injection systems
Ettlingen: remanufactured components
Kirchdorf: hydraulic cylinders
Monterrey: large diameter bearings
Many Years of Experience
Liebherr has decades of experience in the manufacture
of high-quality components used in cranes and construc-
tion machines, in the mining industry, maritime applica-
tions, wind turbines, in vehicle technology or in aerospace
and transportation technology.
The Right Solution for Every Need
A high degree of vertical integration and the use of exi-
ble, state-of-the-art production systems allow Liebherr to
offer its customers tailor-made solutions. Liebherr is your
partner for joint success from the product idea to devel-
opment, manufacture and rst installation right through
to series production. For the various components of the
drivetrain, Liebherr also offers remanufacturing in various
degrees in a dedicated factory.
System Solutions from a Single Source
Components from Liebherr are perfectly matched to each
other with regard to operation. Depending on the require-
ment, individual components from the wide product range
can be expanded through to the complete drivetrain. This
results in impressive system solutions which can be inte-
grated into a variety of applications.
Highest Quality Standards
and Long Service Life
All components meet the very highest demands for func-
tional reliability and durability, even under extreme loads
and harsh conditions. Elaborate quality management and
extensive analysis and test procedures are practised
throughout the entire development and production process,
guaranteeing reliability and long component service life.
www.liebherr.com
Dalian: gearboxes
Liebherr-Components AG
Postfach 222, CH-5415 Nussbaumen AG
+41 56 296 43-00, Telefax +41 56 296 43-01
www.liebherr.com, E-Mail: info.cos@liebherr.com
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