EM1 PDF For Cao Thang TB

BASIC GASOLINE ENGINE MANAGEMENT
RBSI/ASA | 01/2008 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
1 disposal such as copying and passing on to third parties.
GASOLINE ENGINE MANAGEMENT

A. Gasoline engine management - Overview
The History of gasoline engine management development
Gasoline Fuel Injection systems
Mixture formation
The principle of engine control
B. Gasoline engine management systems

Cylinder-charge control systems
Emission control systems
Ignition systems
ESI/KTS overview
AATC
RBSI/ASA | 01/2008 |© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
2 such as copying and passing on to third parties.
ROBERT BOSCH (1861 – 1942)
Robert Bosch, born September 23, 1861

In Albeck near Ulm (Germany)
RBSI/ASA | 01/2008 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
3 disposal such as copying and passing on to third parties.
Low-Tension Voltage Magneto Ignition
AATC
RB 06E188
Milestone of the Automotive Technology with BOSCH
1887 1902 1927 1952 1967 1976 1978
1979
1979 19911987
1991 1995 1995
1991 1997 1995
1997 2000 2000
19972003 2001
2000
2005
ASA | 2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
5 copying and passing on to third parties.
Bosch systems and products
Energy supply Braking systems Central electrics
Ignition Lighting systems Central electronics
Starters Wiper systems Car alarm systems

Gasoline systems Communication
Signal devices
Diesel systems Heating
AATC
4-stroke petrol engine
1st Stroke 2nd Stroke 3rd Stroke 4th Stroke

Induction Compression Power Exhaust
AATC
RBSI/ASA | 2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such
7 as copying and passing on to third parties.
System Development : Carburettor Engine
Air Filter
Venturi
Throttle
Fuel Filter
Valve
Intake manifold
Fuel Pump
Fuel Tank
AATC
Injection Systems : Carburetor / Fuel Injection Systems

air air quantity
metering
fuel
metering
Carburettor Fuel injection
AATC
Injection Systems : External Mixture Formation
Multipoint fuel injection systems
A. Mechanical fuel injection systems

- K-Jetronic
B. Combined mechanical-electronic fuel

injection systems
- KE-Jetronic
C. Electronic fuel injection systems

- L-Jetronic,LH-Jetronic and Motronic
AATC
Injection Systems : Internal Mixture Formation
Direct fuel injection systems
-Motronic MED7
1.Fuel
2.Air
3.Throttle valve (ETC)
4.Intake manifold
5.Injectors
6.Engine
AATC
The History of Gasoline Injection

1967 D-Jetronic
1973 L- and K-Jetronic
1979 Motronic
1981 LH-Jetronic
1982 KE-Jetronic
1987 Mono-Jetronic
1989 Motronic ME (EGAS)
2000 Motronic MED7
AATC

• 1891: The first engine with manifold injection was developed by Deutz.
AATC

• A world record that was valid for 30 years
1939 – 1969
Piston engine flight record: 755 km/h with Bosch fuel injection
AATC

• 1951 : A Bosch direct injection system is built into a passenger car during standard
production for the first time.
1951
Gutbrod Superior 700

2-stroke engine with mechanical
gasoline direct injection
AATC

• 1954 : A Bosch direct injection system is built into the legendary Daimler-Benz 300
SL.
Mercedes Benz 300 SL

with mechanical gasoline direct injection
AATC

The advent of electronics : The Jectronic
1967 : The introduction of the first electronic injection system, the intake manifold
pressure controlled D-Jetronic.
AATC

1973 : The pure mechanically and hydraulically controlled K-Jetronic with continuous
fuel injection
7
6 1 Electric fuel pump

5 2 Fuel accumulator
3 Fuel filter
4 Warm-up regulator
5 Injector
9
6 Electric start valve
8 7 Fuel distributor
10
8 Air-flow sensor
4
3 9 Thermo-time switch
10 Auxiliary
2
1
AATC
K-JETRONIC : SYSTEM OVERVIEW
AATC

1973 : the air-flow measuring L-Jetronic, the injected fuel volume was determined
by the valve opening time appeared at the same time.
4 3 8
1 Electric fuel pump
2 Fuel filter
3 Fuel-pressure
9 regulator
6
5 4 Injector
7
5 Air-flow sensor
6 Thermo-time switch
2 7 Auxiliary-air regulator
8 Throttle-valve switch
9 Lambda sensor
10 ECU
10 1
AATC
L-Jetronic : System Overview
AATC
L-Jetronic
Air-flow meter
AATC

The advent of electronics : The Jetronic
1981 : The flap-type air-flow meter of the basic L-Jetronic system was replaced with
the hot-wire air-mass sensor and sold for the first time as the LH- Jetronic.
4 3 8
2 Fuel filter
3 Fuel-pressure regulator
9 4 Injector
5
5 Hot-wire air-mass sensor
6 7 6 Engine-temperature
sensor
2
7 Rotary idle actuator
9 Lambda sensor
10 ECU
1
10
AATC
LH-Jetronic
Hot-wire air-mass meter HLM
AATC
Hot-film air-mass meter HFM
AATC
RBSI/ASA | 2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such
25 as copying and passing on to third parties.

1982 : The KE-Jetronic, upgraded by an electronic control circuit and the Lambda
sensor.
7 2 Fuel accumulator
6 12 3 Fuel filter
5 4 System pressure
regulator
13 5 Injector
9
6 Cold-start valve
7 Fuel distributor
11 8 Air-flow sensor
10
8 9 Thermo-time switch
10 Auxiliary-air regulator
4 11 Engine-temperature
sensor
3 12 Throttle-valve switch
2
13 Lambda sensor
14 ECU
14 1
AATC
KE-JETRONIC : SYSTEM OVERVIEW
AATC
K-Jet & KE-Jet Comparison
K-Jetronic KE-Jetronic
AATC

1983 : the Mono-Jetronic appeared on the market: a particularly cost-efficient
central injection system.

2 Fuel filter
3a Throttle-valve potentiometer
3b Pressure regulator
3c Injector
3d Connector plug with
intake-air temperature
sensor
3e Throttle-valve idle actuator
4 Engine-temperature sensor
5 Lambda sensor
6 ECU
AATC
Monojetronic: Central Injection Unit
AATC

The advent of electronics : The Motronic Systems
1979 : Motronic: An electronically controlled mixture preparation in combination with
the ignition process. It is the L-Jetronic upgraded by an electronic map ignition.

2 Fuel filter
3 Fuel-pressure regulator
4 Injector
5 Air-flow sensor
6 Engine-temperature
sensor
7 Rotary idle actuator
9 Speed and reference
mark sensor
10 Lambda sensor
11 ECU
12 High-voltage
AATC

The advent of electronics : The Motronic ME Systems
Since 1998, the ME7 Motronic has been torque-controlled.
In the 1990's, the E-GAS electronic gas pedal was introduced into ME1 - ME4 series
Diagnosis module Carbon canister
Electrical secondary
for tank leakage Camshaft Ignition coil/ air pump*
phaser* Spark plug
Canister purge
valve Fuel rail/ Phase
Injectorl sensor
Oxygen sensor
Air mass meter Knock Temp. Pre catalyst
Trottle sensor sensor
Electronic Oxygen sensor
device
control unit Speed
(ETC)
sensor Main catalyst
Accelerator pedal module
CAN
Diagnosis
Source: GS/VSA 6401e

lamp
Diagnosis
interface Fuel pump module with
Immobilizer low pressure pump
ETC = Electronic Throttle Control Camshaft phaser: Bosch components
OBD = On-Board Diagnosis System intake and/or
RLFS = Returnless Fuel Supply System exhaust phasing * option
AATC

The advent of electronics : The Motronic MED Systems
Since 2000, the MED series has been available for direct petrol injection.
High-pressure Fuel rail

pump
Ignition coil
Air-mass meter with MAP sensor Pressure

control valve
air temperature sensor
Lambda-
sensor (LSU)
Electronic Injectors
throttle Pressure
control sensor
ETC Exhaust-gas
Nox-
recirculation
catalytic
valve
converter
Lambda-
Electronic
sensor (LSF)
control unit In-tank module
including the
fuel-supply pump
AATC
Internal Mixture Formation : Gasoline DI Motronic MED 7
AATC
Engine Management
So what is Engine Management?
It is the joint control of both Ignition and fuel injection, at all loads and temperatures,
within one control unit.
The Primary Function of Engine Management :

• To adjust the torque generated by the engine.
The variables that influence the torque are controlled in the various engine
Management subsystems:
• Cylinder charge control
: for Bosch, it is the ETC system
• A/F mixture formation
: the calculated air mass determined the necessary injection time and the optimum
injection point
• Ignition
: the crankshaft angle determined the correct ignition timing
AATC
OBJECTIVES:
• To make available the torque requested by the driver

• For better exhaust emissions control as demands
• Better fuel consumption
• Power output, comfort and safety
AATC
Mixture Formation
Stoichiometric air-fuel ratio:

1 kg fuel
14.7 kg air
Air ratio:
The deviation of actual air-
fuel ratio from the theoretical
(14.7:1) is denoted by the
Greek letter λ (Lambda):
actual inducted air quantity

λ=
theoretical air requirement
AATC
Mixture Formation
rich lean
Engine output
Fuel consumption
AATC
The principle of Engine Control
ECU respond
Driver’s request Required engine torque is generated

- specific torque value via the gas pedal.. and is defined by the following
factors:
• the air filling,
• the quantity of fuel and also
• the ignition time.
AATC
The principle of Engine Control : System Blocks

Engine management as a control circuit
measured variable received, prepared alter the operating state

(electrical signals) and evaluated of the engine
Sensors Engine Control Unit Actuators

(positioners, actuating elements)
AATC
Cylinder-charge control : Conventional throttle valve control
1. Accelerator pedal
2. Linkage
3. Throttle valve
4. Induction passage
5. Intake air flow
6. Bypass air flow
7. Idle-speed actuator
8. ECU
9. Input variables
Conventional fresh gas control via throttle valve

AATC
Cylinder-charge control : E-GAS / ETC

Sensors Actuators
Monitoring
Monitoring
module
module
Accelerator-pedal Engine control unit Throttle device

module
Fresh gas control via EGAS
AATC
Cylinder-charge control : Variable Valve Timing Control (1)

Intake Camshaft Adjustment
1 Camshaft retarded
2 Camshaft normal
3 Camshaft advanced
AATC
Cylinder-charge control : Supercharging (1)

Dynamic supercharging
Swing Intake Manifold Supercharging : Variable Swing Pipe Systems
AATC

Mechanical Supercharging
Intake air
Compressed air
AATC

Exhaust Gas Turbocharging
1. Compressor impeller
2. Shaft
3. Exhaust-gas turbine
4. Intake for exhaust-
gas mass flow
5. Outlet for compressed air
AATC

Boost pressure control with VTG supercharger
AATC
VTG (Variable Turbine Geometry) supercharger
AATC
Emission Control : Exhaust-gas Recirculation (EGR)

2
1. What is the purpose of the EGR system?
1 To reduce the max combustion temperature
so that the formation of nitrogen oxide is
3 reduced.
2. In which load ranges is the EGR system

active?
4
Mainly under part load condition.
3. If an EGR valve is jammed open, what effect

can this have?
1.Engine management No load = engine dies.
2.Solenoid valve
3.EGR valve
4.HFM
AATC
Emission Control : Secondary Air Injection
1. What effect does secondary air injection have

on the emission of harmful substances?
By blowing fresh air into the exhaust

manifold, the pollutants CO and HC are
reduced by re-combustion process.
(only effective in the post-start and warming-
up phase)
AATC
Emission Control : Purge Control

How is the tank ventilation valve activated?
By the system control unit under certain
running conditions (system specific).
1.Fuel tank
2.Vent pipe
3.Charcoal canister
4.Fresh air
5.Regeneration valve Purge control valve
(regeneration valve)
6.Pipe to intake manifold
7.Throttle valve
8.Intake manifold
AATC
Emission Control : Three-way catalytic converter TWC
Ceramic or steel
Lambda monolith
Knitted metal mesh
sensor
CO
Carbon monoxide CO2
Carbon dioxide
HC
Hydrocarbons H2O
Shell Water vapour
NOx
Nitrogen oxides N2
Nitrogen
AATC
Emission Control : Oxygen Sensor

Heating element Protective tube
Connecting
cable Shell
Disc spring Electric

contacts
Supporting ZrO2 sensor ceramics
ceramic tube
AATC

Configuration of a tube-type Lambda
oxygen sensor in the exhaust pipe
1 Sensor ceramic element
2 Electrodes
3 Contacts
4 Housing contact
5 Exhaust pipe
6 Ceramic protective coating (porous)
7 Exhaust gas
8 Outside air
Us Sensor voltage
Operating Concept
Nernst Effect
• Requires Exhaust gas temperature to be 325-350° C
• At high temperatures, the ceramic (electrolyte) displays electrical conductivity and
voltage is produced at the sensor’s electrical connections
AATC
Operating Concept
Nernst Effect
• Sensor produces a high voltage (600mV - 1000mV) when λ < 1 (rich)
Low oxygen content on exhaust gas electrode
High oxygen content on reference air electrode
•Sensor produces a low voltage (0mV - 300mV) when λ > 1 (lean)
High oxygen content on exhaust gas electrode
High oxygen content on reference air electrode
AATC
Emission Control : Oxygen Sensor Operation

Closed-loop control system
Catalytic
Air converter Exhaust gas
Engine
Gasoline
Lambda
oxygen sensor
Fuel
metering
ECU
AATC
Emission Control : Oxygen Sensor Voltage Range

Voltage characteristic of the Oxygen sensor at 600° C (1112° F) working
temperature
a: Rich mixture b: Lean mixture
AATC
AATC ZU 01E181
Ignition
Position of crankshaft and piston at the ignition

point with advanced ignition
TDC - Top Dead Centre
BDC - Bottom Dead Centre
Z - Ignition point
Ignition timing must be selected to comply

with the following criteria:
•Maximum engine power,

•Maximum fuel economy,
•Prevention of engine knock, and
•“Clean” exhaust gas
AATC
High-voltage ignition device 1902
AATC
Conventional Coil Ignition (1934 – 1986)
AATC ZU 04E181
Transistor ignition (1965 to 1993)
TSZ - K
• contact controlled
TSZ - I
• inductor-type trigger
TSZ - H
• hall trigger
AATC
Transistor ignition system : Induction
Pulse generator operating

On the inductive principle
AATC
Transistor ignition system : Hall
1. Hall Sensor/IC
2. Trigger wheel/Vane
3. Distributor base plate
4. Connecting cable with plug
AATC
Hall Effect - Basic Principle
1. What is the Hall effect based on?

A semi-conducting layer of silicon,
through which a current flows, is
exposed to a magnetic field.
2. What causes the effect to take place?

The direction of the current, and
the influence of the magnetic flux.
3. What occurs due to the change in

magnetic flux?
An electric voltage, the Hall voltage
(mV) can be tapped off on the
transverse sides of the semi-
conductor layer.
AATC
Electronic ignition (1983 to 1998)
AATC
Electronic ignition : Ignition Advance Map

Ideal electronic ignition-advance map in
compare with a mechanical adjustment map
a. Ignition-advance map for electronic ignition
b. Ignition-advance response with conventional

coil ignition
AATC
Electronic ignition system with knock control
Signal without knock Knocking combustion
AATC
Distributorless semiconductor ignition (1983 – 1998)
AATC
Motronic : Combined fully electronic ignition and fuel

injection unit (1998 - )
AATC
Plastic embedded ignition coils
Plastic technology
Light and compact

Electric strenght
Temperature resistance
Vibration-proof
Non-mechanical distribution
Wearless
Constant exact ignition point
Silent
AATC
AATC
Spark Plug -Bosch Super

The Conventional Spark Plug
Conductive glass seal

Thermal shrink zone
(contents of steel
shavings determine
the resistance)
Nickel plated shell
AATC
Type of seat
and thread
<20,8>
M 18x1,5
< 16 >
M 14x1,25
< 16 >
M 14x1,25
< 26 >
M 18x1,5
< 16 >
M 10x1
<20,8>
M 14x1,25
<17,5>
M 12x1,25
< 16 >
M 12x1,25
< 14 >
M 12x1,25
Type designation
W D F H M U W X Y Z
Shielded, Shielded, water- Surface-gap Surface-gap Semi- With
Version water-tight, tight, spark plug spark plug suppres- For low-
B for resistance C for resistance E without ground
G with ground
L surface M Motor- R S power
R ignition cable dia ignition cable electrode(s)
air-gap sports sion resistor
engines
electrode spark plug
7 mm dia 5 mm
Heat range
code number 13 12 11 10 9 8 7 6 5 4 3 2 09 08 07 06
7
1 3 1 3 1 3 4 7 4 5 3 4 5 7
Thread lenght
Spark position *11,2 *11,2 17,5 17,5 17,5 17,5 17,5 25
D 12,7 12,7 19 19 9,5 9,5 12,7 19 19 19 26,5 26,5 26,5 26,5
A B C D E F G H K L M N S T
* Thread length for short-thread
Electrode D-plugs: 10.9 mm
version
T D T Q
Electrode Copper Nickel- Plati-

yttri- Silver
material num
um
C C E P S 33 22 15 10
Burn-off Devia- P0 - 2-element Extended PSA-
Version resistor tions version ground insulator version
from with Ni electrode tip
X 0,7 0,8 1,0 1,3 0,9 1,1 1,5 2,0 basic center
version electrode
R S T U V W X Y Z 0 1 2 4 9
AATC
Heat range
0C
Temperature
Too hot Adapted Too cold

Glow ignition 1 spark plug spark plug spark plug
1050
Safety range
900
2
Operating temperature
400
1 2 3
Self-cleaning limit
3
0 100%
Engine load
AATC
Heat range
AATC
Spark Plug -Bosch Super 4

The High Performance Spark Plug
What information is obtain from the

Type Number:
W = Types of seat and thread
56 = Heat ranges (5+6)
R = Burn-off resistor (1 kohm)

Special
Conductive
Seal Inner Sealing Ring
Centre
Electrode Ground Electrodes X4
AATC
Super 4 - Surface Air-Gap Technology
AATC
Spark Plug -Bosch Super Plus

The Innovative Spark Plug
Poin
ted
m grou
riu nd e
Y t t lectr
el- ode
ck
Ni y
allo
Resi
s tor
-> Centre electrode including Yttrium

in its alloy – Long life
-> High level of protection against
corrosion
-> Sharp ground electrode for better
ignition and burning
-> Outstanding ignition reliability
AATC
such as copying and passing on to third parties.
Super Plus - Yttrium in the Alloy

SUPER plus – Yttrium in the Alloy
• Yttrium extends life span i.e additional kilometers
AATC
Control Unit Diagnosis (KTS)
Why Diagnostics? Which area needs diagnostics?

Engine Management
SRS (Airbag)
Braking System (ABS/ASR/ESP/SBC)
Transmission
Immobilizer
Lighting (Litronic)
Instrumentation
Service reset
Oil Level Check
Oil Quality Check
Power Window
Air-conditioning
AND MOREW. Vehicle systems are getting very sophisticated
AATC
Control Unit Diagnosis (KTS)
How are we going to diagnose a modern vehicle?
Information Diagnostics
(ESI[tronic]) (KTS)
ESI[tronic] - Electronic Service Information
ESI[tronic] - Data and Structure

Motor-vehicle Mechanical
Automotive Equipment
Equipment
Motor-vehicle Circuit
Vehicle Diagnostics
Diagrams
Diesel Spare Parts Tecdoc Data
Electrical-system Spare
Automotive Service
Parts
Spare Parts Archive Diesel Test Specification
Component Repair
Work Unit
Instructions
KTS - Control Unit Diagnosis
KTS 650, 550 and 520 : testers Vehicle connection

Straightforward connection to the vehicle e.g. KTS 550
Serial
or
USB
Instrument leads OBD-diagnostics lead
AATC
Thank you for your attention !
AATC

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BASIC GASOLINE ENGINE MANAGEMENT

GASOLINE ENGINE MANAGEMENT

B. Gasoline engine management systems

ROBERT BOSCH (1861 – 1942)

Robert Bosch, born September 23, 1861

Low-Tension Voltage Magneto Ignition

Milestone of the Automotive Technology with BOSCH

1887 1902 1927 1952 1967 1976 1978

Bosch systems and products

Energy supply Braking systems Central electrics

Ignition Lighting systems Central electronics

Starters Wiper systems Car alarm systems

Diesel systems Heating

4-stroke petrol engine

1st Stroke 2nd Stroke 3rd Stroke 4th Stroke

System Development : Carburettor Engine

Injection Systems : Carburetor / Fuel Injection Systems

Carburettor Fuel injection

Injection Systems : External Mixture Formation

Multipoint fuel injection systems

A. Mechanical fuel injection systems

B. Combined mechanical-electronic fuel

C. Electronic fuel injection systems

Injection Systems : Internal Mixture Formation

Direct fuel injection systems

The History of Gasoline Injection

1973 L- and K-Jetronic

1989 Motronic ME (EGAS)

2000 Motronic MED7

The History of Gasoline Injection

The History of Gasoline Injection

The History of Gasoline Injection

Gutbrod Superior 700

The History of Gasoline Injection

Mercedes Benz 300 SL

The History of Gasoline Injection

The History of Gasoline Injection

6 1 Electric fuel pump

K-JETRONIC : SYSTEM OVERVIEW

The History of Gasoline Injection

L-Jetronic : System Overview

The History of Gasoline Injection

Hot-wire air-mass meter HLM

Hot-film air-mass meter HFM

The History of Gasoline Injection

KE-JETRONIC : SYSTEM OVERVIEW

K-Jet & KE-Jet Comparison

The History of Gasoline Injection

1 Electric fuel pump

Monojetronic: Central Injection Unit

The History of Gasoline Injection

1 Electric fuel pump

The History of Gasoline Injection

Source: GS/VSA 6401e

The History of Gasoline Injection

High-pressure Fuel rail

Air-mass meter with MAP sensor Pressure

Internal Mixture Formation : Gasoline DI Motronic MED 7

The Primary Function of Engine Management :

• To make available the torque requested by the driver

Stoichiometric air-fuel ratio:

actual inducted air quantity

The principle of Engine Control