Bosch Training Centre

Diesel Engine

Division : MICO/PDT(BTC)
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Bosch Training Centre

Principle of the reciprocating engine

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Bosch Training Centre

4 stroke cycle diesel engine

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Bosch Training Centre

Fuel layout on a diesel engine(o/f valve on FIP)

Division : MICO/PDT(BTC)
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Bosch Training Centre

Sectional view of the

injection pump PE .. A

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
 Common Rail System
Gear Pump / Feed Pump
 Bosch Training Centre

Fuel Layout - With VE Pump

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Bosch Training Centre
VE Pump - Features

The basic VE Pump contains the following functional

groups:

Vane type supply pump

Distributor Head (High Pressure Pump)

Mechanical Governor

Hydraulic Timer

Electric Shut off Device

Division : MICO/PDT(BTC)
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 Bosch Training Centre

Distributor Pumps - VE Mechanical (sleeve controlled)

Division : MICO/PDT(BTC)
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Bosch Training Centre

Role of Electronics in FIE

Division : MICO/PDT(BTC)
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Bosch Training Centre

EDC System blocks

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
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Bosch Training Centre

VE EDC Pump Structure

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System

Division : MICO/PDT(BTC)
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Bosch Training Centre
Demands & Basic parameters
Emission Legislation
Higher Power and Torque
Fuel Efficient
Smoother drivability
Cost effective

Injection Quantity
Injection Begin
Injection Pressure

Division : MICO/PDT(BTC)
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Bosch Training Centre
Common Rail System

Degrees of Freedom in Common Rail :

• Injection Pressure

• Injection Quantity

• Injection Begin

Division : MICO/PDT(BTC)
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Bosch Training Centre

Common Rail System

What is Common Rail?

Common Rail is a

Modular,
Electronic Controlled,
Diesel Fuel Injection System.

Division : MICO/PDT(BTC)
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Bosch Training Centre

Common Rail System

Special Characteristics :
• Injection Pressure is produced and governed relatively independent of
the Engine Speed and can be selected freely within a wide range.

• Injection begin and Injection Quantity can be freely selected

(EDC function)

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre

Common Rail System

How are the main characteristics of CR system

achieved ?
• CR uses an intermediate High Pressure Accumulator (Rail)

• Uses Electronic Control of Injectors (use of Electro-magnetic

valves)

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System
Injection pressure [bar]

1800

1600

1400 Common Rail

1200

1000

800 other
port-controlled
systems Common Rail
600 Other port controlled
Systems (Conventional)

400

200

1000 2000 3000 4000 5000

Engine speed [RPM]

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Bosch Training Centre
Common Rail System
Driver demand

CP3 MPROP

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre

Common Rail System Layout

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Common Rail System

High Pressure Pump CP1 - Standard

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System
High Pressure Pump CP1 - Standard

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre

Common Rail System

High Pressure Pump CP1 - Standard

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System

High Pressure Pump CP1 - Standard

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre
Common Rail System
High Pressure Pump CP1 - Standard

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Common Rail System
CP3 - High Pressure Pump

Controller (MPROP) - Control at the Pump inlet

Feed Pump (Gear Pump)

 Common Rail System
MPROP - Magnetic Proportional Valve
Maximum delivery
Q [l/h]
Zero delivery

I [A]

Detail A

Fuel

Zero Maximum
delivery delivery
A
Fuel
Bosch Training Centre
Common Rail System

DRV – Pressure Regulator Valve

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
 Bosch Training Centre
Common Rail System
DRV – Pressure Regulator Valve

FMagnet

FMagnet
FSpring
FHigh pressure
Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Bosch Training Centre

Common Rail System

High Pressure Rail

Division : MICO/PDT(BTC)
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Bosch Training Centre

Common Rail System

High Pressure Rail

Factors determining the Rail Volume :

Rail Volume is a compromise based on the following two factors

Volume to be kept as small as possible to keep the response time

of the system short (i.e., the setpoint pressures to be achieved in as
short a time as possible)

Volume should be as large as possible to keep the Pressure oscillation

to minimum possible value.

Division : MICO/PDT(BTC)
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Without their consent, it may not be reproduced or given to third parties.
 Bosch Training Centre

High Pressure Rail

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Pressure Limiter Valve

From Rail Return to Tank

High Pressure Fuel Low Pressure Fuel

2000

1500
pressure [bar]

1000

500

0
0 4

time

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Bosch Training Centre

Injector

Division : MICO/PDT(BTC)
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Bosch Training Centre

Injector

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Injector
Principle

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Injector 2/2 Valve Closed Open
p2 ≈0 p2 ≈0
Outlet
p1 Orifice p1
U
I p st = p1 p1 >p st >p 2

Inlet Control
Orifice volume Vst
Valve Lift

FV F0 F0

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Common Rail System
Injector

Current

Armature Lift

Nozzle end
Pressure

Control Chamber Pressure

Needle Lift

Injection Rate

Time

Division : MICO/PDT(BTC)
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 Bosch Training Centre

Injector Characteristics
100

90
Full Load Area 1600bar

80
1500bar
Quantity (mm3/str.)

70
950bar
Emission area
60

50
600bar

40

Pilot Injection Area 300bar

Low Idle Area
30

250bar
20

10

0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5
Energizing Time
(ms)

Division : MICO/PDT(BTC)
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 Bosch Training Centre
Electronic Control Unit
Input circuits (1) Output circuits (2)

sign. steady
A D correcting
analog process.
signals unit Signal A varaibles

D
sign. processing digital
process. correcting and
unit output signals
digital (3)
signals
Interfaces (5):
communication
diagnosis

Power supply (6) Memory

12/24V (4)

Division : MICO/PDT(BTC)
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 Bosch Training Centre

Common Rail System

Filter assembly

Division : MICO/PDT(BTC)
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Bosch Training Centre

Common Rail System

Electric Fuel Pump

Division : MICO/PDT(BTC)
This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.