238286736-Diesel-Common-Rail (1).ppt

Common-rail Diesel

Common-rail Diesel

Diagnosis Training

High-tech Diagnosis Course for Common-rail 

High-tech Diagnosis Course for Common-rail 

Goals

Goals

–

–

Reduce unnece

Reduce unnece

ssary replacing of

ssary replacing of

parts

parts

(NTF parts reaches 70% in some cases)

(NTF parts reaches 70% in some cases)

–

–

Reduce troubleshooting time

Reduce troubleshooting time

–

High-tech Diagnosis Course for Common-rail 

High-tech Diagnosis Course for Common-rail 

Goals

Goals

–

–

Reduce unnece

Reduce unnece

ssary replacing of

ssary replacing of

parts

parts

(NTF parts reaches 70% in some cases)

(NTF parts reaches 70% in some cases)

–

–

Reduce troubleshooting time

Reduce troubleshooting time

–

High-tech Diagnosis Course for Common-rail 

High-tech Diagnosis Course for Common-rail 

"b#ecti!es

"b#ecti!es

–

–

mpro!e system $noledge

mpro!e system $noledge

–

–

&earn 'T detection conditions

&earn 'T detection conditions

–

–

mplement structured and

mplement structured and

logic troubleshooting

logic troubleshooting

procedures

History of Common-rail System 

History of Common-rail System 

'ifferent !ariations on ommonrail

'ifferent !ariations on ommonrail

–

–

* Generations

* Generations

'

'

i

i

e

e

s

s

e

e

l

l

+

+

F

F









o

o

m

m

m

m

o

o

n

n





r

r

a

a

i

i

l

l

2nd-generation

2nd-generation

,

,

-.* /upply .ump

-.* /upply .ump

,

,

'i

'i

sc

sc

ha

ha

rge 

rge 

al

al

!e

!e

,

,

n#ector ompensation

n#ector ompensation

ode

ode

2nd-generation

2nd-generation

,

, -.* /upply .ump

-.* /upply .ump

,

, 'i

'isc

scha

harge 

rge al

al!e

!e

,

, n#ector ompensation

n#ector ompensation

ode

ode

135 - 160 MPa

135 - 160 MPa

3rd-generation

3rd-generation

,

,

N/R 1 '.NR

N/R 1 '.NR

,

,

.ie2o n#ector

.ie2o n#ector

3rd-generation

3rd-generation

,

, N/

N/R 1

R 1 '.

'.NR

NR

,

, .ie2o n#ector

.ie2o n#ector

160 - 180 MPa

160 - 180 MPa

1st-generation

1st-generation

,

,

ommonrail

ommonrail

,

,

-.3

-.3

/up

/up

pl

pl

y .

y .

um

um

p

p

,

,

/olenoid n#ector

/olenoid n#ector

1st-generation

1st-generation

,

, ommonrail

ommonrail

,

, -.3

-.3 /u

/uppl

pply .

y .um

ump

p

,

, /ol

/oleno

enoid 

id n#e

n#ect

ctor

or

135 MPa

135 MPa

Max. Max. Common-rail Pressure rail Pressure

System Ove

System Ove

rv

rv

iew 

iew 

ommonrai

ommonrai

l /ystem 'iagram (for

l /ystem 'iagram (for

4)

4)

Fuel .ressure Fuel .ressure /ensor /ensor .ressure .ressure &imiter &imiter /upply .ump /upply .ump //

+ngine

+ngine

+5

+5

Fuel Tan$ Fuel Tan$ n#ector n#ector

N+ /ignal

N+ /ignal

G /ignal

G /ignal

arious

arious

/ignals

/ignals

Common-rail Common-rail Fuel ooler Fuel ooler .ressure .ressure /itch /itch Fuel Fuel Filter Filter Fuel /ystem Fuel /ystem 6arning &ight 6arning &ight Other Injectors Other Injectors

+'5

+'5

System Overview 

4ain omponents for ommonrail /ystem

– /hon for the 8'FT engine on the 4

/upply .ump

,/ (/uction ontrol al!e) ,Fuel Temp9 /ensor

n#ector

Engine

Front 

n#ection .ipe

Fuel nlet .ipe

ommonrail

,Fuel .ressure /ensor ,.ressure &imiter

System Overview 

Features of ommonrail /ystem

-igh pressure fuel

-igh pressure fuel

/tores high pressure fuel

/tores high pressure fuel

n#ection pressure: !olume and

timing are controlled electrically

n#ection pressure: !olume and

timing are controlled electrically

, -igh performance and fuel economy

, &o noise and !ibration

, lean emission

-igh pressure in#ection in all

engine speed range

-igh pressure in#ection in all

engine speed range

-igher atomi2ation of fuel

-igher atomi2ation of fuel

-igh accuracy engine control

-igh accuracy engine control

System Overview 

/ensors and ;ctuators

;ir Flo 4eter ;tmospheric Temp9 /ensor

amshaft .osition /ensor

Intake Restrictor Valve (Step Motor)

lo! Plu" Turbo .ressure /ensor 6ater Temp9 /ensor Injector  ran$shaft .osition /ensor nta$e ;ir Temp9 /ensor VSV (#or $ur%o Pressure Sensor) &-VRV (#or &R

Valve Control) VSV (#or &R

Valve Close)

ECD System Components 

/upply .ump

– /upplies the high pressure fuel to the commonrail

HP2

HP3

Type

-.3 ("uter am)

-.* (nner cam)

Generation

st

3nd<*rd

/

3 (Time controlled)

 ('utycycle)

.lunger

= (Radial Type)

3 ("pposite type)

ECD System Components 

/upply .ump (-.*)

– Fuel flo

Click! Movie

ECD System Components 

/upply .ump (-.*)

– /uction and pumping operation

Click! Movie

ECD System Components 

/upply .ump (-.*)

– Fuel control operation (/ opening small)

Click! Movie

ECD System Components 

/upply .ump (-.*)

– Fuel control operation (/ opening large)

Click! Movie

ECD System Components 

/upply .ump (-.*)

– The / opening regulates the pumping !olume to

control fuel pressure

Controls SCV openin" Common-rail  pressure ('ee%ack) ;ccelerator .edal .osition /ensor /

Engine ECU

Fuel .ressure /ensor ran$shaft .osition /ensor

alculation of

target in#ection

pressure

[Fuel Pressure Control]

ECD System Components 

/upply .ump

– / signals

ECD System Components 

ommonrail

– Fuel pressure sensor (.R)

, 'etects the fuel pressure in commonrail and

pro!ides feedbac$

ommonrail

.ressure

/ensor Tip .ressure &imiter From /upply .ump

ommonrail To n#ector

ECD System Components 

ommonrail

– Fuel pressure sensor (.R)

0

@0

ommonrail .ressure (4.a)

90

=93

   "  u    t  p   u    t    0  o    l    t  a   g   e    (    0    )

Output characteristic

ECD System Components 

n#ector

– -igh pressure in#ection for higher atomi2ation

No22le

Needle

.iston

/olenoid

oil

Return to

'uel $ank 

'rom

Common-rail 

No22le

/pring

Click! Movie

No22le

/pring

No22le

Needle

Control

Cham%er 

/olenoid

oil

n#ector -ole

@ or A

n#ector .ressure

*B – A0 4.a

ECD System Components 

n#ector

– /mall in#ection hall (09= mm)

Click! Movie

"1# mm

[$o% o& 'n(ector]

ECD System Components 

n#ector

– 'ifference in the in#ection of gasoline and commonrail

[)asoline Engine]

[Common-rail Engine]

+ngine

+5

+lectricity Time      n    #  e   c    t    i  o  n    0  o    l  u  m   e +lectricity Time ommonrail .ressure +'5

+ngine

+5

onstant &o .ressure >;pproC9 09* 4.a? ariable -igh .ressure >*0 – @0 4.a? on" *i"h n#ection olume

ECD System Components 

n#ector

– n#ection !olume correction

, n#ector compensation code

DR ode

'n(ector

Com%ensation Code

&aser 4ar$ing

ompensation ode Type (DR ode)

E orrection .oint

;cti!ation .ulse orrection TD

     n    #  e  c    t    i  o  n    D  u   a   n    t    i    t  y

Hig* +oltage )eneration

Circuit

ECD System Components 

+'5

T 1H

E,U

Hattery

T3 T* T= F N N3 N* N= GN' GN' "4 ontrol ircuit    0  o    l    t  a   g   e

Time

B0

0

+ngine

+5

*i"h

Volta"e

ECD System Components 

+'5

– n#ector dri!e signals

T

N "4 F

ECD System Components 

"!er!ie +5 nputs

ran$shaft .osition /ensor (Ne) ;ccelerator .edal .osition /ensor (;)

nta$e ;ir Temp9 /ensor (T-;) 6ater Temp9 /ensor (T-6)

Fuel Temp9 /ensor (T-F) Turbo .ressure /ensor (.4)

ehicle /peed /ensor (/.') Fuel .ressure /ensor (.R)

gnition /itch (/T;) asic Parameters

Correction Parameters

Hloer /itch (H&6) ;< ;mplifier (;) ;lternator (;&T)

+ngine

+5

n#ector

+'5

+GR al!e '&* , , ,

ECD System Components 

"!er!ie +5 "utputs

n#ector (Timing and duration) /uction ontrol al!e

+'5 (.oer supply) nta$e Restrictor al!e

Glo .lug '&*

+ngine

+5

arious /ensor , , , +GR al!e

ECD System Components 

ran$shaft .osition /ensor (Ne)

ECD System Components 

;ccelerator .edal .osition /ensor (.;: .;3)

-all

s

ECD System Components 

Turbo .ressure /ensor (.4)

Turbo .ressure /ensor / (for Turbo .ressure /ensor)

+ngine

+5

ECD System Components 

+GR /ystem

– nta$e Restrictor al!e (Rotary /olenoid Type)

– ; Iuic$ response and high precise are reali2ed by

dri!ing a direct !al!e shaft

-all 

4agnet

4agnet

/teel &ayer

4agnet

nta$e Restrictor al!e

.osition /ensor

Rotary /olenoid Type

TorIue 4otor

ECD System Components 

+GR /ystem

– nta$e Restrictor al!e (Rotary /olenoid Type)

, nta$e restrictor shutter !al!e position sensor

nta$e /hutter al!e "pening ;ngle (deg)

   "  u    t  p   u    t    0  o    l    t  a   g   e    (    0    ) 0

+ngine

+5

 &5 -all  4agnet +3 0 (Full lose) 70  (Full "pen)

nta$e /hutter

al!e .osition

/ensor

 B 097 30 00 *9B

Common-rail Control Systems 

"!erall

– onsists mainly to parts: fuel metering part and fuel

supply part

[Electrical Part]

[Mec*anical Part]

/upply .ump n#ector +'5 arious /ensor

_{+ngine +5}

,n#ection olume ontrol ,n#ection Timing ontrol ,dle /peed ontrol

,Fuel .ressure ontrol

,n#ection rate ontrol ,Turbo ontrol

,+GR ontrol ,Glo ontrol ,'iagnosis

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection !olume decision

, +ngine +5 compares the basic and maCimum

in#ection !olumes: and determine the smaller

calculated !alue to be the final in#ection !olume

Engine ECU

+'5 n#ector Hasic n#ection olume 4aCimum n#ection olume Fuel .ressure ompensation alue n#ector Feedbac$ alue 'ecision on 'uration omparison

 ISC* Correction

Common-rail Control Systems 

Fuel n#ection olume ontrol

– Hasic in#ection !olume

Engine ECU

asic 'n(ection +olume

.Ma% ,ata in ECU/ asic 'n(ection +olume Correction ;ccelerator .edal .osition /ensor (.;) ran$shaft .osition /ensor (Ne)

6ater Temp9 /ensor (T-6) lutch /itch (&/6) ehicle /peed /ensor (/.')

JE dle /peed ontrol

0

Common-rail Control Systems 

Fuel n#ection olume ontrol

– Hasic in#ection !olume

Hasic

n#ection

olume

+ngine /peed

[asic 'n(ection +olume Pattern]

E ;mount of ;ccelerator

.edal +ffort (.;)

dle

0%

30%

*0%

B0%

00%

(Full &oad)

Overheating Protection

Common-rail Control Systems 

Fuel n#ection olume ontrol

– 4aCimum in#ection !olume

 Intae !ir Mass

Engine ECU

asicMaimum 'n(ection +olume .Ma% ,ata in ECU/

Maimum 'n(ection +olume

Correction

ran$shaft .osition /ensor (Ne)

;ir Flo 4eter (G) 6ater Temp9 /ensor (T-6)

Turbo .ressure /ensor (.4) nta$e ;ir Temp9 /ensor (T-;)

Fuel Temp9 /ensor (T-F) Fuel .ressure /ensor

Common-rail Control Systems 

Fuel n#ection olume ontrol

– 4aCimum in#ection !olume

+ngine /peed

[Maimum 'n(ection +olume Pattern]

nta$e ;ir

olumesmall

n#ection

olume

_{aries by}

ReIuired olume

nta$e ;ir

olumelarge

Common-rail Control Systems 

Fuel n#ection olume ontrol

– Final in#ection !olume decision

, ase of .; *0%

→

 /elects basic in#ection !olume

+ngine /peed

n#ection

olume

*0% .;

E Hasic n#ection olume

E 4aCimum n#ection olume

elects loest

[,etermining 'n(ection +olume]

Common-rail Control Systems 

Fuel n#ection olume ontrol

– Final in#ection !olume decision

, ase of .; 00%

→

 /elects 4aC9 in#ection !olume

+ngine /peed

[,etermining 'n(ection +olume]

n#ection

olume

00% .;

E Hasic n#ection olume

E 4aCimum n#ection olume

elects

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection !olume correction by inta$e air

['ntake 4ir Pressure Correction]

['ntake 4ir $em%" Correction]

orrection oefficient

Turbo .ressure /ensor "utput () 3 1 'ncrease ,ecrease orrection oefficient ,ecrease # 1

nta$e ;ir Temp9 (deg) "!erload .rotection

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection !olume correction by fuel temperature

[Fuel $em%" Correction]

orrection oefficient

Fuel Temperature (deg) 'ncrease

,ecrease 1

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection !olume correction by ater temperature

[5ater $em%" Correction]

orrection oefficient

6ater Temperature (deg) 'ncrease

# 1

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection duration

.ressure &imiter

+ngine

+5

N+ /ignal

G /ignal

arious

/ignals

Common-rail n#ector E,U

Fuel .ressure /ensor From

/upply .ump

'ecides opening time of in#ector by final in#ection !olume

ontrols opening timing of in#ector

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection duration

Engine ECU

+'5 n#ector Hasic n#ection olume 4aCimum n#ection olume omparison olume n#ector Feedbac$ alue n#ector ompensation alue N Time alculation Fuel .ressure

Common-rail Control Systems 

Fuel n#ection olume ontrol

– n#ection !olume control during starting

Engine ECU

asic 'n(ection +olume

Corrections 6ater Temp9 /ensor ran$shaft .osition /ensor

0

Startin" Injection Volume

gnition /itch (/T;) orrection

oefficient

6ater Temperature (deg) 'ncrease

# 1

Common-rail Control Systems 

Fuel n#ection Timing ontrol

– Hasic in#ection timing

(in#ection timing control after started)

Engine ECU

;ccelerator .edal .osition /ensor (.;) ran$shaft .osition /ensor (Ne)

0

+'5 n#ector 'n(ection $iming Correction

asic 'n(ection $iming

Turbo .ressure /ensor (.4) 6ater Temp9 /ensor (T-6) nta$e ;ir Temp9 /ensor (T-;)

Common-rail Control Systems 

Fuel n#ection Timing ontrol

– n#ection timing control during starting

Engine ECU

$arget 'n(ection $iming Correction

6ater Temp9 /ensor (T-6) gnition /itch (/T;) ran$shaft .osition /ensor

Common-rail Control Systems 

Fuel n#ection Timing ontrol

– n#ection timing corrections

, Target in#ection timing K Hasic timing 1 corrections

HT' (deg)

+ngine /peed (rpm) 16

[asic $arget 'n(ection $iming] E ;mount of ;ccelerator

.edal +ffort (.;)

Timing ;d!ance

(L;)

['ntake 4ir Pressure Correction]

nta$e ;ir .ressure (.4) E +ngine /peed

Timing ;d!ance

(L;)

[5ater $em%" Correction]

+ngine /peed (rpm) E 6ater Temp9 Full &oad &ight &oad -"T "&' -igh rpm &o rpm

Common-rail Control Systems 

dle /peed ontrol

– Target idle speed control

Engine ECU

ran$shaft .osition /ensor (Ne) 'n(ector

+olume Correction $arget Engine %eed

Calculation

4ctual Engine %eed

Com%arison

gnition /itch (/T;) ehicle /peed /ensor (/.')

6ater Temp9 /ensor (T-6)

;< ;mp9 >dleup /ignal? (;T) +lectric &oad

;ccelerator .edal .osition /ensor (.;)

Common-rail Control Systems 

dle /peed ontrol

– Feedbac$ correction

, dle speed fluctuations are detected by comparing

∆

t !alues

Cranks*a&t Position ensor ignal .7e/

Common-rail Control Systems 

Fuel .ressure ontrol

– Target in#ection fuel pressure

Controls SCV openin" Common-rail  pressure ('ee%ack) ;ccelerator .edal .osition /ensor /

Engine ECU

Fuel .ressure /ensor ran$shaft .osition /ensor Calculation o& target in(ection %ressure

Common-rail Control Systems 

Fuel .ressure ontrol

– Target in#ection fuel pressure

, To control target fuel pressure in commonrail by

/

Target n#ection Fuel .ressure

+ngine /peed (rpm)

E alculated Final n#ection olume 4;M

Common-rail Control Systems 

n#ection Rate ontrol

– n#ection rate control

ombustion .rocess n#ection Rate -eat Generation Rate gnition 'elay /mall .remiCture ombustion >.ilot n#ection? -igh n#ection Rate >'elta n#ection? /mall n#ection ;mount .rior to gnition T' -eat &arge .remiCture ombustion (N"C: Noise) mpro!ement

Common-rail Control Systems 

n#ection Rate ontrol

– .ilot in#ection

Engine ECU

ran$shaft .osition /ensor (Ne) +'5 n#ector 6ater Temp9 /ensor (T-6) Pilot 'n(ection

.+olume8 $iming8 'nterval/

Turbo .ressure /ensor (.4) nta$e ;ir Temp9 /ensor (T-;) ;ccelerator .edal

.osition /ensor (.;)

asic Pilot $iming

Common-rail Control Systems 

n#ection Rate ontrol

– 4ain in#ection timing

amshaft .osition

/ensor /ignal (G)

Fuel Duantity n#ection Timing

.ilot n#ection 4ain n#ection

Common-rail Control Systems 

"ther /ystem "peration

– +GR control system

nta$e Restrictor

al!e

nta$e Restrictor al!e .osition /ensor

nta$e Restrictor

al!e ontrol 4otor _Engine

ECU

+R

(for +GR !al!e control) acuum 'amper +GR al!e +GR al!e .osition /ensor Engine acuum .ump ran$shaft .osition /ensor ;ccelerator .edal .osition /ensor Turbo .ressure /ensor 6ater Temp9 /ensor

nta$e ;ir Temp9 /ensor

;tmospheric .ressure

Common-rail Control Systems 

"ther /ystem "peration

– nta$e restrictor !al!e control system

/tep 4otor

;ir N

Reduction Gears nta$e Restrictor al!e

Throttle al!e Fully "pened /itch

Common-rail Control Systems 

"ther /ystem "peration

– nta$e restrictor !al!e control system

nta$e Restrictor al!e nta$e Restrictor al!e .osition /ensor nta$e Restrictor al!e ontrol 4otor

Engine

ECU

;ccelerator .edal .osition /ensor (.;)

ran$shaft .osition /ensor (Ne)

6ater Temp9 /ensor (T-6) nta$e ;ir Temp9 /ensor

(T-;)

Turbo .ressure /ensor (.4) gnition /itch (/T;)