Common-rail Diesel

Training
Video commonrail

2
History of Common-rail System
Different variations on Common-rail
– 3 Generations

Diesel EFI Common-rail

1st-generation
• Common-rail
• HP2 Supply Pump 2nd-generation
• Solenoid Injector
• HP3 Supply Pump
135 MPa • Discharge Valve 3rd-generation
• Injector Compensation
• NSR + DPNR
Code
• Piezo Injector
Max. Common-
rail Pressure 135 - 160 MPa
160 - 180 MPa

3
System Overview
Common-rail System Diagram (for IMV)

NE Signal Engine
EDU
G Signal ECU
Other Injectors
Various
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail

Injector
Pressure
Switch

Fuel Cooler
Fuel
SCV Fuel SystemFilter
Supply Pump Fuel Tank
Warning Light

4
System Overview
Main Components for Common-rail System
– Shown for the 1KD-FTV engine on the IMV
Engine
Front

Injection Pipe Injector

Fuel Inlet Pipe

Common-rail
•Fuel Pressure Sensor
Supply Pump •Pressure Limiter
•SCV (Suction Control Valve)
•Fuel Temp. Sensor
5
System Overview
Features of Common-rail System

Injection pressure, volume and

timing are controlled electrically High accuracy engine control

High pressure fuel Higher atomization of fuel

High pressure injection in all

Stores high pressure fuel
engine speed range

• High performance and fuel economy

• Low noise and vibration
• Clean emission

6
System Overview
Sensors and Actuators

Intake Restrictor
Air Flow Meter Valve (Step Motor)

Atmospheric Intake Air

Temp. Sensor Temp. Sensor

E-VRV (for EGR Turbo Pressure

Valve Control) Sensor

VSV (for EGR

VSV (for Turbo
Valve Close)
Pressure Sensor)

Camshaft
Position Sensor Glow Plug

Injector Water Temp.

Sensor
Crankshaft
Position Sensor

Illustration is for 1CD-FTV on CDE120

7
ECD System Components
Supply Pump
– Supplies the high pressure fuel to the common-rail
HP2 HP3

Type HP2 (Outer Cam) HP3 (Inner cam)

Generation 1st 2nd/3rd
SCV 2 (Time controlled) 1 (Duty-cycle)
Plunger 4 (Radial Type) 2 (Opposite type)
Weight [g (lb.)] 6040 (13.32) 3800 (8.38)
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ECD System Components
Supply Pump (HP3)
– Fuel flow

Click!
Movie

9
ECD System Components
Supply Pump (HP3)
– Suction and pumping operation

Click!
Movie

10
ECD System Components
Supply Pump (HP3)
– Fuel control operation (SCV opening small)

Click!
Movie

11
ECD System Components
Supply Pump (HP3)
– Fuel control operation (SCV opening large)

Click!
Movie

12
ECD System Components
Supply Pump (HP3)
– The SCV opening regulates the pumping volume to
control fuel pressure

[Fuel Pressure Control]

Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU Position Sensor

13
ECD System Components
Common-rail
– Fuel pressure sensor (PCR)
• Detects the fuel pressure in common-rail and
provides feedback
To Injector From Supply Pump

Common-rail

[Fuel Pressure Sensor]

Pressure
Sensor Tip Limiter

Common-rail
Pressure

14
ECD System Components
Injector
– High pressure injection for higher atomization

Solenoid Solenoid
Coil From Coil
Common-rail
Return to
Fuel Tank
Control
Chamber
Nozzle
Spring

Click! Nozzle Piston

Movie Needle

Nozzle
Injector Hole 6 or 8 Spring

Injector Pressure 135 – 180 MPa

Nozzle
Voltage 150 V Needle

15
ECD System Components
Injector
– Small injection hall (0.14 mm)

[Top of Injector]

0.14 mm

Click!
Movie

16
ECD System Components
Injector
– Difference in the injection of gasoline and common-rail
[Gasoline Engine] [Common-rail Engine]

Engine
Engine EDU
ECU
ECU

Constant Low Variable High

Pressure Pressure
[Approx. 0.3 MPa] [30 – 160 MPa]

Injection
Volume
Injection Volume

High
Long
Common-rail
Electricity Time Electricity Time Pressure

17
ECD System Components
Injector
– Injection volume correction
• Injector compensation code

Injector
Compensation Code
QR Code Compensation Code Type (QR Code)

Injection Quantity
Activation Pulse Correction TQ

Laser Marking : Correction Point

18
ECD System Components
EDU
150V

Voltage
Battery 0V
EDU Time
+B COM1

High
Voltage
Generation
Circuit
High
Voltage
IJT#1
INJ#1
IJT#2
Control INJ#2
IJT#3
Circuit INJ#3
IJT#4
Engine INJ#4
IJF
ECU

GND GND

19
ECD System Components
Overview ECU Inputs

Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters

Intake Air Temp. Sensor (THA) EDU

Water Temp. Sensor (THW)
Fuel Temp. Sensor (THF) EGR Valve
Engine
Turbo Pressure Sensor (PIM)
ECU
Vehicle Speed Sensor (SPD) •
Fuel Pressure Sensor (PCR) •
•
Ignition Switch (STA)
Blower Switch (BLW)
A/C Amplifier (AC) DLC3

Alternator (ALT)

20
ECD System Components
Overview ECU Outputs

Injector (Timing and duration)

Suction Control Valve

Various Sensor EDU (Power supply)

Engine
• Intake Restrictor Valve
ECU
•
•
Glow Plug

EGR Valve

DLC3

21
ECD System Components
Crankshaft Position Sensor (Ne)

Crankshaft Position Sensor

22
ECD System Components
Accelerator Pedal Position Sensor (VPA, VPA2)

Magnets

Hall
ICs
23
ECD System Components
Turbo Pressure Sensor (PIM)

Turbo Pressure
Sensor

Engine
ECU

VSV (for Turbo

Pressure Sensor)

24
Common-rail Control Systems
Overall
– Consists mainly two parts, fuel metering part and fuel
supply part
[Electrical Part] •Injection Volume Control •Injection rate Control
•Injection Timing Control •Turbo Control
•Idle Speed Control •EGR Control
•Fuel Pressure Control •Glow Control
•Diagnosis

Various Sensor Engine ECU EDU

Supply Pump

Common-rail
Injector
[Mechanical Part]

25
Common-rail Control Systems
Fuel Injection Volume Control
– Basic injection volume

Accelerator Pedal Crankshaft Position

Position Sensor (VPA) Sensor (Ne)

Basic Injection
Volume Water Temp. Sensor (THW)
(Map Data in ECU)
+
Clutch Switch (CLSW)
Basic Injection
Volume Correction
Vehicle Speed Sensor (SPD)
Engine ECU ISC* Correction

*: Idle Speed Control

26
Common-rail Control Systems
Fuel Injection Volume Control
– Injection duration

Basic Injection Fuel

Volume Pressure

Comparison INJ Time EDU

Volume Calculation

Maximum Injector
Injection Injector
Compensation
Volume Feedback Value
Value
Engine ECU

Injector

27
Common-rail Control Systems
Fuel Pressure Control
– Target injection fuel pressure

[Fuel Pressure Control]

Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU
Position Sensor

28