Classe de Injetor - Bosch

(1)

!

Why IQA?

!

What does IQA do?

!

Operating principles

!

IQA Adjustment Map

!

EOL programming

!

IQA accuracy

(2)

DS/P-IMA (EAC) 382 9973d_Wh IQA training

2 IQA - Injector Quantity Adjustment

Why IQA?

Euro 4

Euro 3

Euro 2

0 0,2

0,4

0,6

0,8

1,0

1,2

NOx + HC [g/km]

0,00

0,02

0,04

0,06

0,08

0,10

0,12

Pa

rticle [g

/km]

+/- 1 mm³/Str (MI) + 0,5 mm³/Str (PI) - 0,5 mm³/Str (PI)

Euro 4 - Application

+/- 1 mm³/Str

Euro 2 - Application

•The actual fuel quantity must be as exact as possible to reach the

emission limit values

(3)

Advantage of IQA is

!

To reach the emission limit values of the future

!

Equal injection fuel quantity for each cylinder

!

To increase the injector first pass yield (FPY) by widening the

production tolerances

!

Correction of the PI within the „plateau“ (i.e. CRI2)

!

Correction of the start of the injection

!

Correction of the drift of the injector (no closed-loop control)

(4)

4 IQA - Injector Quantity Adjustment

!

Correction of the fuel quantity of new injectors

!

Individual correction of tolerances at each point in the

characteristic map for each cylinder (injector)

!

Influence on the fuel quantity by

adjusting the energizing time (ET)

Operating principle IQA

Characteristics

px

p1

p2

Q (mm³)

ET (µs)

actual fuel

quantity of inj.

inj.tolerance for

correction

MV characteristic

(5)

Q

_MV

Quantity

[mm³]

ET [µs]

P = const.

Q

_MV

(ET)

The energizing time map in the ECU

characterises the behaviour of mean

value injectors in the engine.

Precondition:

ET

d

Q

d

ET

d

Q

d

_CRI

_MV

=

Q

_CRI

(ET)

ET

_IQA

∆ET

Q

_TP

Test Point

ET

_TP

∆Q

IMA

∆Q

IMA

=

Q

MV

- Q

TP

(6)

6 IQA - Determination of the adjustment map

!

Definition of the 4 inspection points ID, PI, EP, FL in agreement with the

customer and the injector development

!

Definition of a control duration map from the average of a batch of 25 injectors

- Additional pressure lines may be required

!

Definition of the additional measuring points for the available quantity values

Example

0 10 20 30 40 50 60 70 80 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

ET [ms]

F

u

el

Q

u

an

ti

ty

[m

m

³/

str

o

ke

]

250 bar 400 bar 800 bar 1200 bar 1600 bar

Additional Points

ID

EP

FL

PI

Inspection Points

(7)

0

10

20

30

40

50

60

70

80 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

ET [ms]

F

u

el

Q

u

an

ti

ty

[m

m

³/

str

.]

250 bar

400 bar

800 bar

1200 bar

1600 bar

Additional Points

ID

EP

FL

PI

Inspection Points

!

Selection of the most suitable matching points between inspection points and additional points

Chosen inspection point ID

•Fuel quantity tolerance at additional measuring point 1.98 *

_correction

value ID

PP VL 1600bar/900µs - 250bar/1280µs y = 0,4248x R2_{= 0,1663} -2 -1,5 -1 -0,5 0 0,5 1 1,5 2 -2 -1,5 -1 -0,5 0 0,5 1 1,5 2 PP VL 25 0b ar / 1280µ s PP LL 250bar/810µs _ 250bar/1280µs y = 1,9841x R2_{= 0,9576} -3,00 -2,00 -1,00 0,00 1,00 2,00 3,00 -3,00 -2,00 -1,00 0,00 1,00 2,00 3,00 PP LL 250 b ar /12 80 µs

FL

ID

(8)

8 IQA - Injector Quantity Adjustment

∆∆∆∆FL

0,83

*∆ID

∆∆∆∆ID

0,42

*∆ID

1,98

*∆ID

1,65

*∆ID

0,4

*∆FL

0,84

*∆EP

∆∆∆∆EP

0,45

*∆EP

0,42

*∆ID

0 1,2

*∆EP

1,3

*∆EP

0,9

*∆EP

0 1,65

*∆ID

0

250

400

800 1600

Fuel

Qua

n

ti

ty

[mm3]

Rail Pressure [bar]

0 PI

ID

EP

PL

IQA Adjustment Map

Weighting Factors

Inspection Points

FL

0 1,98

*∆ID

1,98

*∆ID

1,65

*∆ID

(9)

Control duration map

Calculation of ET

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5

q_desired

p_Rail

t ET

1600 bar 800 bar 600 bar 250 bar

E²PROM

Correction Value

∆ EP / ∆ID / ∆FL / ∆ PI /QS

individual for each injector

+

∆∆∆∆q

Flash PROM

InjVlv_stQntAdj_Map

shared for one type of

injector

∆ ∆∆ ∆FL 0,83*∆ID ∆ ∆∆ ∆ID 0,42*∆ID 1,99*∆ID 1,65*∆ID 0,4*∆FL 0,84*∆EP ∆ ∆∆ ∆EP 0,45*∆EP 0,42*∆ID 0 1,2*∆EP 1,3*∆EP 0,9*∆EP 0 1,65*∆ID 0 0 0 0 0 0 0 0 0 0 250 400 800 1600 M eng en w er t d er P rüf punk te [ mm3] ₀ Raildruck [bar] PI ID EP x*FL FL 0 1,99*∆ID 1,99*∆ID 1,65*∆ID

*

Operating principle in ECU

(10)

10 IQA - Operating Principle

Quantity energizing time map - without IQA

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 Ansteuerdauer [µs] 250 400 800 1200 1600

VL

+- 2,1 mm³

EM

+- 3,0 mm³

LL

+- 1,0 mm³

FL

EP

ID

Q

uanti

ty [m

m

³]

ET [µs]

(11)

Quantity energizing time map - with IQA

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 250 400 800 1200 1600

VL

+- 1,1 mm³

EM

+- 1,25 mm³

LL

+- 0,5 mm³

FL

EP

ID

Q

uanti

ty [m

m

³]

ET [µs]

(12)

12 IQA - Injector Quantity Adjustment

Influences on IQA accuracy

!

accuracy of measuring process

"

reproducibility of measurement (RM)

"

accuracy of measuring device

"

stability of injector:

i.e. sensitivity to backflow config., temperature,

test sequence, clamping ...

"

differences between test stations within one production

line and between different production lines (DTS)

!

accuracy of injector

"

quantity stability over lifetime

"

slope variation in the Quantity-ET map (DQ

_CRI

≠ DQ

_MV

) (SV)

"

maximum required correction value (RCV

_max

)

!

compatibility of the production quantity deviation to the

(13)

Code - Input

IQA - Coding

Labeling of injectors with

alpha-numeric and Data-Matrix-Code

Mounting of injectors and

reading of the IQA Code

Transmission of IQA Code into

ECU

Reduction of emission dispersion

in the engine

Implemented process for EOL-Programming

Customer

Bosch

(14)

14 IQA - Injector Quantity Adjustment

Perspective

!

IQA will be introduced in passenger cars in all future projects

!

The inspection points will be determinated by IQA (requirement for

high correlation to additional points)

!

Further optimisation of the IQA algorithm

"

correction of the slope variation

(15)

Summary

!

The IQA functionality is assigned to correct the injector quantity of

each injector of a Common-Rail-System individually and across the

complete range of the Q(ET) - map.

!

The input of the function are the ECU correction values. They

represent the difference to the nominal values of the respective test

point and will be encoded and labeled on top of each injector.

!

At the end of the automobile manufactur line, the ECU adjustment

values of the mounted injectors and the allocated cylinders are

programmed into the ECU.

(16)

16 IQA - Flow Chart for an application

Flow Chart for IMA applications

Time

Preparation

First application with IMA for this customer

Calibration of map

Validation

Presentation IMA Handling Service, EOL programming and after market D: 1 day; R:DS/VXY, DS/P-IMA; 1 1/2 year before customer SOP

EMI reference map of CRI in digital form to DS/EAC, DS/P-IMA

R:DS/EIM, DS/EIP

Information about the relevant working range of the engine

to DS/P-IMA and DS/EAC2 R:DS/Vxy

Determination of IMA addtional measuring points for the IMA adjustment map

R:DS/P-IMA, DS/EAC2

C- & D-sample lot R:BaW,HoW,RBTR Determination of average value R:DS/EIM, DS/EIP Measurement data to DS/P-IMA R:DS/EIM, DS/EIP Selection of 100 CRIs to measure the quantity at the

additional points R:DS/P-IMA, DS/EAC2 Determination of check sequence with addtional

measuring points R:DS/ECR-Ba

Measurement of CRIs R:DS/ECR-Ba

Delivery of nominal injector to customer R:DS/Vxy, DS/EIM, DS/EIP

Determination of ET map R:customer Measurement data to DS/P-IMA D: 1 w.; R:DS/ECR-Ba