Common Rail System

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesels impact on the environment. 1. Up to 1,800-bar injection pressure 2. Up to five times multiple injection per cylinder

The features greatly reduce visible smoke, particulate matter and NOx while minimizing engine noise.

Common Rail System

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesels impact on the environment. 1. Up to 1,800-bar injection pressure 2. Up to five times multiple injection per cylinder

Cleaning up diesel exhaust gas

Diesel fuel is injected into the combustion chamber at ultra high pressures of up to 1,800 bar to ensure more complete combustion for cleaner exhaust gas.

Minimizing engine noise

Highly precise multiple injection creates combustion to reduce NOx emission and combustion noise.

Common Rail System

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Innovative technologies greatly reduce diesels impact on the environment. 1. Up to 1,800-bar injection pressure 2. Up to five times multiple injection per cylinder

Single Injection (Conventional)

Pilot Injection (First-Generation Common Rail)

Multiple Injection (Five Times)

Common Rail System

Single Injection
Single Injection Pilot Injection

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Multiple Injection

time

Condition Passenger Car Engine: 2L / 4cyl Turbo Direct Injection Noise at Idling

Common Rail System

Pilot Injection (Two Times)
Single Injection -3 B Pilot Injection

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Multiple Injection

time

Condition Passenger Car Engine: 2L / 4cyl Turbo Direct Injection Noise at Idling

Common Rail System

Multiple Injection (Five Times)
Single Injection Pilot Injection -4 B

BENEFIT

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Multiple Injection

time

Condition Passenger Car Engine: 2L / 4cyl Turbo Direct Injection Noise at Idling

Common Rail System

TECHNOLOGY Co mmo n Rail Sy stem
1,800 bar injection pressure is equivalent to the water pressure of a depth of 18,000 meters deeper than the Mariana Trench, the worlds deepest ocean bottom. High response injectors by electronic control feature the highly accurate multiple injections (five times). As a result, particulate matter and NOx are markedly reduced, w hile improvements in fuel efficiency and torque are achieved. Plus, engine noise and vibration are also reduced.
High High pressure pressure capacity capacity technology technology Magnetic Magneticvalve valve technology technology

TECHNOLOGY

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine
Diesel Engine Management Sy stem
EGR V alve

DPF

Common Common rail rail technology technology

ECU ECU technology technology Sensor Sensor technology technology

Diesel engines have the advantages of good fuel efficiency and low CO2 emissions. Therefo re, DENSO developed a diesel engine management system to further clean up emissions w hile improving fuel efficiency. This system is a product of various forms of advanced technology. Among them is the common rail system employed in the fuel injection.

Common Rail System

TECHNOLOGY 1 Supply Pump
The first-generation supply pump could generate pressures of up to 1,450 bar, w hich represented the mechanical limits of the inne r cam design. However, to achieve pressures above this, DENSO developed revolutionary new coating and machining technologies, and by the secondgeneration design, changed to an outer cam design in the supply pump to achieve pressures up to 1,800. Supply Pump
Feed Pump To Rail

TECHNOLOGY

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Plunger Cam Ring

Housing Cam Shaft Connecting Pipe Suction Control Valve Eccentric Cam

TECHNOLOGY 2 Co mmon Rail

Common Rail
From Supply Pump To Injector To Injector

In order to w ithstand 1,800-bar pressure the rail must be w ithout any clearance or machining error. In response, DENSO developed a special material that contains few er compounds, w hile exhibiting high purity and high hardness properties to enable ultra high-precision machining. Thus, it is possible to create engine components that can w ithstand pressures up to 1,800 bar for use in the common rail system.

Pressure Sensor

Pressure Limiter

Common Rail System

TECHNOLOGY 3 Solenoid Injector
Compared w ith its first-generation injector (1,450 bar, tw o-times injection) DENSO developed higherresponse solenoid actuator and high-pressure Solenoid Valve injector design. The second-generation injector is able to inject up to 1,800 bar pressure and multiple injection, w ith timing intervals of 4/10,000 seconds during w hich a maximum of five injections takes place. As a result, exhaust gas is cleaner w hile noise is minimized. In injection control systems, advanced piezoelectric components are employed because of their high speed operation capability. But DENSO was successful in developing conventional solenoids that operate in 0.2 millisecond units.
Command Piston

TECHNOLOGY

DENSOs second-generation 1,800-bar common rail for cleaner and quieter diesel engine

Injector (up to 5 times injection a cylinder)

160M Pa Qpilot :2mm3/st , Qpre: 2mm3/st , Qmain:80 mm3/st , Qaft er:5mm3/st , Qpost :2mm3/st ,

From Rail (high pressure) Drive Current (A)

time

Valve Lift (m)

time 1.0ms

Nozz le

Injection Rate (mm3/ms)

time