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Diesel Systems

CRS3.3i

the direct
needle

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rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel Systems

CRI3.3i CR Piezo Injector Direct Needle Actuation


CRI3.3i (2000 bar): RB-SOP not decided yet
Customer Benefit:
Emissions
direct actuated nozzle needle
highest needle dynamics
hydraulic buffer volume
highest multiple injection flexibility
minimum PI quantity (0.5 0.8 mm3/S)
closed loop control
Fuel consumption
close couple combustion concept
no fuel return

HP connector

Electrical
connection

Power & Torque


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.

Diesel Systems CRS3.3i Systemlayout


Metering
unit
ZME

Pressure regulating valve


DRV3.3

Rail pressure
sensor RDS4.3

Rail (LWR3.3)

High
pressure
pump
CP4.1

PiezoInjector
CRI 3.3i
(1...n)

Fuel filter

Tank

Electrical
presupply
pump
EKP

Tank

New

Prefilter
EKP pressure

high pressure

backflow
pressure

Diesel Systems
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Control unit
EDC 17

U [V]

CRS3.3i Function Schematic


200V

Voltage at Piezo actuator

0V

pressure [bar]

2000

coupler
volume
before
nozzle
sack hole

1500

1000

nozzle (pressure chamber)


sackhole
coupler volume
injector (actuator chamber)
before nozzle
coupler chamber

500

sack hole
0

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 mm

injectionP_EVI
rate
signal (-)
[bar]

CRI3.3i

20

15

10

-5
0

Advantage CRI3.3i:
fast needle opening/closing
increased steepness
minimized throtteling effects
square shaped injection rate

5
6
Kurbelwinkel [Grad]

crank angle ()

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.

10

CRS3.3i

Hydraulic Results Characteristic Injection Map


120

180V
2000 bar

0V

100

Q (mm3/S)

Menge HE [mm/Hub]

1600 bar
80

1200 bar

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

1,2

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

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.

CRI3.3i - Results
100

5
2000 bar
1800 bar

90

1600 bar
80

1400 bar

1200 bar

quantity (MI) [mm3/H]

200V

70

0V

1000 bar
800 bar

60

ca. 0,13mm/s

(ca. 0,05mm/s CRI3.3)

600 bar
400 bar

50

250 bar
200 bar

40

0
50

30

75

100

125

150

175

200

20
10
0
0,0

0,5

1,0

1,5

2,0

2,5

AD (MI) [ms]

PI
Sehr
gute Kennfeldlinearitt
Small
quantitiy
delivery possible
Sehr guteofVoraussetzung
frenergizing
Korrelationsfunktionen
(IMA,)
Highsteepness
PI quantity map,
concept has to
be optimized

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.

CRI3.3i - Results
Comparison
stroke/stroke-deviation
Vergleich
H/H-Streuung CRI3.3 zu CRI3.x-CRI3.3i
CRI3.3i
7
6,5
6

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

s/s-deviation [mm/s]

Hub/Hub-Streuung [mm/H]

5,5
5
4,5

H/H (1600bar)= H/H-3mm/H.

4
3,5
3
H/H (1200bar)= H/H-3mm/H.
2,5
2

H/H (300bar)= H/H-1mm/H.

1,5
1

stroke/stroke-deviation independent of energizing time

0,5
0
0

200

400

600

energizing
time [s]
Ansteuerdauer [s]

800

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.

1000

1200

CRS3.3i

Hydraulic Results Characteristic Map EDC17


10

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

1400bar (Offset = +6 mm)

1200bar (Offset = +5 mm)

800bar (Offset = +3 mm)

1600 bar

**

1400 bar

**

1200 bar

* **

1000bar (Offset = +4 mm)


4

1800 bar

**

1600bar (Offset = +7 mm)

2000 bar

**

1800bar (Offset = +8 mm)

**

2000bar (Offset = +9 mm)

1000 bar

* **

800 bar

* **

600bar (Offset = +2 mm)

600 bar

2
400bar (Offset = +1 mm)

*
1

400 bar

200bar (Offset = +0 mm)


200 bar

* **

0
0

*Teilhub

10

**

100

200

Schrittweite 1s

300

400

**Vollhub

500

600

Schrittweite 10s

700

800
900
Ansteuerdauer [s]

1000

1100

ET (s)

Strictly confidential | DS/PJ-ECI 0208_Ze | 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.

1200

1300

1400

1500

50Hub-Messung EMI

CRS3.3i

Hydraulic Results Inj/ Inj + S/S Spread

0,6

0,5

40

0,4

30

0,3

20

0,2

10

0,1

Hub/Hub-Streuung [mm/H]

0,7

S/S spread (mm3/S)

50

0,8

80mm/H.@1400bar

1,5mm/H.@800bar

2mm/H.@2000bar

60

7mm/H.@250bar

Q (mm3/S)

Einspritzmenge [mm/H]

70

20mm/H.@800bar

80

50mm/H.@2000bar

0,9
2mm/H.@1200bar

90

0
1

Prfpunkt
[Nr.]
Test
Points

11

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

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.

Diesel Systems

CRI3.3i Hydraulic Results Pressure Waves


CRI3.3i
CRI3.0

Advantage CRS3.3i:
strongly reduced pressure wave amplitudes
free applicable injection distances, no PWC
highest flexibility
Less SW function efforts
1000 bar /

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CRI3.3i

initial classification

fuel mass

lifetime

NVC

.x
3
I
CR

temperature
stroke

fuel mass

voltage

ISA
voltage

cold start

They finally can enable to be used as


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

ET rpm p

Piezo injectors require precise activation/charging


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

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.

polarization

temp.

init-/ starting-time

CRI3.3i - Results

CRI3.3i needle sensor feasibility


70

Aktorhub:
78m
86m

Einspritzmenge [mm/H]

50

2000bar

ca. 3mm

1500bar

U [V]

60

1000bar
40

70
30

time [s]

500bar

2000bar

60
20

ca. <1mm

1500bar

10

Einspritzmenge [mm/H]

50

without governor
0
100

300

500

700
Ansteuerdauer [s]

1000bar

40

900

1100

30

500bar

20

With active governor


almost no quantity difference

10

0
100

with governor
300

500

700
Ansteuerdauer [s]

14

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.

900

1100

Common Rail System CRS3.3i

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

z
z
z

A6-sample

Technology

Functional Concept

Actuator Module Design

ECU control functions

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.

CRI3.3i at one sight

step injection rate


closed couple PI
reduced pressure wave
oscillations

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

CRI3.3i
CRI3.x

S/S

CRI3.3i
CRI3.x

EM

energizing time

VE

LL

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

injection rate

extreme linear injection map


small sample deviation
very small shot to shot
spread

injection rate

quantity

Summary of hydraulic results:

-1000

time scale

injection rate

reduced quantity wave amplitude


improved accuracy
(at free distance: +/- 0,5 mm3/S)
no rail throttles and PWC
closed PI possible

quantity

time scale

CRS3.3i
CRS3.0

distance PI-MI

Diesel Systems
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.

time scale

VL

CRS3.3i

Costumer benefit with CRS3.3i:

slightly reduced fuel consumption:


a) reduced pump torque due to lack of fuel return
b) possibility of closed PI-strategy

optimized multiple injection capability

reduced quantity drift


means smaller tolerances
means slightly reduced engineering target concerning emissions

Potential of no PWC due to reduced pressure wave oscillations

potential to omit fuel cooler in critical applications

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.

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)
21

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

CRS Roadmap

Roadmap CRS for Diesel Passenger Cars and LD<6t


High Pressure CR System

CRS Premium line

CRS-HP
> 2200bar

0 ms*

Piezo Valve CR System

CRS3.3 2000 bar


CRS3.2 1800 bar

CRS Top line

0 ms*

CRS3.0 1600 bar


CRS2.7 2200 bar

Solenoid Valve CR System

CRS2.6 2000 bar

CRS High line

Adv. Multiple Injection: 0 ms*

CRS Mid line

CRS2.5 1800 bar

CRS2.2 1600 bar, CRS2.0 1450 bar


0,2 ms**

CRS Base line


0,8 ms**

*
**

22

Safety margin 50 s
Typical values

CRS1.x 1400 / 1450 bar


CRS for LPV / EME
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

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

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