Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesel’s impact on the environment.

1. Up to 1,800-bar injection pressure
2. Up to five times multiple injection per cylinder

The features greatly reduce visible smoke,

particulate matter and NOx while minimizing engine noise.
Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesel’s impact on the environment.

1. Up to 1,800-bar injection pressure
2. Up to five times multiple injection per cylinder

Cleaning up diesel exhaust gas Minimizing engine noise

Diesel fuel is injected into the combustion Highly precise multiple injection creates
chamber at ultra high pressures of up to 1,800 combustion to reduce NOx emission and
bar to ensure more complete combustion for combustion noise.
cleaner exhaust gas.
Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesel’s impact on the environment.

1. Up to 1,800-bar injection pressure
2. Up to five times multiple injection per cylinder

Single Injection Pilot Injection Multiple Injection

(Conventional) (First-Generation Common Rail) (Five Times)
Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Single Injection
Single Injection

Pilot Injection

Multiple Injection

Condition
・Passenger Car
・Engine: 2L / 4cyl
・Turbo Direct Injection
time ・Noise at Idling
Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Pilot Injection (Two Times)

Single Injection

-3ｄB
Pilot Injection

Multiple Injection

Condition
・Passenger Car
・Engine: 2L / 4cyl
・Turbo Direct Injection
time ・Noise at Idling
Common Rail System BENEFIT

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Multiple Injection (Five Times)

Single Injection

Pilot Injection
-4ｄB Multiple
Injection

Condition
・Passenger Car
・Engine: 2L / 4cyl
・Turbo Direct Injection
time ・Noise at Idling
Common Rail System TECHNOLOGY

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

TECHNOLOGY Co mmo n Rail Sy stem Diesel Engine Management Sy stem

1,800 bar injection pressure is equivalent to

the water pressure of a depth of 18,000 meters EGR V alve

deeper than the Mariana Trench, the world’s

deepest ocean bottom. High response injectors
by electronic control feature the highly
accurate multiple injections (five times). As a
result, particulate matter and NOx are
markedly reduced, w hile improvements in fuel
efficiency and torque are achieved. Plus, engine
noise and vibration are also reduced.

DPF
High
High pressure
pressure
capacity
capacity technology
technology
Magnetic
Magneticvalve
valve Diesel engines have the advantages of good fuel
technology
technology
efficiency and low CO2 emissions. Therefo re, DENSO
Common
Common rail
rail
developed a diesel engine management system to
technology
technology
further clean up emissions w hile improving fuel
ECU efficiency. This system is a product of various forms
ECU technology
technology
Sensor
Sensor technology
technology of advanced technology. Among them is the common
rail system employed in the fuel injection.
Common Rail System TECHNOLOGY

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

TECHNOLOGY 1 Supply Pump

The first-generation supply pump could generate Supply Pump
pressures of up to 1,450 bar, w hich represented Feed Pump
the mechanical limits of the inne r cam design. Plunger
To Rail
However, to achieve pressures above this, Cam Ring
DENSO developed revolutionary new coating and
machining technologies, and by the second-
generation design, changed to an outer cam Housing
design in the supply pump to achieve pressures Suction
Cam Shaft Connecting Control Valve Eccentric Cam
up to 1,800. Pipe

TECHNOLOGY 2 Co mmon
Common Rail
Rail
In order to w ithstand 1,800-bar pressure the rail From Supply Pump
must be w ithout any clearance or machining error.
To Injector To Injector
In response, DENSO developed a special material
that contains few er compounds, w hile exhibiting
high purity and high hardness properties to enable
ultra high-precision machining. Thus, it is possible
to create engine components that can w ithstand
pressures up to 1,800 bar for use in the common Pressure Sensor Pressure Limiter
rail system.
Common Rail System TECHNOLOGY

DENSO’s second-generation 1,800-bar common rail for cleaner and quieter diesel engine

TECHNOLOGY 3 Solenoid Injector

Compared w ith its first-generation injector (1,450
bar, tw o-times injection) DENSO developed higher-
response solenoid actuator and high-pressure
injector design. The second-generation injector is
Injector (up to 5 times injection a cylinder)
160M Pa
Solenoid Valve Qpilot :2mm3/st , Qpre: 2mm3/st , Qmain:80 mm3/st ,
Qaft er:5mm3/st , Qpost :2mm3/st ,

able to inject up to 1,800 bar pressure and multiple From Rail

injection, w ith timing intervals of 4/10,000 seconds (high pressure)
during w hich a maximum of five injections takes Drive Current
place. As a result, exhaust gas is cleaner w hile (A)
noise is minimized. time

Command
Piston
In injection control systems, advanced piezoelectric Valve Lift
components are employed because of their high (μm)
speed operation capability. But DENSO was time
successful in developing conventional solenoids
that operate in 0.2 millisecond units. 1.0ms

Injection Rate
Nozz le (mm3/ms)

time