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© 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. 1 Advanced Diesel Common Rail Injection System for Future Emission Legislation Roger Busch Common Rail System Engineering for PC Diesel Systems Robert Bosch GmbH 10th Diesel Emission Reduction Conference

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Page 1: Advanced Diesel Common Rail Injection System for · PDF fileAdvanced Diesel Common Rail Injection System ... Injector with hydraulic pressure ... Advanced Diesel Common Rail Injection

© 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.

1

Advanced Diesel Common Rail Injection System for Future Emission Legislation

Roger Busch

Common Rail System Engineering for PCDiesel SystemsRobert Bosch GmbH

10th Diesel Emission Reduction Conference

Page 2: Advanced Diesel Common Rail Injection System for · PDF fileAdvanced Diesel Common Rail Injection System ... Injector with hydraulic pressure ... Advanced Diesel Common Rail Injection

© 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.

2

• Drivers and Challenges for PC and LDT - Diesel

• Overall System Requirements for Advanced Common Rail

• BOSCH 4th Gen Common Rail Injection Systems

• Potential Evaluation of 4th Gen Common Rail Systems

Outlook

Page 3: Advanced Diesel Common Rail Injection System for · PDF fileAdvanced Diesel Common Rail Injection System ... Injector with hydraulic pressure ... Advanced Diesel Common Rail Injection

© 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.

3

Diesel System Innovations

Diesel Progress - PC

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4

13,0 kW/l

51 Nm/l

33 kW

9,5 l/100km

130 kW

6,5 l/100km

spec

. Tor

que

[Nm

/l]

spec. Power [kW/l]

Con

sum

ptio

n[l/

100

km]

eff. Power [kW]

1936

149 Nm/l

48,4 kW/l

2003

Diesel System Innovations

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Approval Data for PC - Diesel at least Euro 3

source: KBA Germany

Page 6: Advanced Diesel Common Rail Injection System for · PDF fileAdvanced Diesel Common Rail Injection System ... Injector with hydraulic pressure ... Advanced Diesel Common Rail Injection

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6

Diesel System Innovations

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7

• Drivers and Challenges for PC and Truck - Diesel

• Overall System Requirements for Advanced Common Rail

• BOSCH 4th Gen Common Rail Injection Systems

• Potential Evaluation of 4th Gen Common Rail Systems

DEER 20044th Gen Diesel Common Rail Injection System

Outlook

Page 8: Advanced Diesel Common Rail Injection System for · PDF fileAdvanced Diesel Common Rail Injection System ... Injector with hydraulic pressure ... Advanced Diesel Common Rail Injection

© 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.

8

PC Common Rail System 4th Generation

FIE Requirements EvaluationSensitivity analysis of important injection parameters for the engineperformance

Feature:1 Pilot injection (number, time gap, quantity, tolerance)2 Opening pressure, influence of pressure ramp, gradient3 Max. injection pressure, influence of small nozzle holes4 Pressure gradient during closing5 Post injection (near, late, influence of pressure level) 6 Opening and closing speed of the needle

1 2a

3

4

Pressure at the needle max. injection pressure

Time

2b

5

Needle lift

6a 6b

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9

FIE Requirement Evaluation - Summary

Potential Analysis for PC an LD-Combustion Process and FIE

„vario“ nozzlerate shaping

fast needle opening velocity but: injection rate during ignition delayinjection rate after start of combustion

Euro3

n = 2000/min, BMEP = 6,5 bar

Euro4

Euro4/ 3 1400 kg inertia weight0

1234567

Concept A

Concept B

Concept C

Concept D

Concept E

Concept F

Concept G

Concept H

Concept I

Concept K

Concept L

Concept M

NO

X[g

/kg]

Parti

cles

/ NO

x=

1/10

series applications

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10

"Euro 5" - Einspritzsystem4th Gen Diesel Common Rail Injection System

“Optimal” Shape for PC Engines

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11

full flexible timing of multiple injection events

full flexible choise of injection pressure in the engine map

small precise and stable injection quantities

DEER 20044th Gen Diesel Common Rail Injection System

still valid and well - known from series Common Rail

technology, gaining goals onnoise, power, Euro4 - emission and

maintaining EGT

CRS System Requirements for PC - Summary

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12

DEER 20044th Gen Diesel Common Rail Injection System

very fast needle opening @ start of injection

limited quantity during ignition delay, but

max. allowed injection rate to increase local air ratio

strong increase of injection rate after start of combustion

high maximum of main injection rate

strong rate decrease and fast needle @ end of injection

good spray formation

low Noise and NOx - formation

high spray momentum

increase EGR -acceptance

seperate injection and

burning phase

CRS System Requirements for PC - Summary

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13

• Drivers and Challenges for PC and Truck - Diesel

• Overall System Requirements for Advanced Common Rail

• BOSCH 4th Gen Common Rail Injection Systems

• Potential Evaluation of 4th Gen Common Rail Systems

DEER 20044th Gen Diesel Common Rail Injection System

Outlook

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14

PC Common Rail System 4th Generation

Injector -CharakteristicsBasis: CRI3Systempressure 1600/1800 barSpace requirement as CRI3One row for part loadBoth rows for full load

Piezo-Injector with Coaxial-Vario-Nozzle CRI4-PV

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15

4th Generation Common Rail System for PC

hydraulic flow / cyl. displacement[cm³/30s@100bar/dm³]

200 400 600 800 1000 1200 1400

101

98

95

92

898683

w/o PI

with PI

Com

bust

ion

Noi

se[d

B(A

)]

Avoidance of PI

(except for cold engine and idle)

Emission reduction

Reduction of QHYD

Noise reduction

Indepentantly switchable 2nd row

of spray holes

appropriate power outputCurrent Configuration Potential Vario Nozzle

NO

x[g

/kg]

*

12108

6420

w/o PI

with PI

n=2000rpm, BMEP=6,5bar

Vario Nozzle Strategies

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16

CRS 4 - Hydraulically Amplified Diesel Injection System

• Functions

Rail Pressure up to 1350 bar HAD - Injector with hydraulic pressure amplificationsophisticated closed loop fuel metering controlinnovative, delivery controlled high pressure pump platform

• Advantages

small Qhyd and passive rate shaping to pull down raw emissions and noise @ part loadmax pressure > 2200 bar @ spray hole to reach high power and reduce raw emissions @ full load (US 06, e.g. LD in EU)

DEER 20044th Gen Diesel Common Rail Injection System

Advanced Common Rail Systems for PC

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17

Injector-CharacteristicsSystem pressure up to 1.350bar Pressure amplification ≈1:2Pressure at the nozzle up to 2.200barPressure/lift controlled needleRamp rate shapeSpace requirements as CRI2Conventional nozzle

PC Common Rail System 4th Generation

Hydraulically Amplified Diesel Injector (HADI)

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18

CRS - Roadmap Pkw und Light Duty < 6t

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19

Advanced Control Functions

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20

Advanced Control Functions

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21

• Drivers and Challenges for PC and Truck - Diesel

• Overall System Requirements for Advanced Common Rail

• BOSCH 4th Gen Common Rail Injection Systems

• Potential Evaluation of 4th Gen Common Rail Systems

DEER 20044th Gen Diesel Common Rail Injection System

Outlook

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22

Common Rail System 4th Generation

Diesel System Optimization

EGT €FIE

Vehiclemass kW/l

EGT=exhaust gas treatment FIE= fuel injection equipment

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23

Europe

• next step in legislation: Euro 5• NEFZ - cycle *

** UBA - Requirement 06.2003

Diesel System Innovations

* no high load test under discussion

Scenario 1:

• PM = 0,01 g/km

• NOx = 0,2 g/km

• CO/HC = 1,0/0,05 g/km

Scenario 2:

• PM = 0,0025 g/km**

• NOx = 0,08 g/km**

• CO/HC = 1,0/0,05 g/km

Diesel Challenges - Emission Legislation PC

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24

0,10

0,20

0,15

NOx

g/km

0,05

0,140,12

Euro 5

CRS 3.01600 bar

CRS 3.21800 bar

Euro 5 - Estimation for PC

Scenario 2:

Scenario 1:

0,08

Eng. Goal

Eng. Goal

CRS 4 CRS 4

0,10

25 %

35 %

55 %47 %

36 %

withDPFNSC

„Euro 4 - engines“ „Euro 5 - engines“ &low ε , TC2, pHCCI ...

Euro 5 Estimation, Vehicle Inertia Mass: 1400 kg, out of best single cylinder results with series and prototype FIE

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25

0,10

0,20

0,15

NOx

g/km

0,05

Euro 5

CRS 3.01600 bar

CRS 3.21800 bar

Euro 5 - Estimation for PC

Scenario 2:

Scenario 1:

0,08

Eng. Goal

Eng. Goal

CRS 4 CRS 4

25 %

35 %

„Euro 4 - engines“ „Euro 5 - engines“ &low ε, TC2,pHCCI ...

0,19

0,22

0,15

withDPFNSC

58 %

71 %

66 %

36 %

Euro 5 Estimation, Vehicle Inertia Mass: 1800 kg, out of best single cylinder results with series and prototype FIE

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26

• Facing a weak Euro 5 - scenario (NOx = 0,2 g/km) it‘s most likely to fulfill the limits w/o DeNOx - measures, also with „Euro 4 - engines“

DEER 2004Common Rail Potential Evaluation for PC

• Facing a severe Euro 5 - scenario (NOx = 0,08 g/km) and „Euro 4 -engines“ a DeNOx - measure seems to be mandatory. The DeNOx -effort can significantly be reduced using high tech CR - systems

• First results out of advanced „Euro 5 - engine“ - technology combinedwith engine measures (e.g. pHCCI, TC2 ) and CRS4 - FIE shows tremendeous improvement in NOx - reduction

• Additonal EGT - effort scales with CRS - performance, vehicle weightand desired power output

Summary PC

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27

• The biggest challenge for future Diesel technology are thecontiniously strengthenend emission targets

DEER 20044th Gen Diesel Common Rail Injection System

• 4th Gen Common Rail Injection Systems combinded with modern Diesel engines provide lowest raw emissions and fuel consumption values.

• Key factors like power output, vehicle weight and the engine itself scaling the effort on exhaust gas treatment side

Conclusion

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28

10th Diesel Emission Reduction Conference

Thank you for your attention.

BOSCH