BOSCH共軌噴射燃料系統

BOSCH 共軌噴射燃料系統
Common Rail System

林振江、
林振江 、施保重

丞雄實業有限公司
Autowin Industrial Corp
初稿：2004/04/06
初稿：2004/04/06
修改：2007/06/26
修改： 2007/06/26

Bosch CRS
„ 市場主流
„ 歐洲:
„ BMW, RENAULT, BENZ, VW, VOLVO, …
„ 亞洲:
„ KIA, Hyundai, Mitsubishi

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 Bosch CRS for passenger cars
„ Bosch Common Rail System for passenger cars (1st)

Source: Bosch

Bosch CRS for 8-Cylinder

passenger cars
„ V8 Diesel Engine (1st)

Source: Bosch

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 Bosch CRS for 6-Cylinder Trucks

Bosch CRS 代別概要

Turbo 預供泵
代別 噴油嘴 噴射壓力 壓力調節 法規
charger (低壓泵)
WGT 機械泵*1 高壓泵出油流量調節 PCV
1 或 電磁式 1350bar 或 或 EURO 2
VGT 電動泵 共軌高壓洩油壓力調節 PCV

共軌高壓洩油壓力調節 PCV EURO 3

WGT
2 或 電磁式 1600bar 同上 高壓泵進油流量調節 PCV*2
VGT + EURO 4
共軌高壓洩油壓力調節 PCV

1600bar 高壓泵進油流量調節 PCV*2

EURO 4
3 VGT 壓電式 同上 +
EURO 5
1800bar 共軌高壓洩油壓力調節 PCV

*1 使用在大排氣量引擎上

*2 又稱 MPROP 或 IMV, 低壓流量調節

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 Bosch Common Rail injection system –
Milestones of development
„ 2002:
1997:
„ First generation
2nd Common RailCommon
systemRail
in the
for world
trucks for
gives
passenger
lower emissions,
cars.
„ improved fuel consumption
Injection pressure: 1,350 bar.and more power.
„
„ IFirst
Injection
j ti pressure:
production use:1,600
1 Alfa
600 Romeo
bar.
b and Mercedes-Benz.
„ First production use: MAN.
„ 1999:
„ 2003:
„ Common Rail system for trucks.
„ Injection pressure:
3rd generation 1,400Rail
Common bar.
with rapid-switch piezo inline injectors
„ for cars.
First production use: Renault (RVI).
„ Advantages: up to 20 % lower emissions or up to 5 % more power
„ 2001:
or up to 3 % lower fuel consumption or up to 3 dB(A) less engine
„ 2nd
noise.generation Common Rail for passenger cars makes diesel
„ engines
g
Injection even more 1,600
pressure: economical,
bar. , cleaner,, quieter
q and more powerful.
p
„
„ Injection pressure:
First production use:1,600
Audi. bar.
„ First production use: Volvo and BMW
„ 4th generation of Common Rail for passenger cars
„ 2002:
„ Bosch is currently exploring designs.
„
„
2nd
Usinggeneration Common
even higher Rail
injection for trucks
pressures ofgives
morelower emissions,
than 2,000 bar.
improved fuel consumption and more power.
„ Injectors with variable injection geometry.
„ Injection pressure: 1,600 bar.
„ First production use: MAN.

Bosch Common Rail injection system –

Milestones of development
„ 2003:
„ 3rd generation Common Rail System with rapid-switch piezoelectric
inline
e injectors
jecto s for
o ca
carss was
as a
announced
ou ced at tthe
e Frankfurt
a utS Show
o 2003.
003
And it has actually been in production since May of 2003.
„ Injection pressure:
„ It is 1,600 bar, same as for the 2nd generation, when this generation
CRS was introduced.
„ Subsequently, it was changed up to 1,800 bar.
„ First production use: Audi A8.
„ 4th generation of Common Rail for passenger cars
„ Bosch is currently exploring designs.
„ Using even higher injection pressures of more than 2,000 bar.
„ Injectors with variable injection geometry.

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 Common rail fuel-
fuel-injection system

High Pressure Circuit

„ 產生和儲存高壓
„ 柴油經過濾器送至高壓泵加壓並輸送到高壓蓄壓器(共軌)中儲存。
„ 儲存在中的柴油壓力最高可達 1,350
1 350 ~ 1800bar 。
„ 閉迴路控制共軌中的柴油壓力
„ 由共軌壓力感知器偵測高壓蓄壓器(共軌)的油壓。
„ ECM根據共軌壓力感知器傳來的共軌油壓訊號來驅動壓力控制閥。當
油過高時，壓力控制閥打開, 燃油流回油箱。為了控制精確控制共軌
中的油壓， ECM採DUTY CYCLE(1kHz)的方式驅動它，使每一次的柴
油取自高壓蓄壓器的燃油噴射, 都能維持一定，確保不會超過或低於
期望值。
„ 柴油噴射
„ 由ECM控制
„ 柴油都是取自於高壓蓄壓器的高壓柴油，然後直接噴入燃燒室中。

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 Pre-Supply Pump
„ Type 1:
2:
MPROP

Pre-supply pump Supply pump

Source: Bosch

High Pressure Pump

„ Also called: Supply Pump
„ Model : Rotary
„ Type : Bosch

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 Common Rail Assy
壓力感知器
Common Rail Pressure Sensor

壓力控制閥
Pressure control valve

Common Rail Assy

壓力感知器
Common Rail Pressure Sensor 壓力控制閥
Pressure control valve

Source: Hyundai

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 高壓油泵

A: 回油口(回至油箱)
B: 進油口(來自油箱)
C:至高壓共軌

燃油壓力調節閥
(流量調節閥)

噴油嘴
„ 型式:
„ 電磁式: 1st, 2nd generation
„ 壓電晶體式 3rd
壓電晶體式: 3 d generation
ti
„ 功能:
„ 依ECU的送來的控制訊號將來自共管的高壓燃料霧
化直接噴入燃燒室中。
„ 噴油嘴控制方式:
„ 間接控制
„ 控制項目:
„ 適當的噴射正時
„ 正確的噴油量
„ 各個噴射階段的正確噴射油量

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 Magnetic injector
節流孔2 回油口
電磁閥

控制室

節流孔1

控制室詳圖 進油口

閥針
控制柱塞

回位彈簧

Source: Bosch

控制系統方塊圖
Input signals Controller Output actuators
加速踏板感知器 噴油嘴電磁閥
1. 噴射量控制
曲軸感知器
2. 噴射正時控制
凸輪軸感知器
PCV :
共軌燃油壓力感知器 噴射壓力控制
燃油控制電腦 ●

其他感知器 (ECU)
渦輪增壓電磁閥
•燃油溫度感知器
燃油溫度感知器
•水溫感知器 ● 增壓控制
•大氣溫度感知器 EGR電磁閥(馬達)
•增壓壓力感知器(BPS) ● EGR控制
：
開關訊號 大氣壓力感知器
自我診斷
•起動訊號…

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 加速踏板位置感知器

+2.5V

V l
Values
Potentiometer 1. Potentiometer 2.
IDLE 0.6 ~ 0.9V 0.25 ~ 0.6V
WOT 3.6 ~ 4.6V 1.60 ~ 2.5V

凸輪軸感知器

Source: Hyundai

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 曲軸感知器

Source: Hyundai

曲軸、凸輪軸訊號感知器

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 共管(軌)壓力感知器

共軌壓力之調節
„ 壓力調節之方式：
„ 高壓油泵出口流量調節: 洩放從高壓油泵壓出送至共軌的油量來調節
壓力(CP.1)
„ 高壓共軌洩油調節: 洩放儲存在共軌中的油量來調節壓力(CP.2)
„ 低壓供油流量調節+高壓共軌洩油調節: CP.3~
„ 壓力控制閥 (Pressure Control Valve, PCV) :
„ 採高壓洩油方式調節並維持共軌中的燃油壓力。
„ 為一常開洩油型電磁閥，電腦採PWM控制來調節壓力。
„ 安裝位置：位於高壓油泵上(出口流量調節)或共軌上(洩油調節) 。
„ 流量控制閥(Intake regulating valve, MPROP)
„ 採低壓洩油方式調節供應到高壓油泵的油量。
„ 為一常開洩油型電磁閥，電腦採PWM控制來調節流量。
„ 安裝位置：位於油泵總成上。
„ 優點：可減少引擎驅動的負擔，降低油溫。

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 壓力控制閥 (PCV)
„ 高壓洩油調節型(rail)
„ 常閉
„ 關閉壓力(彈簧彈力): 50~60bars

Source: Hyundai

Opening degree of the PCV

(Pulse width modulated control with frequency 1.0 kHz)

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 進油流量調節閥(常通型)
„ Bosch: MPROP

噴油嘴的噴油控制

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 噴油嘴的作動
Control current

Stroke in mm

Fuel pressure
△p

Injection rate

Source: Hyundai

Control circuit of injectors

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 Injector coil charging Capacitor
„ Capacitor of the charging circuit in ECU

Source: Hyundai

Injection pulse

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 噴油嘴的分級
„ 柴油引擎噴油嘴在製造上屬於高精密的加工，
( )
要製造出特性相同的噴油嘴有其困難(均一性)，
特別是在高壓噴射場合。
„ 共軌系統噴油嘴的使用時期來分(和排放法規
相關)：
1.不分級： (EURO II)
2.粗分級： (EURO III)，粗分成三等級，並標示在噴
油嘴上。
3.細分級： (EURO IV)，將噴油嘴參數以編碼標示在
噴油嘴上，需利用診斷儀器將該編碼登錄
到EDM中。(6~7碼)

噴油嘴等級編號及組合
Grade X Y Z

Combination 1 0 4 0

Combination 2 1 3 0

Combination 3 0 3 1

Combination 4 2 2 0

噴油嘴等級編號* Combination 5 0 2 2
編號方式：1, 2, 3 噴油嘴零件號碼
A, B, C
X, Y, Z

* 引擎上最多只能使用兩種等級的噴油嘴, 且不能同時使用 X、Z

級，中間等級噴油嘴的使用數量需至少要在汽缸數一半以上。

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 噴油嘴等級-特性編號

噴油嘴特性編號(IMA)

IMA 登錄

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 控制內容
„ 噴射量(噴射率)控制:
„ 不同運轉條件下的噴射量控制
„ 噴油嘴
„ 噴射正時控制
„ 噴油嘴
„ 噴射壓力控制
„ PCV(高壓)
„ 流量控制閥(低壓至高壓)

理想的噴射正時與噴射率控制

前導噴射 預噴射 主噴射 後噴射 後期噴射

為了能預先在燃 為了能在主噴射 為了能使燃燒殘 在原本的燃燒控制
燒室內形成容易 前在燃燒室內形 留的燃料完全燃 噴射是沒有此一噴
燃燒混合氣而執 成種子火苗所執 燒所追加的燃油 射, 它是為了促進
行的燃油噴射。 行的燃油噴射。 噴射。 廢氣排放後處理效
果所執行的燃油噴
射。
減少 PM 減少 NOx 減少 PM
減少 HC 降低噪音 減少 NOx
Source: Bosch

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 噴射率控制
„ 前導噴射(Pilot injection)
„ 在主噴射之前的小量燃料噴射
„ 依系統的控制能力可再細分為：
„ 前導噴射
„ 預噴射 (Pre-injection)

„ 主噴射(Main injection)
„ (
後期噴射(Post injection)
j )
„ 在主噴射之後的小量燃料噴射，使用在廢氣後處理時。
„ 依系統的控制能力可再細分為：
„ 後噴射(After injection)
„ 後期噴射

增壓壓力感知器(BPS)

Source: Hyundai

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 EURO 4 的影響
„ 1.低含硫量的柴油
„ 2 使用後處理系統
2.使用後處理系統
„ Diesel Oxidation Catalyst (DOC)
„ Diesel Particulate Filter (CR-DPF, CPF)
„ 使用的低煙灰含量的機油: E4 ~ E6等級
„ 3.大量EGR回流：改用馬達控制
„ 4. 使用壓電式噴油嘴的第三代共軌系統
„ 可不使用DPF即可通過EURO 4

(DPF)

PM

(DOC)
利用氧化方式去除CO、HC及一部分PM成分的觸媒。
將它們轉化為CO2及H2O等無害之物質, 並將NO轉為NO2。
CO + 0.5O2 = CO2
Source: Bosch
HC +O2 = CO2 + H2O

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 PM filter (DPF)

Active DPF regeneration

Temp. between catalyst and filter Temp. after filter

Pressure cross filter

Temp. before
f catalyst

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 3RD generation CRS

Source: Bosch

Special features (Advantages)

of the 3rd generation
„ The inline injectors with their piezoelectric actuator
built into the injector shaft and lying very close to the
needle of the injector jet
jet.
„ "The new injectors have 75% fewer moving parts
and 75% less mass. This allows them to switch twice
as fast as conventional magnetic and piezoelectric
injector."
„ Lower diesel engine emissions by up to 20%,
„ Increase the achievable engine power by 5% to 7% 7%,
„ Reduce fuel consumption by 3%
„ And noticeably lower engine noise by 3 dB(A) -
depending on the specifics of engine development".

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 Piezo inline injector

Source: Bosch

Source: Bosch

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 Conclusions
„ The higher the injection pressure, the higher the
thermodynamic efficiency.
„ The higher the injection pressure, the injection duration
will be shorten.
„ This makes the direct injection diesel engine the most
thermodynamically efficient of all the internal combustion
alternatives.
„ Raising the injection pressure results in higher engine
output, improved d torque, better
b fuel
f l efficiency,
ff reduced
d d
emissions and lower noise levels.
„ 2nd & 3rd generation CR systems inject the fuel at an
even higher pressure than the original, 1st-generation
systems, increasing the benefits still further.

Thank you
謝謝!

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