DIESEL COMMON RAIL

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DIESEL COMMON RAIL

2
TRITON

3
 TYPE OF ENGINE

MITSUBISHI 4M41 ( 3200 cc. ) , 4D56 ( 2500 cc. )

4M41 4D56 4
 CONVENTIONAL DIESEL
ENGINES
• Why now engine diesels have to used CRS?
• Because convention diesels engine have some problem. “ Examples ”

Emission
Odor

Noisy

Difficult to Start 5
 DIESEL ENGINE IMPROVEMENTS

COMMON RAIL SYSTEM

Higher injection pressure, Improved atomization, Multiple injection

Clean

Low
Easy to Start Noise 6
 REQUIREMENTS OF THE NEW FUEL INJECTION
SYSTEM

COMMON
COMMONRAIL
RAILSYSTEM
SYSTEM
Injection Timing Injection Rate
Injection Pressure Control Control Control
Optimization, High Pressurization Optimization Pilot Injection

Injection Rate
Main
Common Rail
Injection Pressure

Common Rail Injection

Injection Timing
System
System
Crankshaft Angle
Particulate

NOx
Injection Quantity Control
Cylinder Injection Volume
Conventional Conventional Correction
Pump Pump

Speed
Engine Injection Engine
Speed Pressure Speed 1 3 4 2

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WORLD OF THE COMMON RAIL SYSTEM DIESEL

8
 DENSO’S DIESEL HISTORY: COMMON RAIL
SYSTEM

• 1995 – Launched the WORLD’S FIRST INNOVATIVE Common

Rail System for trucks.

• 1996 – Began supplying Common Rail Systems for passenger cars.

• 1999 – Debuted a Common Rail System for the European market.

• 2002 –Introduced the 1,800 bar Common Rail System technology

(HIGHEST IN THE WORLD*).

*- DENSO’s 1,800 bar Common Rail System comfortably cleared EURO 4 emission regulations (Standards
apply to emission limits for new model year passenger vehicles, as of January 1, 2005).

9
 PRESSURE

NOT TO
SCALE!

~1,834 Kg/cm2
~1,834 Kg
180 MPa
1 Cm
1Cm

This means 16 average adult male African elephants (5.2 t) can weight up on the name card
(45cm2 ).
10
 INJECTION RATE

NOT TO SCALE!

Average Human Y
Blink Injection
Volume
74 mm3
(mm3/stroke) Main
Injection

2 mm3
Pilot
Injection

X
Time
(msec)
300-400 msec. 1.1 msec.

11
 PLUNGER CLEARANCE

NOT TO SCALE! X-Sectional View of

Human Hair
0.5 ~ 1 μm (Magnification)
Cylinder

Plunger 70 ～ 100 μm 12
 COMPOSITION AND OPERATION

Vehicle Speed
Accelerator Opening
Intake Air Pressure
Intake Air Temperature
Coolant Temperature E.C.U.
Crankshaft Position
Fuel Delivered to
Cylinder Recognition Sensor
Injectors
Intake Airflow Rate

Pressure Injector
Limiter
LEGEND Rail
Low Pressure Fuel
Rail Pressure
High Pressure Fuel Sensor
Return Fuel

Electrical Signal

Supply Pump
Depend on

Fuel Tank
Fuel Suction Control
Valve (SCV) 13
Temperature
Sensor
 COMPOSITION

Crankshaft
Position
Cylinder
Recognition E.C.U.
Sensor
135
135MPa.
MPa.
Various
Sensor
Pressure
Limiter
Rail Injector
(G2)
Rail Pressure
Sensor
Supply
Supply Pump
Pump
Pressure SW.
(HP3)
(HP3)

Fuel
Filter Fuel
FuelFilter
Filterand
andWater
Waterlevel
level
warning lamp.
warning lamp.
Suction Control Fuel Tank
Valve (SCV) 14
 COMMON RAIL SYSTEM

Good point of CRS System

Injection Pressure , Injection Rate , Accurate for Engine Operate

Injection Timing Control by ECU

Fuel high pressure Atomize Fuel injection

High pressure Fuel Injection all

Fuel high pressure storage Engine speed

After diesel engine used CRS. we get up

• High performance and Fuel Economize

• Low noise and Reverberate
• Low Pollution 15
 CONVENTIONAL VS. COMMON RAIL
SYSTEM

Weak point
Un-constant High Pressure
CONVENTIONAL PUMP

Pump Timer
Governor Nozzle

Feed Pump
In-line Fuel Filter
Fuel Tank

COMMON RAIL SYSTEM

Fuel Filter Pressure Sensor Two Way

Valve

Constant High Injector

Pressure
Fuel Tank
Rotary
Good point 16
 COMPARE HOW TO CONTROL BETWEEN
CONVENTIONAL AND COMMON RAIL SYSTEM

In-Line Type Common Rail System

Constant High Pressure
Un-Constant High Pressure

High Pressure
System Pipe
Rail
Timer
Governor
Nozzle
Supply Pump Injector
In-Line Pump
(HP3)

Injection Quantity Control Governor Engine ECU, Injector

Injection Timing Control Timer Engine ECU, Injector
Pressurization Pump Engine ECU, Supply Pump
Fuel Distribution Pump Engine ECU, Rail
Injection Pressure Control Depends on SPEED and INJECTION quantity. Engine ECU, Suction Control Valve

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 COMMON RAIL SYSTEM
Parts Location
Front Engine

Fuel pipe to injector Injector

Fuel pipe to Rail

Supply pump Rail

•SCV • Pressure sensor
•Fuel temperature • Pressure limiter
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19
 SUPPLY PUMP
Model: HP3 Type

Rotational Ratio (Np:Ne): 1:1

Maximum Speed: 4,600 RPM

Direction of Rotation: Clockwise (drive shaft)

Supply Pump Feed Pump Trochoid Type
(HP3)
Rated volt 12 volt

Operation Volt
Assured Op 8 ~ 16 volt
Feed Minimum Op 6 volt

Component Parts
Pump

SCV
Type Normally Open
Electric
2.1 Ω
Resistance
Drive Suction Between
Shaft Control Terminal and More than 100M Ω
Valve Plunger valve
Aluminum / DiameterNo.  8.5 mm  2
Steel Hybrid
Construction Lift Amount 5.6 mm

Fuel Temp. Sensor 110.8  25.420

K
      
SUPPLY PUMP STRUCTURE

     

Ring Cam Delivery valve

Suction valve

     

Plungers      
Feed pump

Fuel
temperature
sensor
SCV
( Suction Control Valve ) 21
Plungers (A and B) are Plunger A
mounted on top and bottom of
the ring cam. The intake Feed
valves are mounted on the top Pump
and bottom of plungers A and
B respectively.

Ring
Drive
Cam
Shaft

Plunger B
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 OPERATION OF THE SUPPLY PUMP

Intake
Valve
Discharge
valve
Plunger A

Eccentric
Cam
Ring Cam

Drive
Shaft
Plunger B
SCV

Discharge
valve 23
Intake Valve
 SUPPLY PUMP

– SCV opening for fuel quantity control and make high pressure control

[ Fuel pressure control ]

Rail Pressure Sensor ( Pc Sensor )

SCV
Sends a signal to the engine ECU

Sends a signal to
Control SCV opening Crankshaft Position
Calculate for
target pressure

Accelerator Opening
Engine ECU.
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 FUEL TEMPERATURE SENSOR

Rear
View Temperature Resistance
(ºC) Values (k)
-30 25.4
-20 15.01.5
-10 9.16
Fuel HP3 0 5.74
Temperature 10 3.70
Sensor 20 2.450.24
30 1.66
40 1.15
50 0.811
60 0.584
70 0.428
80 0.3180.031
90 0.240
100 0.1836
110 0.1417
120 0.1108

N.T.C. = Negative Temperature

Exterior View of Fuel
Coefficient 25
Temperature Sensor
 FUEL TEMPERATURE SENSOR

The fuel temperature sensor detects the fuel temperature and outputs it to the E.C.U. The
sensor uses a thermistor, which varies resistance according to temperature. As the E.C.U.
applies voltage to the thermistor, it uses a voltage divider circuit contained inside the
E.C.U. to detect the temperature.

E.C.U.

+5V VTHL
RD 5
VTHL

Output Voltage
4
3

(V)
Fuel
2
Temperature
Sensor 1
A-GND
0 THL
-40 -20 0 20 40 60 80 10 12 (ºC
(ºC
-40 -4 32 68 10 14 17 21
0 248
0 (º)F)
4 0 6 2
Fuel 26
Temperature
27
 RAIL STRUCTURE

Rail Pressure
Sensor

Inlet
Fuel
Rail

Pressure
Limiter

To
injector
(4)

Exterior View of the Rail

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 RAIL STRUCTURE

System Pressure
180 MPa
(NORMAL):

Pressure
Limiter

Rail Stores pressurized fuel that has been

Pressure Rail delivered from the supply pump (HP3)
Sensor Fuel and distributes the fuel to each injectors.
Inlet A rail pressure sensor and the pressure
limiter are adopted in the rail.

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 RAIL PRESSURE SENSOR

Fuel pressure detect ( in the rail )

Qualification of Sensor
Pressure Sensor

4.2
3.56

V out
2.6
1.32
1.0

0 20 100 160 200

Rail Pressure (MPa)
Fuel Pressure from the Rail

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 RAIL PRESSURE SENSOR

Pressure Sensor The rail pressure sensor (Pc) is attached to the rail,
(CUT AWAY) in order to detect the fuel pressure.
It is a semiconductor type pressure sensor that
utilizes the characteristics of silicon, whereby the
A electrical resistance changes when pressure is
applied to it.

V out / V c V c = 5V
Pressure
0.84
Sensor
Rail

0.2
Vc Vout GND
0 200
31
View A Rail Pressure
(MPa)
 PRESSURE LIMITER

Role of the pressure limiter is to release any

ABNORMALLY high pressure generated
inside the rail.
When the rail pressure reaches approximately
221MPa, it trips the pressure limiter (valve
opens). During this time, the pressure will
drop to 50MPa. When it does, the pressure
limiter returns to its normal state (valve
closes) in order to maintain the proper
pressure inside the rail.
Pressure
Limiter 221 MPa
Valve Open
Rail

Operating Pressure: 2219 MPa

Valve Close
50 MPa
Return Pressure: 50 MPa

Pressure (MPa) 32
 RAIL

• Storage fuel high pressure (Maximum. 180 MPa) from Supply pump

Pressure Limiter
Pressure Sensor

Rail

From Supply To Injector To Fuel Tank

pump 33
34
 CONSTRUCTION  OPERATION

Engine Model: 4D56

Operating Voltage: 85V~12V

Injection Frequency: 2 Times

85 V
Model: DLL-P
Nozzle

Opening Pressure: 2.950.5 MPa

Driving Pulse
Spray Hole
DiameterNo. of  0.153mm6
Holes:
Injector
Nozzle
(G2)
Needle

Spray Hole 35
( )
 CONSTRUCTION  OPERATION
Inject the fuel high pressure with atomize.

ID CODE

FUEL RETURN TO FROM THE

THE TANK RAIL

4D56 = 0.153 X 6 MM.

36
 INJECTOR CONSTRUCTION

Solenoid

From Rail
Fuel return to the
tank

Command
Piston

Nozzle
Spring

Nozzle
Needle 37
Injection speed ： 200m/sec
38
Spray size ： 20 ～ 30μ ｍ
 INJECTOR

Pilot injection control for reduce noise and Nox after combustion

Main
Pilot
Injection Rate
Large First-stage
Combustion ( Nox and
Noise )

Heat Release Rate

TDC TDC
Normal Injection Pilot Injection

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40
CONTROL YSTEM

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 EDU (Electronic Driver Unit)

Activate Injector with high accuracy.

Command

Battery

DC High Voltage
DC // DC
DC
Converter

Crankshaft Position Command

Control
Control
Cylinder Recognition Sensor Confirm Circuit
Circuit

Various Sensor Work at high speed

EDU response

Injector

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 MITSUBISHI TRITON COMMON-RAIL DIESEL

High efficiency of Electronic control system will be adjust the injection rate and timing with
more accuracy depending on driving condition.

Driving condition
Vehicle Speed
ECU 32 bit

Accelerator Injection timing control

Injection rate control
Opening
+
Various Sensors Pilot Injection

More accuracy of Electronics

control system

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 MASS AIR FLOW SENSOR

Intake Air
Temperature sensor

Thermister Air Flow

Hot Wire

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Vacuum Chamber
Silicon Chip Intake Air
pressure sensor
5V
PB
GND

P-GND

Filter To Intake
Silicon Chip Air manifold
Intake Air pressure

4.5
Output Voltage (PB)

3.2

0.5

66.6 202.7 266.6 kPa(abs)

(500) (1520) (2000) (mmHg)(abs) 45
 FUEL SYSTEM
Fuel Filter
Fuel filter
Warning switch Hand pump

To supply pump

From Fuel tank

Fuel filter case

(Aluminum)

Filter
Water level
warning switch

46
 FUEL SYSTEM

Hand pump
Fuel filter
Warning switch

From Fuel Tank To Supply pump

Filter Fuel filter case

(Aluminum)

Water level
warning switch

47
 FUEL FILTER WARNING LAMP

Clogging of Fuel filter will be detected by Fuel filter warning switch .

Fuel filter warning

switch
Fuel Filter
warning lamp

Clogging

Combination meter.

Fuel Filter
- When Fuel filter have some
problem the Fuel warning lamp
will be show 48
 49

cleaner tomorrow
Thank-you!