Diesel Systems

CRS3.3i

… the direct
needle

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Diesel Systems

CRI3.3i CR Piezo Injector – Direct Needle Actuation

CRI3.3i (2000 bar): RB-SOP not decided yet
HP connector
Customer Benefit:
Emissions Ð
• direct actuated nozzle needle Electrical
connection
⇒ highest needle dynamics
• hydraulic buffer volume
⇒ highest multiple injection flexibility
• minimum PI quantity (0.5 – 0.8 mm3/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

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Diesel Systems – CRS3.3i Systemlayout

Metering
unit
ZME Pressure regulating valve
Rail pressure
DRV3.3
sensor RDS4.3

Rail (LWR3.3)

High
pressure
pump
CP4.1

Piezo-
Injector
CRI 3.3i
Fuel filter (1...n) Control unit
EDC 17

Electrical
presupply

Tank
pump
EKP Tank
New
Prefilter
EKP pressure high pressure backflow
pressure

Diesel Systems
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CRS3.3i Function Schematic

200V Voltage at Piezo actuator

U [V]
0V
2000

pressure [bar]
1500

1000

nozzle (pressure chamber)

coupler
volume 500
coupler volume
sackhole
injector (actuator chamber)
before nozzle
before coupler chamber
nozzle sack hole
0
sack hole
time scale

Diesel Systems
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We reserve all rights of disposal such as copying and passing on to third parties.
CRI3.3i - Results

CRI3.3i Hydraulic Results – Injection Rate

CRI3.x 1000 bar / 40.0 mm³
CRI3.3i signal (-)

20

15
[bar]

10
rate
injectionP_EVI

-5
0 1 2 3 4 5 6 7 8 9 10
Kurbelwinkel [Grad]
crank angle (°)
Advantage CRI3.3i:
• fast needle opening/closing
• increased steepness
• minimized throtteling effects
• square shaped injection rate

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 CRS3.3i

Hydraulic Results – Characteristic Injection Map

120

180V
2000 bar
100 0V

1600 bar

80
Menge HE [mm³/Hub]

1200 bar
Q (mm3/S)

800 bar
60

40

200 bar
20

0
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

ET (ms)
Dauer HE [ms]

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

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We reserve all rights of disposal such as copying and passing on to third parties.
CRI3.3i - Results

100 5
2000 bar
90 1800 bar 200V
4
1600 bar
80 1400 bar
1200 bar 3
0V
70
quantity (MI) [mm3/H]

1000 bar
800 bar 2
ca. 0,13mm³/µs
60 (ca. 0,05mm³/µs CRI3.3)
600 bar

50 400 bar 1
250 bar
40 200 bar
0
50 75 100 125 150 175 200
30

20

10

0
0,0 0,5 1,0 1,5 2,0 2,5
AD (MI) [ms]

Î Small Sehr
Î PI gute Kennfeldlinearität
quantitiy delivery possible
Î Sehr guteofVoraussetzung
HighÎsteepness fürenergizing
PI quantity map, Korrelationsfunktionen (IMA,…)
concept has to be optimized

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 CRI3.3i - Results

Comparison stroke/stroke-deviation
Vergleich H/H-Streuung CRI3.3 zu CRI3.x-CRI3.3i
CRI3.3i
7
1600bar CRI3.3 1200bar CRI3.3
6,5
300bar CRI3.3 1600bar Inj.CRI-PDN A1.2
6 1200bar Inj.CRI-PDN A1.2 300bar Inj.CRI-PDN A1.2
5,5

5
Hub/Hub-Streuung [mm³/H]
s/s-deviation [mm³/s]

4,5 H/H (1600bar)= H/H-3mm³/H.

3,5

3
H/H (1200bar)= H/H-3mm³/H.
2,5

2
H/H (300bar)= H/H-1mm³/H.
1,5

0,5
Î stroke/stroke-deviation independent of energizing time
0
0 200 400 600 800 1000 1200
energizing time [µs]
Ansteuerdauer [µs]

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 CRS3.3i

Hydraulic Results – Characteristic Map EDC17

10
2000bar (Offset = +9 mm³)
* ** 2000 bar

9
1800bar (Offset = +8 mm³)
* ** 1800 bar

8
1600bar (Offset = +7 mm³)
* ** 1600 bar

7
spread (mm3/S)

1400bar (Offset = +6 mm³)

* ** 1400 bar
Hub/Hub-Streuung [mm³/H]

6
1200bar (Offset = +5 mm³)
* ** 1200 bar

5
1000bar (Offset = +4 mm³) * ** 1000 bar

4
800bar (Offset = +3 mm³) * **
S/S

800 bar

3
600bar (Offset = +2 mm³)
* ** 600 bar

2
400bar (Offset = +1 mm³)

* ** 400 bar

1
200bar (Offset = +0 mm³)
200 bar
* **
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
*Teilhub Schrittweite 1µs **Vollhub Schrittweite 10µs Ansteuerdauer [µs] 50Hub-Messung EMI
ET (µs)

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 CRS3.3i

Hydraulic Results – Inj/ Inj + S/S Spread

90 0,9

2mm³/H.@1200bar

50mm³/H.@2000bar

2mm³/H.@2000bar
80 0,8

80mm³/H.@1400bar
20mm³/H.@800bar

7mm³/H.@250bar

1,5mm³/H.@800bar
70 0,7

Hub/Hub-Streuung [mm³/H]
S/S spread (mm3/S)
Einspritzmenge [mm³/H]

60 0,6
Q (mm3/S)

50 0,5

40 0,4

30 0,3

20 0,2

10 0,1

0 0
1 2 3 4 5 6 7
Test Points
Prüfpunkt [Nr.]

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

11 Strictly confidential | DS/PJ-ECI 0208_Ze | 08.04.2007 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
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Diesel Systems

CRI3.3i Hydraulic Results – Pressure Waves

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
1000 bar /

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 CRI3.3i

lifetime

3 .x

fuel mass
I
NVC CR
initial classification
voltage temperature

stroke
fuel mass

ISA

U
voltage
temp.

cold start

polarization
• Piezo injectors require precise activation/charging

ET rpm p
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. init-/ starting-time

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all rights of disposal such as copying and passing on to third parties.
 CRI3.3i - Results

CRI3.3i – needle sensor feasibility

70

60
Aktorhub: 2000bar

78µm

U [V]
86µm ca. 3mm³ 1500bar
50
Einspritzmenge [mm³/H]

1000bar
40

70
30
500bar time [s] 2000bar
60
20
ca. <1mm³ 1500bar
50
10 Einspritzmenge [mm³/H]

without governor 40
1000bar

0
100 300 500 700 900 1100
Ansteuerdauer [µs] 30
500bar

20

Î With active governor 10

almost no quantity difference with governor

0
100 300 500 700 900 1100
Ansteuerdauer [µs]

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14 all rights of disposal such as copying and passing on to third parties.
Common Rail System CRS3.3i

Status 09/07
Project
z Internal A-sample successfully tested
z CRI Test Bench: > up to 2000h reached
z Engine Test: > up to 400h cumulated
A6-sample
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

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CRI3.3i at one sight

Summary of hydraulic results:

extreme linear injection map
962_01
962_03

Î
962_05
962_06
962_11
962_12
962_13
CRI3.3i
CRI3.3i
CRI3.x
CRI3.x
small sample deviation
962_14
962_15

quantity
Î
962_16

S/S
Î very small shot to shot
spread
energizing time EM VE LL VL
Î step injection rate 1200

1000

injection rate

injection rate
800

Î closed couple PI 600

400

200

Î reduced pressure wave 0

-200

-400

oscillations -600

-800

-1000

time scale time scale

Î reduced quantity wave amplitude

injection rate
improved accuracy
quantity

(at free distance: +/- 0,5 mm3/S)

Î no rail throttles and PWC CRS3.3i
CRS3.0

Î „closed PI“ possible distance PI-MI time scale

Diesel Systems
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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
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 CRI3.3i

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)
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 CRS Roadmap
Roadmap CRS for Diesel Passenger Cars and LD<6t
High Pressure CR System
CRS-HP
CRS Premium line > 2200bar
0 ms*
Piezo Valve CR System
CRS3.3 2000 bar
CRS Top line CRS3.2 1800 bar
0 ms*
CRS3.0 1600 bar
Solenoid Valve CR System CRS2.7 2200 bar
CRS2.6 2000 bar
CRS High line Adv. Multiple Injection: 0 ms*
CRS2.5 1800 bar
CRS Mid line CRS2.2 1600 bar, CRS2.0 1450 bar
0,2 ms**

CRS1.x 1400 / 1450 bar

CRS Base line
0,8 ms** CRS for LPV / EME
Safety margin 50 µs
* Typical values 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
**

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