Microsoft PowerPoint - Common Rail_bosch_bbr.ppt [相容模式]

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1 BOSCH 共軌噴射燃料系統 Common Rail System 林振江施保重丞雄實業有限公司 Autowin Industrial Corp 初稿 :2004/04/06 修改 :2007/06/26 市場主流歐洲 : Bosch CRS BMW, RENAULT, BENZ, VW, VOLVO, 亞洲 : KIA, Hyundai, Mitsubishi 1

2 Bosch CRS for passenger cars Bosch Common Rail System for passenger cars (1 st ) Source: Bosch Bosch CRS for 8-Cylinder passenger cars V8 Diesel Engine (1 st ) Source: Bosch 2

共軌高壓洩油壓力調節 PCV EURO 3 高壓泵進油流量調節 PCV* 2 + 共軌高壓洩油壓力調節 PCV EURO 4 3 VGT 壓電式 1600bar 1800bar 同上

3 Bosch CRS for 6-Cylinder Trucks Bosch CRS 代別概要代別 1 Turbo charger 噴油嘴噴射壓力預供泵 ( 低壓泵 ) 壓力調節 WGT 機械泵 * 1 高壓泵出油流量調節 PCV 或電磁式 1350bar 或或 VGT 電動泵共軌高壓洩油壓力調節 PCV 法規 EURO 2 2 WGT 或 VGT 電磁式 1600bar 同上共軌高壓洩油壓力調節 PCV EURO 3 高壓泵進油流量調節 PCV* 2 + 共軌高壓洩油壓力調節 PCV EURO 4 3 VGT 壓電式 1600bar 1800bar 同上高壓泵進油流量調節 PCV* 2 + 共軌高壓洩油壓力調節 PCV EURO 4 EURO 5 * 1 使用在大排氣量引擎上 * 2 又稱 MPROP 或 IMV, 低壓流量調節 3

4 Bosch Common Rail injection system Milestones of development 2002: 1997: 2nd First generation Common Rail Common system Rail in the for world trucks for gives passenger lower emissions, cars. Injection improved pressure: fuel consumption 1,350 bar. and more power. Injection First production pressure: use: 1,600 Alfa Romeo bar. and Mercedes-Benz. First production use: MAN. 1999: 2003: Common Rail system for trucks. 3rd Injection generation pressure: Common 1,400Rail bar. with rapid-switch piezo inline injectors for First cars. production use: Renault (RVI). Advantages: up to 20 % lower emissions or up to 5 % more power 2001: or up to 3 % lower fuel consumption or up to 3 db(a) less engine noise. 2nd generation Common Rail for passenger cars makes diesel engines Injection even pressure: more 1,600 economical, bar. cleaner, quieter and more powerful. First Injection production pressure: use: 1,600 Audi. bar. First production use: Volvo and BMW 4th generation of Common Rail for passenger cars 2002: Bosch is currently exploring designs. Using 2nd generation even higher Common injection Rail pressures for trucks of gives more lower than 2,000 emissions, bar. improved fuel consumption and more power. Injectors with variable injection geometry. Injection pressure: 1,600 bar. First production use: MAN. Bosch Common Rail injection system Milestones of development 2003: 3rd generation Common Rail System with rapid-switch piezoelectric inline injectors for cars was announced at the Frankfurt Show And it has actually been in production since May of Injection pressure: It is 1,600 bar, same as for the 2nd generation, when this generation CRS was introduced. Subsequently, it was changed up to 1,800 bar. First production use: Audi A8. 4th generation of Common Rail for passenger cars Bosch is currently exploring designs. Using even higher injection pressures of more than 2,000 bar. Injectors with variable injection geometry. 4

根據共軌壓力感知器傳來的共軌油壓訊號來驅動壓力控制閥當油過高時, 壓力控制閥打開, 燃油流回油箱為了控制精確控制共軌中的油壓, ECM 採 DUTY CYCLE(1kHz)

5 Common rail fuel-injection system High Pressure Circuit 產生和儲存高壓柴油經過濾器送至高壓泵加壓並輸送到高壓蓄壓器 ( 共軌 ) 中儲存儲存在中的柴油壓力最高可達 1,350 ~ 1800bar 閉迴路控制共軌中的柴油壓力由共軌壓力感知器偵測高壓蓄壓器 ( 共軌 ) 的油壓 ECM 根據共軌壓力感知器傳來的共軌油壓訊號來驅動壓力控制閥當油過高時, 壓力控制閥打開, 燃油流回油箱為了控制精確控制共軌中的油壓, ECM 採 DUTY CYCLE(1kHz) 的方式驅動它, 使每一次的柴油取自高壓蓄壓器的燃油噴射, 都能維持一定, 確保不會超過或低於期望值柴油噴射由 ECM 控制柴油都是取自於高壓蓄壓器的高壓柴油, 然後直接噴入燃燒室中 5

6 Type 1: 2: MPROP Pre-Supply Pump Pre-supply pump Supply pump Source: Bosch High Pressure Pump Also called: Supply Pump Model : Rotary Type : Bosch 6

7 Common Rail Assy 壓力感知器 Common Rail Pressure Sensor 壓力控制閥 Pressure control valve Common Rail Assy 壓力感知器 Common Rail Pressure Sensor 壓力控制閥 Pressure control valve Source: Hyundai 7

generation 功能 : 依 ECU 的送來的控制訊號將來自共管的高壓燃料霧化直接噴入燃燒室中噴油嘴控制方式

8 高壓油泵 A: 回油口 ( 回至油箱 ) B: 進油口 ( 來自油箱 ) C: 至高壓共軌燃油壓力調節閥 ( 流量調節閥 ) 型式 : 噴油嘴電磁式 : 1st, 2nd generation 壓電晶體式 : 3d 3rd generation 功能 : 依 ECU 的送來的控制訊號將來自共管的高壓燃料霧化直接噴入燃燒室中噴油嘴控制方式 : 間接控制控制項目 : 適當的噴射正時正確的噴油量各個噴射階段的正確噴射油量 8

增壓壓力感知器 (BPS) 開關訊號起動訊號 Controller 燃油控制電腦 (ECU) 大氣壓力感知器 Output actuators 噴油嘴電磁閥 1.

9 Magnetic injector 節流孔 2 電磁閥回油口控制室節流孔 1 控制室詳圖進油口閥針控制柱塞回位彈簧 Source: Bosch 控制系統方塊圖 Input signals 加速踏板感知器曲軸感知器凸輪軸感知器共軌燃油壓力感知器其他感知器燃油溫度感知器水溫感知器大氣溫度感知器增壓壓力感知器 (BPS) 開關訊號起動訊號 Controller 燃油控制電腦 (ECU) 大氣壓力感知器 Output actuators 噴油嘴電磁閥 1. 噴射量控制 2. 噴射正時控制 PCV : 噴射壓力控制渦輪增壓電磁閥增壓控制 EGR 電磁閥 ( 馬達 ) EGR 控制 : 自我診斷 9

10 加速踏板位置感知器 +2.5V Values Potentiometer 1. Potentiometer 2. IDLE 0.6 ~ 0.9V 0.25 ~ 0.6V WOT 3.6 ~ 4.6V 1.60 ~ 2.5V 凸輪軸感知器 Source: Hyundai 10

11 曲軸感知器 Source: Hyundai 曲軸凸輪軸訊號感知器 11

12 共管 ( 軌 ) 壓力感知器壓力調節之方式 : 共軌壓力之調節高壓油泵出口流量調節 : 洩放從高壓油泵壓出送至共軌的油量來調節壓力 (CP.1) 高壓共軌洩油調節 : 洩放儲存在共軌中的油量來調節壓力 (CP.2) 低壓供油流量調節 + 高壓共軌洩油調節 : CP.3~ 壓力控制閥 (Pressure Control Valve, PCV) : 採高壓洩油方式調節並維持共軌中的燃油壓力為一常開洩油型電磁閥, 電腦採 PWM 控制來調節壓力安裝位置 : 位於高壓油泵上 ( 出口流量調節 ) 或共軌上 ( 洩油調節 ) 流量控制閥 (Intake regulating valve, MPROP) 採低壓洩油方式調節供應到高壓油泵的油量為一常開洩油型電磁閥, 電腦採 PWM 控制來調節流量安裝位置 : 位於油泵總成上優點 : 可減少引擎驅動的負擔, 降低油溫 12

13 壓力控制閥 (PCV) 高壓洩油調節型 (rail) 常閉關閉壓力 ( 彈簧彈力 ): 50~60bars Source: Hyundai Opening degree of the PCV (Pulse width modulated control with frequency 1.0 khz) 13

14 進油流量調節閥 ( 常通型 ) Bosch: MPROP 噴油嘴的噴油控制 14

15 噴油嘴的作動 Control current Stroke in mm Fuel pressure p Injection rate Source: Hyundai Control circuit of injectors 15

16 Injector coil charging Capacitor Capacitor of the charging circuit in ECU Source: Hyundai Injection pulse 16

細分級 : (EURO IV), 將噴油嘴參數以編碼標示在噴油嘴上, 需利用診斷儀器將該編碼登錄到 EDM 中 (6~7 碼 ) 噴油嘴等級編號及組合 Grade X Y Z Combination 1 0 4 0

17 噴油嘴的分級柴油引擎噴油嘴在製造上屬於高精密的加工, 要製造出特性相同的噴油嘴有其困難 ( 均一性 ), 特別是在高壓噴射場合共軌系統噴油嘴的使用時期來分 ( 和排放法規相關 ): 1. 不分級 : (EURO II) 2. 粗分級 : (EURO III), 粗分成三等級, 並標示在噴油嘴上 3. 細分級 : (EURO IV), 將噴油嘴參數以編碼標示在噴油嘴上, 需利用診斷儀器將該編碼登錄到 EDM 中 (6~7 碼 ) 噴油嘴等級編號及組合 Grade X Y Z Combination Combination Combination Combination 噴油嘴等級編號 * 編號方式 :1, 2, 3 A, B, C X, Y, Z 噴油嘴零件號碼 Combination * 引擎上最多只能使用兩種等級的噴油嘴, 且不能同時使用 X Z 級, 中間等級噴油嘴的使用數量需至少要在汽缸數一半以上 17

18 噴油嘴等級 - 特性編號噴油嘴特性編號 (IMA) IMA 登錄 18

減少 HC 為了能在主噴射前在燃燒室內形成種子火苗所執行的燃油噴射減少 NOx 降低噪音為了能使燃燒殘留的燃料完全燃燒所追加的燃油噴射減少 PM

19 控制內容噴射量 ( 噴射率 ) 控制 : 不同運轉條件下的噴射量控制噴油嘴噴射正時控制噴油嘴噴射壓力控制 PCV( 高壓 ) 流量控制閥 ( 低壓至高壓 ) 理想的噴射正時與噴射率控制前導噴射預噴射主噴射後噴射後期噴射為了能預先在燃燒室內形成容易燃燒混合氣而執行的燃油噴射減少 PM 減少 HC 為了能在主噴射前在燃燒室內形成種子火苗所執行的燃油噴射減少 NOx 降低噪音為了能使燃燒殘留的燃料完全燃燒所追加的燃油噴射減少 PM 在原本的燃燒控制噴射是沒有此一噴射, 它是為了促進廢氣排放後處理效果所執行的燃油噴射減少 NOx Source: Bosch 19

injection) 在主噴射之後的小量燃料噴射, 使用在廢氣後處理時依系統的控制能力可再細分為 : 後噴射 (After

20 噴射率控制前導噴射 (Pilot injection) 在主噴射之前的小量燃料噴射依系統的控制能力可再細分為 : 前導噴射預噴射 (Pre-injection) 主噴射 (Main injection) 後期噴射 (Post injection) 在主噴射之後的小量燃料噴射, 使用在廢氣後處理時依系統的控制能力可再細分為 : 後噴射 (After injection) 後期噴射增壓壓力感知器 (BPS) Source: Hyundai 20

使用壓電式噴油嘴的第三代共軌系統可不使用 DPF 即可通過 EURO 4 (DPF) PM (DOC)

21 1. 低含硫量的柴油 2. 使用後處理系統 EURO 4 的影響 Diesel Oxidation Catalyst (DOC) Diesel Particulate Filter (CR-DPF, CPF) 使用的低煙灰含量的機油 : E4 ~ E6 等級 3. 大量 EGR 回流 : 改用馬達控制 4. 使用壓電式噴油嘴的第三代共軌系統可不使用 DPF 即可通過 EURO 4 (DPF) PM (DOC) 利用氧化方式去除 CO HC 及一部分 PM 成分的觸媒將它們轉化為 CO 2 及 H 2O 等無害之物質, 並將 NO 轉為 NO 2 Source: Bosch CO + 0.5O 2 = CO 2 HC +O 2 = CO 2 + H 2O 21

22 PM filter (DPF) Active DPF regeneration Temp. between catalyst and filter Temp. after filter Pressure cross filter Temp. before catalyst 22

3RD generation CRS Source: Bosch Special features (Advantages) of the 3rd generation The inline injectors with their piezoelectric actuator built into the

This allows them to switch twice as fast as conventional magnetic and piezoelectric injector.

23 3RD generation CRS Source: Bosch Special features (Advantages) of the 3rd generation The inline injectors with their piezoelectric actuator built into the injector shaft and lying very close to the needle of the injector jet. "The new injectors have 75% fewer moving parts and 75% less mass. This allows them to switch twice as fast as conventional magnetic and piezoelectric injector." Lower diesel engine emissions by up to 20%, Increase the achievable engine power by 5% to 7%, Reduce fuel consumption by 3% And noticeably lower engine noise by 3 db(a) - depending on the specifics of engine development". 23

24 Piezo inline injector Source: Bosch Source: Bosch 24

25 Conclusions The higher the injection pressure, the higher the thermodynamic efficiency. The higher the injection pressure, the injection duration will be shorten. This makes the direct injection diesel engine the most thermodynamically efficient of all the internal combustion alternatives. Raising the injection pressure results in higher engine output, improved torque, better fuel efficiency, reduced d emissions and lower noise levels. 2 nd & 3 rd generation CR systems inject the fuel at an even higher pressure than the original, 1st-generation systems, increasing the benefits still further. Thank you 謝謝! 25

Microsoft PowerPoint - Common Rail_general_bbr.ppt [相容模式]

Microsoft PowerPoint - Common Rail_general_bbr.ppt [相容模式] 共軌噴射燃料系統 Common Rail System 林振江施保重丞雄實業有限公司 Autowin Industrial Corp 2004/04/06 初稿 2008/06/30 修訂 Emissions legislation Emissions legislation for Diesel passenger cars 1990 1993 1995 1996 2000 2005 Source: