Diesel Systems

CRS3.3i

the direct needle

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Diesel Systems

CRI3.3i CR Piezo Injector Direct Needle Actuation

CRI3.3i (2000 bar): RB-SOP not decided yet Customer Benefit: Emissions
direct actuated nozzle needle highest needle dynamics hydraulic buffer volume highest multiple injection flexibility minimum PI quantity (0.5 0.8 mm3/S) closed loop control
HP connector

Electrical connection

Fuel consumption
close couple combustion concept no fuel return

Power & Torque

more injected fuel quantity in less time maximum engine power + torque output
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Diesel Systems CRS3.3i Systemlayout

Metering unit ZME

Pressure regulating valve DRV3.3

Rail pressure sensor RDS4.3

Rail (LWR3.3)

High pressure pump CP4.1

Fuel filter

PiezoInjector CRI 3.3i (1...n)

Control unit EDC 17

Tank

Electrical presupply pump EKP Prefilter

Tank

New
EKP pressure high pressure backflow pressure

Diesel Systems
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CRS3.3i Function Schematic

U [V]
200V 0V 2000 Voltage at Piezo actuator

pressure [bar]

1500

1000

coupler volume before nozzle sack hole

500

nozzle (pressure chamber) sackhole coupler volume injector (actuator chamber) before nozzle coupler chamber

sack hole
0

time scale

Diesel Systems
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CRI3.3i - Results

CRI3.3i Hydraulic Results Injection Rate

CRI3.x CRI3.3i 1000 bar / 40.0 mm

injectionP_EVI [bar]signal (-) rate

20

15

10

-5 0 1 2 3 4

Advantage CRI3.3i: fast needle opening/closing increased steepness minimized throtteling effects square shaped injection rate

crank angle ()

5 6 Kurbelwinkel [Grad]

10

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CRS3.3i

Hydraulic Results Characteristic Injection Map

120

180V
100

0V

2000 bar 1600 bar

Menge HE [mm/Hub]

80

1200 bar

Q (mm3/S)

60

800 bar

40

200 bar
20

0 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 Dauer HE [ms]
1.Q=f(AD)_7461_0003A.xls 1.Q=f(AD)_7461_0008A.xls 1.Q=f(AD)_7461_0004.xls 1.Q=f(AD)_7461_0010A.xls 1.Q=f(AD)_7461_0005A.xls 1.Q=f(AD)_7461_0011A.xls 1.Q=f(AD)_7461_0006A.xls 1.Q=f(AD)_7461_0012A.xls 1.Q=f(AD)_7461_0007A.xls 1.Q=f(AD)_7461_0013A.xls

ET (ms)

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CRI3.3i - Results
100 2000 bar 90 80 1800 bar 1600 bar 1400 bar 1200 bar

200V

quantity (MI) [mm3/H]

70 60 50 40 30 20 10 0 0,0

0V

1000 bar 800 bar 600 bar 400 bar 250 bar 200 bar

ca. 0,13mm/s
(ca. 0,05mm/s CRI3.3)

0 50 75 100 125 150 175 200

0,5

1,0

1,5

2,0

2,5

AD (MI) [ms]

Sehr gute delivery possible Small PI quantitiy Kennfeldlinearitt Sehr gute PI quantity map, energizing concept has (IMA,) High steepness ofVoraussetzung fr Korrelationsfunktionen to be optimized
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CRI3.3i - Results Comparison stroke/stroke-deviation CRI3.x-CRI3.3i Vergleich H/H-Streuung CRI3.3 zu CRI3.3i

7 6,5 6 5,5 Hub/Hub-Streuung [mm/H] 1600bar CRI3.3 300bar CRI3.3 1200bar Inj.CRI-PDN A1.2 1200bar CRI3.3 1600bar Inj.CRI-PDN A1.2 300bar Inj.CRI-PDN A1.2

s/s-deviation [mm/s]

5 4,5 4 3,5 3 H/H (1200bar)= H/H-3mm/H. 2,5 2 1,5 1 0,5 0 0 200 400 H/H (300bar)= H/H-1mm/H. H/H (1600bar)= H/H-3mm/H.

stroke/stroke-deviation independent of energizing time

energizing time [s] Ansteuerdauer [s]
600 800 1000 1200

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CRS3.3i

Hydraulic Results Characteristic Map EDC17

10 2000bar (Offset = +9 mm)

* * * * * * ** * ** ** ** **

** **

2000 bar

1800bar (Offset = +8 mm)

1800 bar

1600bar (Offset = +7 mm)

1600 bar

S/S spread (mm3/S) Hub/Hub-Streuung [mm/H]

1400bar (Offset = +6 mm)

1400 bar

1200bar (Offset = +5 mm)

1200 bar

5 1000bar (Offset = +4 mm) 4 800bar (Offset = +3 mm) 3 600bar (Offset = +2 mm) 2 400bar (Offset = +1 mm)

1000 bar

800 bar

* ** **

600 bar

*
1 200bar (Offset = +0 mm)

400 bar

0 0 100 200

* **
300 400 500 600 700
Schrittweite 1s

200 bar

*Teilhub

**Vollhub

Schrittweite 10s

800 900 Ansteuerdauer [s]

1000

1100

1200

1300

1400

1500

ET (s)

50Hub-Messung EMI

10

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CRS3.3i

Hydraulic Results Inj/ Inj + S/S Spread

90 2mm/H.@1200bar 50mm/H.@2000bar 2mm/H.@2000bar 0,9 20mm/H.@800bar 80mm/H.@1400bar 80 0,8 7mm/H.@250bar

70 Einspritzmenge [mm/H]

1,5mm/H.@800bar

0,7

60

0,6

50

0,5

40

0,4

30

0,3

20

0,2

10

0,1

0 1 2 3 4 Prfpunkt [Nr.] Test Points

Q 7461_0003A 3s H/H 7461_0003A Q 7461_0004A 3s H/H 7461_0004A Q 7461_0005A 3s H/H 7461_0005A Q 7461_0006A 3s H/H 7461_0006A Q 7461_0007A 3s H/H 7461_0007A Q 7461_0008A 3s H/H 7461_0008A Q 7461_0010A 3s H/H 7461_0010A Q 7461_0011A 3s H/H 7461_0011A Q 7461_0012A 3s H/H 7461_0012A

0 5 6 7

Q 7461_0013A 3s H/H 7461_0013A

11

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S/S spread (mm3/S)

Hub/Hub-Streuung [mm/H]

Q (mm3/S)

Diesel Systems

CRI3.3i Hydraulic Results Pressure Waves

CRI3.3i CRI3.0

Advantage CRS3.3i: strongly reduced pressure wave amplitudes free applicable injection distances, no PWC highest flexibility Less SW function efforts
1000 bar /

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CRI3.3i lifetime
fuel mass

NVC
voltage

x I 3. CR

initial classification
fuel mass

temperature
stroke U

ISA
voltage

temp.

They finally can enable to be used as on-board sensor in a closed-loop control structure.

ET rpm p

Piezo injectors require precise activation/charging as a function of rail pressure, temperature, lifetime, etc.

init-/ starting-time

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polarization

cold start

CRI3.3i - Results

CRI3.3i needle sensor feasibility

70 60 50 Einspritzmenge [mm/H]

ca. 3mm

1500bar

1000bar 40

70
30 500bar

U [V]

Aktorhub: 78m 86m

2000bar

time [s]

2000bar

60
20

ca. <1mm
50

1500bar

10

without governor
40
0 100 300 500 700 Ansteuerdauer [s] 900 1100

Einspritzmenge [mm/H]

1000bar

30

500bar

20

With active governor almost no quantity difference

10

with governor
300 500 700 Ansteuerdauer [s] 900 1100

0 100

14

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Common Rail System CRS3.3i

Status 09/07
Project Internal A-sample successfully tested CRI Test Bench: > up to 2000h reached Engine Test: > up to 400h cumulated Technology Functional Concept Actuator Module Design ECU control functions applicable Q-Hyd range > 880ccm
Optimisation Step: Improvement of CRI Hydraulics and Actuator
A6-sample

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CRI3.3i at one sight

Summary of hydraulic results:

extreme linear injection map small sample deviation very small shot to shot spread step injection rate closed couple PI reduced pressure wave oscillations reduced quantity wave amplitude improved accuracy (at free distance: +/- 0,5 mm3/S) no rail throttles and PWC closed PI possible
Diesel Systems
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quantity

962_01 962_03 962_05 962_06 962_11 962_12 962_13 962_14 962_15 962_16

CRI3.3i CRI3.x

CRI3.3i CRI3.x

S/S
EM
1200 1000 800 600 400 200 0 -200 -400 -600 -800 -1000

energizing time

VE

LL

VL

injection rate

time scale

injection rate

time scale

CRS3.3i CRS3.0

distance PI-MI

injection rate

quantity

time scale

CRS3.3i

Costumer benefit with CRS3.3i:

slightly reduced fuel consumption:
a) reduced pump torque due to lack of fuel return b) possibility of closed PI-strategy

optimized multiple injection capability reduced quantity drift

means smaller tolerances means slightly reduced engineering target concerning emissions

Potential of no PWC due to reduced pressure wave oscillations potential to omit fuel cooler in critical applications no fuel return lines from injectors

do the benefits justify the add-on costs ?

Diesel Systems
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CRI3.3i

Conclusion
CRS3.3i technically feasible; though fuel-resistant piezo stack is
a challenge long piezo stack is driving costs of system (stack and ECU) higher compared to CRS3.x, but market demands lower costs reducing piezo length would require higher transition ratio either hydraulically (coupler) or mechanically higher transition ratio means less stiffness (reduced performance) system more sensitive toward tolerances

higher tolerance sensitivity means more critical over lifetime more critical injector/injector Bosch conclusion: CRI3.3i is the right approach to get the best injector performance CRI piezo direct is no favorable business case for customer / Bosch Bosch is developing advanced solenoid CR systems (CRS2.5,6,7)
21
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CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD<6t

High Pressure CR System

CRS Premium line

Piezo Valve CR System

0 ms*

CRS-HP > 2200bar

CRS3.3 2000 bar CRS3.2 1800 bar

0 ms*

CRS Top line

Solenoid Valve CR System

CRS3.0 1600 bar CRS2.7 2200 bar CRS2.6 2000 bar CRS2.5 1800 bar

CRS High line CRS Mid line

Adv. Multiple Injection: 0 ms*

CRS2.2 1600 bar, CRS2.0 1450 bar

0,2 ms**

CRS Base line

0,8 ms**

CRS1.x 1400 / 1450 bar CRS for LPV / EME

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

* **

Safety margin 50 s Typical values

22

Streng vertraulich | B2978_4e - DS/EVL2-Gu | 26.06.2007 | B2978_4e.ppt | Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.