10th Diesel Emission Reduction Conference

Advanced Diesel Common Rail Injection System for Future Emission Legislation
Roger Busch Common Rail System Engineering for PC Diesel Systems Robert Bosch GmbH

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Outlook
Drivers and Challenges for PC and LDT - Diesel

Overall System Requirements for Advanced Common Rail

BOSCH 4th Gen Common Rail Injection Systems

Potential Evaluation of 4th Gen Common Rail Systems

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Diesel System Innovations

Diesel Progress - PC

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Diesel System Innovations

1936

2003

spec. Torque [Nm/l]

Consumption [l/100 km]

149 Nm/l

9,5 l/100km 33 kW

51 Nm/l

48,4 kW/l

6,5 l/100km

130 kW eff. Power [kW]

13,0 kW/l spec. Power [kW/l]

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Approval Data for PC - Diesel at least Euro 3

source: KBA Germany

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Diesel System Innovations

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

DEER 2004 4th Gen Diesel Common Rail Injection System

Outlook
Drivers and Challenges for PC and Truck - Diesel

Overall System Requirements for Advanced Common Rail

BOSCH 4th Gen Common Rail Injection Systems

Potential Evaluation of 4th Gen Common Rail Systems

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

PC Common Rail System 4th Generation

FIE Requirements Evaluation

Pressure at the needle

3 max. injection pressure 2b 4

Sensitivity analysis of important injection parameters for the engine performance

Needle lift

2a

6a

6b
Time

Feature: 1 Pilot injection (number, time gap, quantity, tolerance) 2 3 4 5 6 Opening pressure, influence of pressure ramp, gradient Max. injection pressure, influence of small nozzle holes Pressure gradient during closing Post injection (near, late, influence of pressure level) Opening and closing speed of the needle
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FIE Requirement Evaluation - Summary

Potential Analysis for PC an LDCombustion Process and FIE

NOX [g/kg] Particles / NOx = 1/10 7 6 5 4 3 2 1 0
series applications cept cept cept cept cept cept ept cept cept cept cept ept c c n on on on on on on Co on on on on on
C C C C C C C C C C C A B C D E F G H I K L M

n = 2000/min, BMEP = 6,5 bar Euro3 Euro4

Euro4/ 3 1400 kg inertia weight

fast needle opening velocity but: injection rate during ignition delay injection rate after start of combustion

vario nozzle rate shaping

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4th Gen Diesel Common Rail Injection System "Euro 5" - Einspritzsystem

Optimal Shape for PC Engines

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DEER 2004 4th Gen Diesel Common Rail Injection System

CRS System Requirements for PC - Summary

full flexible timing of multiple injection events full flexible choise of injection pressure in the engine map
still valid and well - known small precise and stable injection quantities

from series Common Rail technology, gaining goals on noise, power, Euro4 - emission and maintaining EGT
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DEER 2004 4th Gen Diesel Common Rail Injection System

CRS System Requirements for PC - Summary

good spray formation low Noise and NOx - formation high spray momentum increase EGR acceptance seperate injection and burning phase

very fast needle opening @ start of injection limited quantity during ignition delay, but

max. allowed injection rate to increase local air ratio strong increase of injection rate after start of combustion high maximum of main injection rate strong rate decrease and fast needle @ end of injection

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DEER 2004 4th Gen Diesel Common Rail Injection System

Outlook
Drivers and Challenges for PC and Truck - Diesel

Overall System Requirements for Advanced Common Rail

BOSCH 4th Gen Common Rail Injection Systems

Potential Evaluation of 4th Gen Common Rail Systems

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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PC Common Rail System 4th Generation

Piezo-Injector with Coaxial-Vario-Nozzle CRI4-PV

Injector -Charakteristics z Basis: CRI3
z z z z

Systempressure 1600/1800 bar Space requirement as CRI3 One row for part load Both rows for full load

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4th Generation Common Rail System for PC

Vario Nozzle Strategies

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NOx [g/kg]*

10 8 6 4 2 0 101 98 95 92 89 86 83 200 400 600

n=2000rpm, BMEP=6,5bar

with PI w/o PI

Avoidance of PI (except for cold engine and idle) Emission reduction Reduction of QHYD Noise reduction Indepentantly switchable 2nd row

Combustion Noise [dB(A)]

w/o PI

with PI

of spray holes
800 1000 1200 1400

hydraulic flow / cyl. displacement [cm/30s@100bar/dm] Current Configuration Potential Vario Nozzle
copying and passing on to third parties.

appropriate power output

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DEER 2004 4th Gen Diesel Common Rail Injection System

Advanced Common Rail Systems for PC

CRS 4 - Hydraulically Amplified Diesel Injection System Functions Rail Pressure up to 1350 bar HAD - Injector with hydraulic pressure amplification sophisticated closed loop fuel metering control innovative, delivery controlled high pressure pump platform Advantages small Qhyd and passive rate shaping to pull down raw emissions and noise @ part load max pressure > 2200 bar @ spray hole to reach high power and reduce raw emissions @ full load (US 06, e.g. LD in EU)
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PC Common Rail System 4th Generation

Hydraulically Amplified Diesel Injector (HADI)

Injector-Characteristics z System pressure up to 1.350bar z Pressure amplification 1:2 z Pressure at the nozzle up to 2.200bar z Pressure/lift controlled needle z Ramp rate shape z Space requirements as CRI2 z Conventional nozzle

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CRS - Roadmap Pkw und Light Duty < 6t

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Advanced Control Functions

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Advanced Control Functions

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DEER 2004 4th Gen Diesel Common Rail Injection System

Outlook
Drivers and Challenges for PC and Truck - Diesel

Overall System Requirements for Advanced Common Rail

BOSCH 4th Gen Common Rail Injection Systems

Potential Evaluation of 4th Gen Common Rail Systems

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Common Rail System 4th Generation

Diesel System Optimization

Vehicle mass

kW/l

EGT

FIE

EGT=exhaust gas treatment

FIE= fuel injection equipment

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Diesel System Innovations

Diesel Challenges - Emission Legislation PC

Europe
next step in legislation: Euro 5 NEFZ - cycle *

Scenario 1:
PM NOx = 0,01 g/km = 0,2 g/km

Scenario 2:
PM NOx = 0,0025 g/km** = 0,08 g/km**

CO/HC = 1,0/0,05 g/km

CO/HC = 1,0/0,05 g/km

* no high load test under discussion

copying and passing on to third parties.

** UBA - Requirement 06.2003

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Euro 5 - Estimation for PC

Euro 5 Estimation, Vehicle Inertia Mass: 1400 kg, out of best single cylinder results with series and prototype FIE
Euro 5 - engines & low , TC2, pHCCI ... Scenario 1:
0,14 55 % 0,12 47 % 0,10 36 %
Eng. Goal

Euro 4 - engines
0,20 NOx g/km 0,15 25 %

Euro 5
Scenario 2:

0,10 0,08 0,05 35 %

Eng. Goal
CRS 3.2 1800 bar CRS 4 CRS 4

CRS 3.0 1600 bar

with DPF NSC

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Euro 5 - Estimation for PC

Euro 5 Estimation, Vehicle Inertia Mass: 1800 kg, out of best single cylinder results with series and prototype FIE
Euro 5 - engines & low , TC2,pHCCI ... Scenario 1:
0,15 66 % 58 %
Eng. Goal

0,22

Euro 4 - engines
0,19 71 %

0,20 NOx g/km 0,15 25 %

Euro 5
Scenario 2:
36 %

0,10 0,08 0,05 35 %

Eng. Goal
CRS 3.2 1800 bar CRS 4 CRS 4

CRS 3.0 1600 bar

with DPF NSC

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DEER 2004 Common Rail Potential Evaluation for PC

Summary PC
Additonal EGT - effort scales with CRS - performance, vehicle weight and desired power output Facing a weak Euro 5 - scenario (NOx = 0,2 g/km) its most likely to fulfill the limits w/o DeNOx - measures, also with Euro 4 - engines Facing a severe Euro 5 - scenario (NOx = 0,08 g/km) and Euro 4 engines a DeNOx - measure seems to be mandatory. The DeNOx effort can significantly be reduced using high tech CR - systems First results out of advanced Euro 5 - engine - technology combined with engine measures (e.g. pHCCI, TC2 ) and CRS4 - FIE shows tremendeous improvement in NOx - reduction
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Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

DEER 2004 4th Gen Diesel Common Rail Injection System

Conclusion
The biggest challenge for future Diesel technology are the continiously strengthenend emission targets Key factors like power output, vehicle weight and the engine itself scaling the effort on exhaust gas treatment side 4th Gen Common Rail Injection Systems combinded with modern Diesel engines provide lowest raw emissions and fuel consumption values.

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10th Diesel Emission Reduction Conference

Thank you for your attention.

BOSCH

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