Bosch DEF Doser Overview 06062013 01

Bosch DEF Doser Overview
CES DEF Doser Team

June 06, 2013
Contents
 System Schematic
 DEF Doser Components Options
 DEF Doser Components Details
– Supply Module, SM2.2
– Dosing Module, DM2.2 and DM2.5
– High Flow Dosing System
 Integrated Dosing Control
 RDM Operating States
 State Flow
 IUDC Heating Strategy
 IUDC Fault Codes
 Installation Layout
 Application Sign-off / Validation
 Recently Added (or in process to be added) Requirements
2 6/11/2013 Cummins Confidential

Abbreviations
 DEF: Diesel Exhaust Fluid
 SM: Supply Module
 DM: Dosing Module
 DCU: Dosing Control Unit
 IUDC: Integrated Urea Dosing Controls
 ECM: Engine Control Module
 DRT: Decomposition Reactor Tube

System Schematic

DEF Doser Components Options
Dosing Module, 2010 / 2013 On Highway,

DM2.2 T4F MR (QSB>174, QSL)
Supply Module,
SM2.2
Dosing Module, T4F LHP (QSF3.8),

DM2.5 T4F MR (QSB<174, QSB4.5)
Supply Module, Dosing Module,

SM2.2 DM2.2 T4F HD (QSX15)
(high flow) (high flow)

Standard DEF Dosing System
 DEF Flow Range: 0.036 – 7.2 kg/h
 DeNOx2.2- Standard dosing system consists of
– Supply Module, SM2.2
– Dosing module, DM2.2

Supply Module

Supply Module
 Pump Motor
– Uni-directional diaphragm pump
– Pump delivery: 20 L/h @ 9 bar (gauge)
– Pump motor driven by PWM signal
– Same PWM signal wire is used to transmit
SM temperature and SM heater temperature
to ECM
– Pump can only operate after SM defrosted
to avoid damage

Supply Module
 Reverting Valve
– Allows purging of hydraulic line with uni-
directional pump
– Enabled during After-Run stage (max. 3A @
16V, -15°C)
– Digital output signal from ECM (on/off)
– Operating temp: -15°C to 80°C
– Voltage range: 9V – 16V

Supply Module
DEF Backflow Connector
(Connecting geometry
according to SAE J2044 3/8”)
DEF Outlet Connector
DEF Inlet Connector (Connecting geometry
(Connecting geometry according to SAE
according to SAE J2044 5/16”)
J2044 3/8”)
On Highway Off Highway

Dosing Module (DM2.2)
Coolant Connectors DEF Connector

(Connecting geometry (Connecting geometry
according to SAE according to SAE
J2044 3/8”) J2044 5/16”)
Coolant
 Solenoid injector that delivers pressurized urea into exhaust

 Mounted on exhaust pipe with flange
 DEF spray through 3 holes
 Integrated filter
 Actively cooled with engine coolant water
Dosing Module (DM2.5)
Coolant Connectors
DEF Connector
(Connecting geometry according
(Connecting geometry
to SAE J2044 3/8”)
according to SAE J2044
5/16”)
Coolant Circuit
Electrical
Connector
Heat
Shield
Mounting Holes (3x)
 Solenoid injector that delivers pressurized urea into exhaust

 DEF spray through 6 holes
 Mounted on exhaust pipe with flange
 Integrated filter
 Actively cooled with engine coolant water
DM2.2 vs DM2.5
 Improved coolant body
 Improved materials of
injector components
(grommet, o-ring and
inner filter screen)
 Benefits of DM2.5:
– Improved temperature
robustness
– DM DEF inlet temp (max)
limit increased from 70°C
to 85°C
– DM Ambient temp
(continuous) limit increased
from 120°C to 140°C
2013 DRT Design
Mounting Mounting
Bolts Spacers Dosing
Module
Encapsulated
Gasket
Exploded view at
DRT interface
DRT with Dosing Module Clocking
On Highway Off Highway
Concerns:

High Flow Dosing System
 DEF Flow Range: 0.062 – 12.0 kg/h
 High flow dosing system vs standard dosing system
– Dosing Module: Orifice plate of the dosing valve is different
– Supply Module:
• ASIC integrated on pump motor PCB
• Reduced return flow
– No changes in the external dimensions, mounting requirements or electrical interface of
the components
– 4 New Part Numbers: 12V & 24V Supply module, backflow connector and dosing module
Pump motor
PCB- ASIC
integrated
hr
Orifice Plate
Backflow
connector
Electrical Specification
Item / Description Specification
without 12 V: 9-16 V
Performance Degradation (V) 24 V: 18-32 V
Commonality between 12V and Separate Supply Module PN for 12 vs 24

24V Systems Volt system
Poke Yoke between 12V and 24V Mechanical poke-yoke: different elec.
system if not common connectors
DM (12 V and 24 V): 1 A
Maximum Continuous Current Draw with
SM operation (12 V and 24 V):2 A
heating – SM, DM (A)
SM heating (12 V and 24 V): 10 A
Engine / Aftertreatment Communication
Electrical Interface
Network
EMC CISPR level 5
Quantity required
Manufacturer Function Part Number for each system
A 928 000 453, Kompakt 1.1 a
Dosing Module
Bosch Kompakt or 1
(Connector)
1 928 A00 517, Kompakt 4 (DM2.5)
Supply Module (12V) 1-1703639-1 1
Tyco
Supply Module (24V) 2-1703639-1 1

Integrated Dosing Control (IUDC)

Dosing control
Urea Tank
Line Heater
ECM DCU
Supply Module
Dosing Actuator
Cummins Bosch OEM
 Integrated Urea Dosing Control (IUDC) has been developed to

integrate controls functions of Bosch DCU into ECM.

IUDC Hardware System Block Diagram
SM Heater Line Heater

Relay (8) Relay (15)
Vbatt HR Vbatt
Unit Tmptr Heater Tmptr

Pressure
Sensor - Digital Sensor –
Sensor (2)
(6) Digital (7)
V 12/24 Accumulator
Heater (8a)
X
Pump HR
Motor (15c)
(4) GND GND
Power Supply to Dosing Line
Pump Motor Supply
Flow Control Valve (3) (10)
(4a) Unit
Intake Line (11) Return Line (9)
HR HR
Sensors: Doser Unit
(15a) (15b) (1)
• Supply Module pressure sensor GND GND
• Supply Module temperature sensor
• Supply Module heater temperature sensor Level
Sensor Tank Tmptr
• Tank Temperature (12) Sensor
• Tank Level (13)
Tank Unit
Coolant Valve
Actuators: for Heating (14)
• Pump Motor
• Reverting Valve
• Doser Injector Valve
• Supply module heater
Dosing Control

DEF Pump Control
1200 120
1000 100
800 80
Pump Pressure, Pump Cmd
600 60
400 40
200 20
0 0
20 40 60 80 100 120 140 160
-200 -20
Time (sec)
Pump Pressure (kpa) Pump Cmd (PWM)

RDM Operating States

RDM Operating States
 Init
– Startup. Heating ON if required.
 Standby
– USM request Standby. Determine if system ready conditions are met, e.g., tank and lines defrosted, exhaust
temperature above threshold, no doser related faults, etc.
 Preparing
– System Ready Conditions met. Dosing system is filled with DEF. Stable operating pressure is achieved.
 Dosing
– Stable operating pressure is achieved. Closed loop DEF pressure control. Open loop dosing rate command.
 OFF
– Return DEF from dosing system to the DEF tank and disable all heating circuits.
 SysErr
– System error detected. Return DEF from dosing system to DEF tank and disable all heating circuits.
 Service
– Service tool requests, e.g., bucket test, prime override, EOL

State Flow

Off Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
Defrost (if required)
CLOSED
Standby
Pressure Control
Fill
Fill
Pressure Control Pressure Vent

Pressure Control)
(Metering Control Pressure Vent

Init Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill
Fill

Pressure Control)

Temp Reading Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill
Fill

Pressure Control)

Temp Check Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill
Fill

Pressure Control)

Defrost Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill
Fill

Pressure Control)

Standby Mode
Off
[Key-On] SM OFF
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill
Fill

Pressure Control)

Fill Mode (Prime)
Off
[Key-On] SM ON
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill

(Metering Control)

Pressure Control Mode (Metering Control)
Off
[Key-On] SM ON
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
Standby
Pressure Control
Fill

(Metering Control)

Pressure Control Mode (Metering Control)
Off
[Key-On] SM ON
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
Standby
Pressure Control
Fill
Dosing of
Pressure Control Pressure Vent urea in
(Metering Control) exhaust pipe

Pressure Vent Mode
Off
[Key-On] SM
ON
Init
Temp Processing ON
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill

(Metering Control)

Fill Mode (Prime)
Off
[Key-On] SM ON
Init
Temp Processing OFF
Temp Reading
Temp Check p
Urea Purge
CLOSED
Standby
Pressure Control
Fill

(Metering Control)

Urea Purge (Prime)
Off
[Key-On] SM OFF
ON
Init
Temp Processing
Temp Reading
Temp Check p
Urea Purge
OPENED
Standby
Pressure Control
Fill

(Metering Control)

IUDC Heating Strategy

Urea Heating Control (UHC)
 At key-on, if urea is frozen, ECM will defrost system before priming the pump
– SM defrost is closed-loop controlled based on its own temperature sensor reading.
– Tank defrost is also closed-loop controlled based on tank temperature sensor
– Urea lines defrost is open-loop controlled based on ambient temperature (provided
by ECM)
 Once all circuits (SM, tank and lines) are defrosted, ECM will initiate
command to prime the pump.
– ECM will wait till all defrost is finished, before priming the pump.
– Under special situations, ECM can initiate prime command, as soon as SM is
defrosted
 After defrost is finished, if amb is still cold, maintenance heating will activate
to prevent urea from freezing again.
– SM will lose its temperature reading once defrost is finished (due to Bosch design),
therefore, SM heating is based on amb temp.
– Tank heating is still closed-loop based on its temperature
– Line heating is open-loop control based amb temp.

SM Heating Calibrations
 Defrost
– On: below C_USM_trc_UreaSuppT1_MinThd (-4 C)
– Off: above C_USM_trc_UreaSuppT1_MinThd(-4 C )
(no hysteresis)
 Maintenance heating (based on amb temp)

Line Heating Calibration
 Defrost
– On: Below C_UTC_trc_LineHtr1_ThawTmptrThd
default - 4 [degC]
– Off: Controlled by Thaw time
 Maintenance heating
– On: below 4 [degC]
– Off: above 6 [degC]

Prime Attempt After Defrost
 At normal key-on, if any of the heaters are in

defrost mode, the ECM will wait until defrost is
finished before sending prime command.

IUDC Fault Codes

Fault Codes

Fault Codes

Installation Layout

Installation Layout – Option A
 When this layout is used the bottom of the Supply Module must be
above the maximum possible fill level inside the DEF tank.

Installation Layout – Option B
 In the case that the Dosing Module is mounted below the highest point of the
Supply Module, there must be a hose siphon in the pressure line. This is to
ensure any residual fluid remaining in line after the purge cycle does not
reach the Dosing Module.

Installation Layout – Option C
 The Dosing Module is mounted above the maximum DEF level in the
Tank.

Installation Layout – Option D
 In the case that the Dosing Module is mounted below the highest
point of the Supply Module meaning there must be a hose siphon in
the pressure line.

Application Sign-off / Validation

Validation Tests
 Tests required for application sign-off;

– Hot Test
– Cold / Thaw test
– Vibration Test

Hot Test
 A hot test is required to validate the dosing system does not exceed its maximum
operating temperatures during the worse case scenario.
 Specific activities during test:
– Normal driving
• Full Tank
– Uphill driving
• 50% - 25% tank level
– 15 min idle after uphill drive
– Hot shut down
– Hot start up
– Downhill driving
– Running dry
– Stop – Go driving
– Stationary Regen

DEF Doser Temperature Limits
Specification Maximum
Location
Temperature
Max 70°C, 50°C Avg over lifetime

DM, DEF at Inlet (DM2.2)
(T3) Max 85°C, 60°C Avg over lifetime
(DM2.5)
DM, Coolant in,
110°C
out (T4 & T5)
DM, Electrical
120°C (DM2.2)
connector temp
140°C (DM2.5)
(T7)
DM, Fixing point
200°C
(T8)
120°C (Continuous)
DM, DEF at
120°C- 140°C: max 50 hours over Dosing module temperature
injector tip (T9)
lifetime measurement points
SM, Ambient 85°C
Max 70°C
SM, DEF at Inlet
50°C Average over lifetime
DEF Tank 50°C
Instrumentation points
 Dosing Module
– Nozzle tip
– Solenoid valve
– DEF temp at tip
– Coolant In / Out
– DEF temp to DM
– Body
– Electrical Connector
– Mounting flange
 Supply Module
– Supply connector
– Backflow connector
– Pressure connector
– Ambient
– Body

Cold Test
 Determine heating capability – successful thaw,

prime and normal dosing sequence.

Vibration Test
 Verify the vibration loads on the Supply Module and Dosing Module on pave
or rough road condition.
– The Dosing components are capable of meeting the vibration profile
defined in ISO 16750-3. The OEM must demonstrate these levels of
vibration are not exceeded during the normal operation of the vehicle.

Instrumentation points
Tri-axial acc
Tri-axial acc

Recently Added (or in process to be added)
Requirements
 DM coolant line routing requirement
 DM DEF line routing requirement

Coolant Line Routing Requirement
 Coolant lines must be routed in a way that will support cooling of the
dosing module under hot system conditions after engine shutdown.
Routing the coolant lines in this way will permit steam bubbles to vent
and replace the hot fluid from the Dosing Module cavity.
– For horizontal DRT installation
• The coolant line connected to the highest point on the dosing module must be routed with a
minimum positive slope of 35°and maintain a minimum of 16 cubic centimeters volume of
coolant immediately above dosing module before any dips in the line are allowed.
• The lower coolant line must be routed with a maximum positive slope of 0°from the
horizontal and maintain a minimum of 16 cubic centimeter volume of coolant before any
rises in the line are allowed.
– For vertical DRT installation
• As both the coolant connectors on the dosing module will be in the same horizontal plane,
one of the two coolant lines connected to the dosing module must be routed with a
minimum positive slope of 35°and maintain a minimum of 16 cubic centimeters volume of
coolant immediately above dosing module before any dips in the line are allowed.
• The other coolant line must be routed with a maximum positive slope of 0°from the
horizontal and maintain a minimum of 16 cubic centimeter volume of coolant before any
rises in the line are allowed.

Coolant Line Routing Requirements for Horizontal
DRT
90°
35°
0° A
0°
B
A: Coolant line connected at highest point

B: Coolant line connected at lowest point
90º Coolant Line Routing
Requirements for Vertical DRT
35°
0º
0º
0º
DRT
62 6/11/2013 CumminsConfidential
Cummins Confidential
DEF Line Routing Requirement
Minimum Elevation Angle ‘Yo’
DEF Line DEF line length above the Minimum Elevation

Length doser ‘X’ Angle Yo
1.0 M 300 mm (12 inches) 10
1.5 M 300 mm (12 Inches) 10
2.0 M 450 mm (18 Inches) 10
2.5 M 450 mm (18 Inches) 10
3.0 M 450 mm (18 Inches) 10

Thank You!

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Bosch DEF Doser Overview

CES DEF Doser Team

2 6/11/2013 Cummins Confidential

3 6/11/2013 Cummins Confidential

4 6/11/2013 Cummins Confidential

Dosing Module, 2010 / 2013 On Highway,

Dosing Module, T4F LHP (QSF3.8),

Supply Module, Dosing Module,

5 6/11/2013 Cummins Confidential

6 6/11/2013 Cummins Confidential

7 6/11/2013 Cummins Confidential

8 6/11/2013 Cummins Confidential

9 6/11/2013 Cummins Confidential

On Highway Off Highway

10 6/11/2013 Cummins Confidential

Coolant Connectors DEF Connector

 Solenoid injector that delivers pressurized urea into exhaust

Mounting Holes (3x)

 Solenoid injector that delivers pressurized urea into exhaust

15 6/11/2013 Cummins Confidential

Commonality between 12V and Separate Supply Module PN for 12 vs 24

17 6/11/2013 Cummins Confidential

18 6/11/2013 Cummins Confidential

Cummins Bosch OEM

 Integrated Urea Dosing Control (IUDC) has been developed to

19 6/11/2013 Cummins Confidential

SM Heater Line Heater

Unit Tmptr Heater Tmptr

21 6/11/2013 Cummins Confidential

Pump Pressure (kpa) Pump Cmd (PWM)

22 6/11/2013 Cummins Confidential

23 6/11/2013 Cummins Confidential

24 6/11/2013 Cummins Confidential

25 6/11/2013 Cummins Confidential

Temp Processing OFF

Pressure Control Pressure Vent

26 6/11/2013 Cummins Confidential

Temp Processing OFF

Pressure Control Pressure Vent

27 6/11/2013 Cummins Confidential

Temp Processing OFF

Pressure Control Pressure Vent

28 6/11/2013 Cummins Confidential

Temp Processing OFF

Pressure Control Pressure Vent

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Temp Processing OFF

Pressure Control Pressure Vent

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Temp Processing OFF

Pressure Control Pressure Vent

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Temp Processing OFF

Pressure Control Pressure Vent

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Temp Processing OFF

Pressure Control Pressure Vent

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Temp Processing OFF

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Pressure Control Pressure Vent

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Temp Processing OFF

Pressure Control Pressure Vent