Doosan Common Rail Engine

Feb, 2009
Overseas Product Support Team
Text No. ENG0001
Contents

1. Electrical engine system (Common Rail System)

2. Over view common rail engine ( DL06/ 08, DV11)
3. ECU
4. CP Pump
5. Common Rail
6. Injector
7. Sensors
8. Valve Gap Adjusting & Maintenance
9. Fault Code
10. Trouble Shooting

1
1. Electrical engine system (Common Rail System)

2
Issue of current diesel engine

Why do we need to use a new generation engine?

What is the difference between current engine and new generation engine ?

3
Current Issues of Diesel Engines

Emission
- Nitric oxide (NOx) Regulation
- Particulate matter (PM)
- Power density
- Noise
NOx, PM,…
- …….

4
Emission regulation

1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

37kw-75kw 9.2/0.85 (NOx/PM) 7.0/0.4 [4.7]/0.4[Nox+HC]/PM

(~ DB58)

75kW-130kW 9.2/0.70 (Stage-1) 6.0/0.3 (Stage-2) [4.0]/0.3 (Stage-3)

(DB58T/TI)

130kW-560kW 9.2/0.54 6.0/0.2 [4.0]/0.2

(DE08 ~)

Nox (g/kWh) 9.2 → 6.0 → 4.0

DL08 ~
PM (g/kWh) 0.54→0.2 → 0.2

5
 Emission Regulation (EU) - 1

Off-Road Engines (g/kWh)

Net Power Effective
Regulation CO HC NOx PM Engine
kW(HP) from
Stage2 Jan. 2003 5.0 1.0 6.0 0.3 DB58TIS
75 130 Stage3A Jan. 2007 5.0 4.0 0.3 DL06
(100) (175) Stage3B Jan. 2012 5.0 0.19 3.3 0.025 DL06
Stage4 Oct. 2014 5.0 0.19 0.4 0.025 DL06

Stage2 Jan. 2002 3.5 1.0 6.0 0.2 DE08TIS, DE12TIS

130 560 Stage3A Jan. 2006 3.5 4.0 0.2 DL08, DV11
(175) (750) Stage3B Jan. 2011 3.5 0.19 2.0 0.025 DL08, DV11
Stage4 Jan. 2014 3.5 0.19 0.4 0.025 DL08, DV11

On-Road Engines (Heavy Duty) (g/kWh)

Effective
Regulation CO HC NOx PM Engine
from
Euro3 Oct. 2000 2.1 0.66 5.0 0.10 DL06/DL08/DV11
Euro4 Oct. 2005 1.5 0.46 3.5 0.02 DL06/DL08/DV11
Euro5 Oct. 2008 1.5 0.46 2.0 0.02 DL06/DL08/DV11

6
Emission Regulation (EU) - 2

(DB58TIS)

(DE08~)

7
 Emission Regulation (USA)

8.0
NOx [g/kW.h]

Off-road(75-130kw)
6.0 US1998
Off-road(130-560kw)
4.0 On-road vehicles

2.0 US2004 US2007

0.0
1995 2000 2005 2010 2015

0.6
PM [g/kW.h]

0.4 Tier 2 Tier 3

0.2
Tier 4
0.0
1995 2000 2005 2010 2015

8
Diesel engine combustion process

Compression stroke
(High air temp.)
1. Fuel injection

2. Fuel evaporate and mix air

Combustion stroke
 Ignition delay

3. Combustion
Exhaust stroke  Beginning of combustion

4. Diffusion combustion
Intake stroke

9
Rate of heat release diagram

Beginning of
combustion (3)
Temp.
NOx
Diffusion combustion (4) Last combustion

PM (Smoke)

Ignition
delay (2)

170 180 190 200 Crank Angle

• To reduce NOx Combustion temperature ▼

- Common rail system : Pilot injection, EGR
• To reduce Smoke Fuel injection pressure ▲ (for perfect combustion)
- Common rail system : Fuel atomization

10
Mechanical Fuel Injection System (1)

Fuel injection is controlled

by mechanical system.
- Fuel injection pressure is limited
(100 ~ 500 bar)
- Fuel injection timing is limited
(BTDC 20 ~ ATDC 10)
- Fuel injection frequency is limited
(Max. 2 times by 2 stage nozzle)
- Fuel injection quantity is limited
(Plunger capacity)

Mechanical fuel injection system is insufficient for satisfying the severe emission regulations.

11
 Mechanical Fuel Injection System (2)

1.Injector :
1. Injector Injection fuel to cylinder by mechanical control and one or
two time injection fuel.

2. Plunger :
Make high pressure fuel to deliver fuel

3. Timer :
Adjust fuel injection timing.

3. Timer 4. Balance weight :

Determine injection fuel volume by engine RPM .

4. Balance weight
2. plunger

12
Common Rail System

Fuel injection is controlled electronically

- Fuel injection pressure can be increased
(400 ~ 1600 bar)
- Fuel injection timing is more flexible

- Fuel injection frequency is more flexible

- Fuel injection quantity is more flexible

Common rail system can overcome the several

limitations of mechanical fuel injection system.

Common Rail System is the better solution to meet the stronger emission regulations.

13
Common Rail System

• High pressure fuel supply pump

 high fuel pressure

• ECU :
Determine the optimal fuel quantity,
injection timing, and injection frequency

14
Main Components (1)

1) High pressure fuel supply pump (CP pump)

2) High pressure pipe (=Injection pipe)

3) Common rail with pressure limiter valve and rail pressure sensor

4) Injector / High pressure connector

5) ECU

6) Sensors (Accel. Pedal, Temperature ,Pressure …)

7) Harness (Engine, Injector, Vehicle harness)

15
Main Components (2)

High Pressure fuel

supply pump (CP3) Rail Pressure Sensor

High Pressure
Pipe

Injector

Pressure Limiter Valve

ECU
Common Rail

16
Common Rail Fuel Supply System

17
Heat release diagram of Engine

Temp’
NOx
①

PM (Smoke)
②

CRS Angle

① Reduce Temp. : Multiple injection and E.G.R.

② Completely burn fuel : Better fuel atomization by high press fuel injection

18
Multiple Injection

Dispose noxious fumes Inj.

Main Inj.

Noise Control Inj.

Post Injection
Pilot Injection

19
IEGR - Internal Exhaust Gas Recirculation (I)

A little exhaust gas is mixed with intake fresh air through the small opening of intake valve during the
exhaust stroke.
1. Prevent excessive supply of oxygen into cylinder during air suction stroke.
2. Reduce the combustion gas temperature

20
IEGR -Internal Exhaust Gas Recirculation (II)

EGR makes combustion temperature dropped. How?

Combustion stroke

1) If ‘only fresh air’ is supplied into cylinder, combustion gas

temperature is higher than the case of ‘fresh air and
exhaust gas’.

2) If ‘fresh air and a little exhaust gas’ is supplied into

cylinder, combustion temperature is lower than the case
of ‘only fresh air’ because of less oxygen in cylinder.

In order to increase the exhaust gas temperature 1℃,

lots of calorie is needed. It means that the exhaust gas
consumes lots of energy to increase the temperature.

21
Fuel Injection Pressure (Common Rail vs. Other System)

Common Rail Unit Injector

2200 2200
2000 2000

Injection Pressure, bar

1800 1800
Injection Pressure,bar

1600 1600
1400 1400
1200 1200
1000 1000
800 800
600 600
400 400
200 200
0
0
0 500 1000 1500 2000 2500 0 500 1000 1500 2000 2500
E n gi n e s pe e d,r pm Engine s peed, rpm

22
Fuel Injection Pressure vs. Atomization

Injection volume SMD Particle number

7.8mm 1
250mm3 20μm 59,683,116
10μm 477,464,929

23