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DCR

Deutz Common Rail System


TE-TM1 05.02.04
Challenges in the Future Answered by
Deutz CR

• New emission legislations


- On-road Euro 4 (10/2005) incl. exhaust aftertreatment
- Off-road Stage 3 (01/2006 ... 01/2008)
• Cost reduction
- DEUTZ‘s Medium Duty FIE (el. UPS) has a cost penalty against the
main C&I competitors‘ option for Stage 3
(el. distributor pump)
• Customer requirements
- Noise reduction ~ 3 dB(A) until 2006
- Torque increase 10...20 % (low end and max. torque)
- Main customer RVI is “Common Rail – minded“
Deutz FIE Strategy for the Future

• New electronic FIE to be developed for the Medium


duty engine families (SOP‘s: mid 2005)

• 2015 FIE (el. UPS) is attractive for the future

• 2011, 914: Product concept/strategy under work


(SOP‘s > 2006)
Medium Duty families: Situation today
E in s p r itz le itu n g

Deutz mech. UPS Best in class


Up to 1350 bar
(el. distr. pump)
Emission EU2,
E in s p r itz p u m p e

C&I stage 2
K u r b e lg e h ä u s e
System cost  
Electronics on A u s g le ic h s c h e ib e
R o lle n s tö ß e l
Fuel consumption  
demand N o c k e n w e lle Cold start  
Electronic functions  (EMR variant) 

Deutz UPS Best in class


(Common Rail)
System cost  
Fuel consumption  
Low end torque  
Up to 1600 bar Engine noise  
Emission EU3
Options for the future

 Unit Pump Systems  Unit Injector System


 DaimlerChrysler, Mack, DAF  Volvo, Iveco, DDC, CAT
 DEUTZ liquid cooled  VW passenger car

• High peak pressure


• Favourable injection
rate

 Common-Rail
 Almost every • Pressure flexibility
passenger car • Multiple injection
 RVI, JohnDeere, • Silent gear train
Cummins, CAT
DCR - System
ECU
1 Heater (optional)
2 Pressure sensor
Injector
3 MProp

pm in > 0,5 ÷ 1,0 bar


pm ax < 10,5 ÷ 13 bar
pSystem = 300 ÷ 1600 bar
Pressure
pback, m ax < 1,2 bar
sensor
Rail
DBV
3
Prefilter with HP-pump
water separator 1 2

FCU
Supply Main
pump filter
Thermostatic
Hand- valve
primer
ECU: Electronic Control Unit
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FCU: Fuel Control Unit


DBV: Pressure limiter valve
High Pressure System
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High Pressure System
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CR-Injector / Variants
• 4-Valve-Injektor • 2-Valve-Injektor
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CR-Injector / Function
Cross Section of a BOSCH-CRIN 2nd Generation Injector

Magnet coil

Magnet core Armature Control chamber High pressure channel Pressure piece

Features:
• Injector just opens when current is on
• A leakage occurs during opening which is systematically caused (dependend on rail pressure and

injection duration)
• Spring is just applied to keep the injector closed against compression pressure
TE-TM1 05.02.04

in combustion chamber
• Exchange of nozzles is not permitted ! The whole injector has to be removed !
• Service concept is in progress
Rail
• High pressure storage of injection system
• Rail contains pressure relieve valve (DBV) and rail pressure sensor (RDS)

Pressure sensor

Pressure relieve valve (integrated)

• The system is adjusted that after each injection a corresponding fuel quantity is delivered by
TE-TM1 05.02.04

the pump always before the next injection occure


Pressure Relieve Valve (DBV)

Features:

• Pressure relieve valve is a mechaninical safety device, which opens at


1950(-100) bar and protects the system concerning over pressure caused by any
malfunction

• If opened the rail pressure remains in the range of 650 - 850 bar (dependend on speed
and load). The engine keeps running but if necessary with decreased performance (limp
home mode)

• Under usual conditions the DBV will not open during engine operation
TE-TM1 05.02.04
Rail Pressure Sensor (RDS)
• Input variable for rail pressure controller
• If any malfunction is detected the ECU may force the DBV to open by putting over
pressure onto the system

Signal voltage
5V
4,5 V

0,5 V
0V Pressure
TE-TM1 05.02.04

0 bar 1800 bar


High Pressure Pump (PF 45)
HD-connector

I/O-Valve
(integrated)

ND-connector

I/O-Ventil keeps two functions:


• Hydraulic separation of high pressure side
during suctioning
• Filling of pumps is just possible at a minimum
pressure of approx. 1.7 bar
TE-TM1 05.02.04
High Pressure Pump (PF 45)

TCD 2013 TCD 2012


• Pump housing is common for all engines

• Roller tappet is common for all engines


• Spring cup seat differs between engines
- short seat: TCD 2012
- long seat/1 TCD 2013 L4/6 2V
- long seat/2 TCD 2013 L4/6 4V
TE-TM1 05.02.04
Fuel Control Unit (FCU)
FCU (Fuel Control Unit):

From feed To high


pump pressure
pump
02.12.02 TK-TM1

back to tank
Fuel Control Unit (FCU)

• FCU controlles filling of high pressure pumps


M-Prop
• It is just delivered as much as needed to reach or
keep the rail pressure setpoint

Inlet 3,5

Fuel flow [l/min]


to PF 45 2,5

Outlet 1,5

0,5
• Supplier: BOSCH
0
• FCU for all DCR systems usable 300 500 700 900 1100 1300 1500
TE-TM1 05.02.04

Current [mA]
• Tested Part from Supplier
Characteristic of Overflow Valve
Low Pressure vs. Engine Speed
8

7,5
Pressure [bar, absolute]

6,5

5,5

4,5

4
0 500 1000 1500 2000 2500 3000
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Engine speed [rpm]


Gear Pump - New Requirements
2014 pump
Specifications:
gear driven
pgegen [bar] nMotor [1/min] Q [L/min]
3 100 0,333
10 1000 1,83
10 2300 2,92

4-7L Tier III


belt driven
TE-TM1 05.02.04

Suction pressure: p = 0,5 – 1.0 bar abs


Prefilter Requirements

• Prefiltration of Particle 30 m

• Water seperation of > 98 %


• Fuel preheating by means of
a thermostatic valve
• Water storage with water level
sensor
• Mechanical water draining
(optional magnetic valve)
• integrated primer pump
TE-TM1 05.02.04

• 1000 h exchange interval

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