10_16_2007_Cummins_CRS3.3i(2)

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1 Diesel Systems

CRS3.3i

needle

… the direct

Strictly confidential | 0281_Ze DS_PC/PJ-ECI| 07.08.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Diesel Systems

CRI3.3i CR Piezo Injector – Direct Needle Actuation

HP connector

Electrical

connection

CRI3.3i (2000 bar): RB-SOP not decided yet

Customer Benefit:

Emissions

Ð

• direct actuated nozzle needle

⇒ highest needle dynamics

• hydraulic buffer volume

⇒ highest multiple injection flexibility

• minimum PI quantity (0.5 – 0.8 mm

3 _/S)

• closed loop control

Fuel consumption

Ð

• close couple combustion concept

• no fuel return

Power & Torque

Ï

• more injected fuel quantity in less time

• maximum engine power + torque output

Internal | DS-PC/PJ-ECI | 25.07./2007 | 0277_Ze | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Diesel Systems – CRS3.3i Systemlayout

Tank

Control unit

EDC 17

Prefilter

Fuel filter

high pressure

backflow

pressure

Pressure regulating valve

DRV3.3

Tank

Electrical

presupply

pump

EKP

Piezo-Injector

CRI 3.3i

(1...n)

Metering

unit

ZME

Rail pressure

sensor RDS4.3

EKP pressure

Rail (LWR3.3)

High

pressure

pump

CP4.1

New

Diesel Systems

Vertraulich | DS/ECP2-Kc | 21.11.2005 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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CRS3.3i Function Schematic

nozzle (pressure chamber)

sackhole

injector (actuator chamber)

coupler chamber

pres

sure [bar] U [V]

2000

1500

1000

500

0 coupler volume

before nozzle

sack hole

Voltage at Piezo actuator

200V

0 V

before

nozzle

sack hole

coupler

volume

time scale

Diesel Systems

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CRI3.3i - Results

CRI3.x

CRI3.3i

0 1 2 3 4 5 6 7 8 9 10 Kurbelwinkel [Grad] P_EVI [bar ] -5 0 5 10 15 20

1000 bar / 40.0 mm³

CRI3.3i Hydraulic Results – Injection Rate

crank angle (°)

in

je

ct

ion

ra

te

sign

al

(-)

Advantage CRI3.3i:

• fast needle opening/closing

• increased steepness

• minimized throtteling effects

• square shaped injection rate

Strictly confidential | DS/EIP2 | 01.05.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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7 CRS3.3i

Hydraulic Results – Characteristic Injection Map

0

20

40

60

80

100

120

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]

Meng

e HE

[mm

³/Hu

b

]

1.Q=f(AD)_7461_0003A.xls 1.Q=f(AD)_7461_0004.xls 1.Q=f(AD)_7461_0005A.xls 1.Q=f(AD)_7461_0006A.xls 1.Q=f(AD)_7461_0007A.xls 1.Q=f(AD)_7461_0008A.xls 1.Q=f(AD)_7461_0010A.xls 1.Q=f(AD)_7461_0011A.xls 1.Q=f(AD)_7461_0012A.xls 1.Q=f(AD)_7461_0013A.xls

2000 bar

1600 bar

1200 bar

800 bar

200 bar

180V

0V

Q (mm3/S)

ET (ms)

Strictly confidential | DS/PJ-ECI 0208_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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CRI3.3i - Results

0

10

20

30

40

50

60

70

80

90

100 0,0

0,5

1,0

1,5

2,0

2,5

2000 bar

1800 bar

1600 bar

1400 bar

1200 bar

1000 bar

800 bar

600 bar

400 bar

250 bar

200 bar

Î

Sehr gute Kennfeldlinearität

Î

Sehr gute Voraussetzung für Korrelationsfunktionen (IMA,…)

AD (MI) [ms]

quantity (MI) [mm

3 /H]

0

1

2

3

4

5

50

75

100

125

150

175

200 Î

Small PI quantitiy delivery possible

Î

High steepness of PI quantity map, energizing concept has to be optimized

200V

0V

ca. 0,13mm³/µs

(ca. 0,05mm³/µs CRI3.3)

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CRI3.3i - Results

Vergleich H/H-Streuung CRI3.3 zu CRI3.3i

0 0,5

1 1,5

2 2,5

3 3,5

4 4,5

5 5,5

6 6,5

7

0

200

400

600

800 1000

1200

Ansteuerdauer [µs]

Hub/Hub-Stre

uung [

m

m³/H]

1600bar CRI3.3

1200bar CRI3.3

300bar CRI3.3

1600bar Inj.CRI-PDN A1.2

1200bar Inj.CRI-PDN A1.2

300bar Inj.CRI-PDN A1.2

H/H (300bar)= H/H-1mm³/H.

H/H (1200bar)= H/H-3mm³/H.

H/H (1600bar)= H/H-3mm³/H.

Comparison stroke/stroke-deviation CRI3.x-CRI3.3i

s/s-deviation

[mm³/s]

energizing time [µs]

Î

stroke/stroke-deviation independent of energizing time

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10 CRS3.3i

Hydraulic Results – Characteristic Map EDC17

0 1 2 3 4 5 6 7 8 9 10 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Ansteuerdauer [µs] Hu b/Hu b-S tre uu ng [mm ³/H] 2000 bar 1800 bar 1600 bar 1400 bar 1200 bar 1000 bar 800 bar 600 bar 400 bar 200 bar 200bar (Offset = +0 mm³) 400bar (Offset = +1 mm³) 600bar (Offset = +2 mm³) 800bar (Offset = +3 mm³) 1000bar (Offset = +4 mm³) 1200bar (Offset = +5 mm³) 1400bar (Offset = +6 mm³) 1600bar (Offset = +7 mm³) 1800bar (Offset = +8 mm³) 2000bar (Offset = +9 mm³) 50Hub-Messung EMI

*

Teilhub

Schrittweite 1µs

**

Vollhub

Schrittweite 10µs

*

**

S/

S spread (mm3/S)

ET (µs)

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11 CRS3.3i

Hydraulic Results – Inj/ Inj + S/S Spread

0

10

20

30

40

50

60

70

80

90

1

2

3

4

5

6

7 Prüfpunkt [Nr.]

Ein

spr

itz

m

en

ge [

m

m³

/H]

0 0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

H

u

b/

Hu

b-S

tr

eu

u

n

g

[mm³/H

]

Q 7461_0003A Q 7461_0004A Q 7461_0005A Q 7461_0006A Q 7461_0007A Q 7461_0008A Q 7461_0010A Q 7461_0011A Q 7461_0012A Q 7461_0013A 3s H/H 7461_0003A 3s H/H 7461_0004A 3s H/H 7461_0005A 3s H/H 7461_0006A 3s H/H 7461_0007A 3s H/H 7461_0008A 3s H/H 7461_0010A 3s H/H 7461_0011A 3s H/H 7461_0012A 3s H/H 7461_0013A

20 m

m

³/H

.@800b

ar

2mm³/H.@120

0bar

7 m

m³/H

.@250b

ar

50 m

m

³/H

.@2000

bar

2 m

m³/H

.@2000

bar

1 ,5

m

m³/H

.@800b

ar

80 mm

³/H.@1400

bar

Q (mm3/S)

Test Points

S/

S spread (mm3/S)

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Diesel Systems

1000 bar /

CRI3.3i

CRI3.0

Advantage CRS3.3i:

Î

strongly reduced pressure wave amplitudes

Æ free applicable injection distances, no PWC

Æ highest flexibility

Î

Less SW function efforts

CRI3.3i Hydraulic Results – Pressure Waves

Streng vertraulich | Department | 03.2007 | 783d_0596_Sk | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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CRI3.3i

NVC

fuel

mass

ISA

voltage

fuel

mass

voltage

polarization

ET

rpm

p

init-/

starting-time

stroke

temp.

U

CR

I3.x

• Piezo injectors require precise activation/charging

as a function of rail pressure, temperature, lifetime, etc.

• They finally can enable to be used as

„on-board sensor“ in a closed-loop control structure.

initial classification

lifetime

temperature

cold start

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14 CRI3.3i - Results

CRI3.3i – needle sensor feasibility

0 10 20 30 40 50 60 70 100 300 500 700 900 1100 Ansteuerdauer [µs] E inspri tzmenge [ m m³ /H ] 2000bar 1500bar 1000bar 500bar

with governor

ca. <1mm³

Î

With active governor

almost no quantity difference

0 10 20 30 40 50 60 70 100 300 500 700 900 1100 Ansteuerdauer [µs] E in s pritz m eng e [mm ³/H] 2000bar 1500bar 1000bar 500bar

ca. 3mm³

without governor

78µm

86µm

Aktorhub:

U [V]

time [s]

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Common Rail System CRS3.3i

Status 09/07

A6-sample

Project

z

Internal A-sample successfully tested

z

CRI Test Bench: > up to 2000h reached

z

Engine Test:

> up to 400h cumulated

☺

Technology

Î

Functional Concept

Î

Actuator Module Design

Î

ECU control functions

Î

applicable Q-Hyd range > 880ccm

Optimisation Step: Improvement of CRI Hydraulics

and Actuator

Strictly confidential | DS/PJ-ECI 0228_Ze, 0185_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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CRI3.3i at one sight

Summary of hydraulic results:

CRI3.3i CRI3.x

EM VE LL VL

S/S

CRI3.3i

CRI3.x

Î

extreme linear injection map

Î

small sample deviation

Î

very small shot to shot

spread

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

energizing time

quantity

Î

step injection rate

Î

closed couple PI

Î

reduced pressure wave

oscillations

-1000 -800 -600 -400 -200 0 200 400 600 800 1000 1200

inj

ection rate

inj

ection rate

time scale

Strictly confidential | DS/PJ-EII | 0096_Pa_587 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel Systems

distance PI-MI

quantity

Î

reduced quantity wave amplitude

Î

improved accuracy

(at free distance: +/- 0,5 mm

3 _/S)

Î

no rail throttles and PWC

Î

„closed PI“ possible

inj

ection rate

CRS3.3i CRS3.0

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CRS3.3i

Costumer benefit with CRS3.3i:

Î

slightly reduced fuel consumption:

a) reduced pump torque due to lack of fuel return

b) possibility of closed PI-strategy

Î

optimized multiple injection capability

Î

reduced quantity drift

Æ

means smaller tolerances

Æ

means slightly reduced engineering target concerning emissions

Î

Potential of no PWC due to reduced pressure wave oscillations

Î

potential to omit fuel cooler in critical applications

Î

no fuel return lines from injectors

do the benefits justify the add-on costs ?

Diesel Systems

Strictly confidential | DS/PJ-EII | 0214_Ze; 0096_Pa_587 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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21 CRI3.3i

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

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)

• CRI piezo direct is no favorable business case for customer / Bosch

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22 CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD<6t

High Pressure CR System

*

Safety margin 50 µs

**

Typical values

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

CRS3.2 1800 bar

CRS3.0 1600 bar

CRS2.5 1800 bar

CRS2.2 1600 bar, CRS2.0 1450 bar

CRS3.3 2000 bar

Solenoid Valve CR System

Piezo Valve CR System

CRS Premium line

CRS Top line

CRS High line

CRS Mid line

CRS Base line

0 ms*

Adv. Multiple Injection: 0 ms*

0,2 ms**

CRS1.x 1400 / 1450 bar

CRS for LPV / EME

0,8 ms**

CRS2.6 2000 bar

0 ms*

CRS2.7 2200 bar

CRS-HP

> 2200bar

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