TECHNICAL FEATURES

The Common Rail Diesel Injection System Explained

By source: Robert Bosch GmbH Jun 7, 2004, 10:15 In recent years, more and more drivers have been dra n to diese!"#o ered vehic!es$ Bosch has #!ayed a ma%or ro!e in this &uro#ean diese! boom$ 'he modern hi(h"#ressure in%ection systems )*44 distributor"#um#, +nit In%ector and ,ommon Rai! have trans-ormed the #onderous, smo.e"be!chin( s!o coaches o- yesterday into the s#orty, -ue!"e--icient and c!ean automobi!es o- today$ 'he ,ommon Rai! system in #articu!ar (ives en(ine deve!o#ers the -reedom they need to reduce e/haust emissions even -urther, and es#ecia!!y to !o er en(ine noise$ 'he #articu!ar desi(n o- ,ommon Rai!, ith its -!e/ib!e division o- in%ection into severa! #re", main and #ost"in%ections, a!!o s the en(ine and the in%ection system to be matched to each other in the best #ossib!e ay$ In the ,ommon Rai! accumu!ator in%ection system, the (eneration o- the in%ection #ressure is se#arate -rom the in%ection itse!-$ 0 hi(h"#ressure #um# (enerates in an accumu!ator 1 the rai! 1 a #ressure o- u# to 1,200 bar 3determined by the in%ection #ressure settin( in the en(ine contro! unit4, inde#endent!y o- the en(ine s#eed and the 5uantity o- -ue! in%ected$ 'he -ue! is -ed throu(h ri(id #i#es to the in%ectors, hich in%ect the correct amount o- -ue! in a -ine s#ray into the combustion chambers$ 'he &!ectronic 6iese! ,ontro! 3&6,4 contro!s e/treme!y #recise!y a!! the in%ection #arameters 1 such as the #ressure in the Rai! and the timin( and duration o- in%ection 1 as e!! as #er-ormin( other en(ine -unctions$

In the 1st and 2nd (eneration o- Bosch7s ,ommon Rai!, the in%ection #rocess is contro!!ed by a ma(netic so!enoid on the in%ectors$ 'he hydrau!ic -orce used to o#en and c!ose the in%ectors is trans"mitted to the %et need!e by a #iston rod$ In the 8rd (eneration o- ,ommon Rai! -or #assen(er cars, the in%ector actuators consist o- severa! hundred thin #ie9o crysta! a-ers$ *ie9o crysta!s have the s#ecia! characteristic o- e/#andin( ra#id!y hen an e!ectric -ie!d is a##!ied to them$ In a #ie9o in!ine in%ector, the actuator is bui!t into the in%ector body very c!ose to the %et need!e$ 'he movement o- the #ie9o #ac.et is transmitted -riction"-ree, usin( no mechanica! #arts, to the ra#id!y s itchin( %et need!es$ 'he advanta(es over the ear!ier ma(netic and current conventiona! #ie9o in%ectors are a more #recise meterin( o- the amount o- -ue! in%ected and an im#roved atomi9ation o- the -ue! in the cy!inders$ 'he ra#id s#eed at hich the in%ectors can s itch ma.es it #ossib!e to reduce the interva!s bet een in%ections and s#!it the 5uantity o- -ue! de!ivered into a !ar(e number o- se#arate in%ections -or each combustion stro.e$ 6iese! en(ines become even 5uieter, more -ue! e--icient, c!eaner and more #o er-u!$ :or its 4th (eneration o- ,ommon Rai! -or #assen(er cars Bosch is current!y e/#!orin( desi(ns usin( even hi(her in%ection #ressures o- more than 2,000 bar, as e!! as in%ectors ith variab!e in%ection (eometry$

Bosch ,ommon Rai! in%ection system 1 ;i!estones o- deve!o#ment 1<<7: :irst ,ommon Rai! system in the or!d -or #assen(er cars$ In%ection #ressure: 1,850 bar$ :irst #roduction use: 0!-a Romeo and ;ercedes"Ben9$ 1<<<: ,ommon Rai! system -or truc.s$ In%ection #ressure: 1,400 bar$ :irst #roduction use: Renau!t 3R)I4$ 2001: 2nd (eneration ,ommon Rai! -or #assen(er cars ma.es diese! en(ines even more economica!, c!eaner, 5uieter and more #o er-u!$ In%ection #ressure: 1,200 bar$ :irst #roduction use: Vol o and B;=$ 2002: 2nd (eneration ,ommon Rai! -or truc.s (ives !o er emissions, im#roved -ue! consum#tion and more #o er$ In%ection #ressure: 1,200 bar$ :irst #roduction use: ;0>$ 2008: 8rd (eneration ,ommon Rai! ith ra#id"s itch #ie9o in!ine in%ectors -or cars$ 0dvanta(es: u# to 20 ? !o er emissions or u# to 5 ? more #o er or u# to 8 ? !o er -ue! consum#tion or u# to 8 dB304 !ess en(ine noise$ In%ection #ressure: 1,200 bar$ :irst #roduction use: 0udi$ 'he 8rd (eneration ,omon Rai! -rom Bosch is characteri9ed by ra#id"s itch, com#act #ie9o"in!ine"in%ectors$ The inno ati e injection system p!o ides "o! lo# exha$st emissions in the ne# V% diesel en&ine o" the A$di A'(