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DCR

Deutz Common Rail System

Challenges in the Future Answered by Deutz CR

• New emission legislations

- On-road Euro 4 (10/2005) incl. exhaust aftertreatment

- Off-road Stage 3 (01/2006 ... 01/2008)

• Cost reduction

- DEUTZ‘s Medium Duty FIE (el. UPS) has a cost penalty against

the main C&I competitors‘ option for Stage 3

(el. distributor pump)

• Customer requirements

- Noise reduction ~ 3 dB(A) until 2006

- Torque increase 10...20 % (low end and max. torque)

- Main customer RVI is “Common Rail – minded“

Deutz FIE Strategy for the Future

• New electronic FIE to be developed for the Medium

duty engine families (SOP‘s: mid 2005)

• 2015 FIE (el. UPS) is attractive for the future

• 2011, 914: Product concept/strategy under work

(SOP‘s > 2006)

Einspritzleitung

Nockenwelle

Rollenstößel

Ausgleichscheibe

Kurbelgehäuse

Einspritzpum pe

Medium Duty families: Situation today

Deutz UPS Best in class (Common Rail)

System cost Fuel consumption Low end torque Engine noise Up to 1600 bar

Emission EU3

Deutz mech. UPS Best in class (el. distr. pump)

System cost Fuel consumption Cold start Electronic functions (EMR variant)

Up to 1350 barEmission EU2, C&I stage 2Electronics on demand

Options for the future

Unit Injector System Volvo, Iveco, DDC, CAT VW passenger car

Unit Pump Systems DaimlerChrysler, Mack, DAF DEUTZ liquid cooled

•High peak pressure•Favourable injection rate

Common-Rail Almost every

passenger car RVI, JohnDeere,

Cummins, CAT

•Pressure flexibility•Multiple injection•Silent gear train

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DCR - System

ECU

Thermostaticvalve

Prefilter withwater separator

Hand-primer

Supplypump

Mainfilter

HP-pump

Injector

DBV

Rail

FCU

Pressuresensor

11 22

33

11

22

33

Heater (optional)

Pressure sensor

MProp

pback, max < 1,2 bar

pSystem = 300 ÷ 1600 bar

pmin > 0,5 ÷ 1,0 bar

pmax < 10,5 ÷ 13 bar

ECU: Electronic Control Unit FCU: Fuel Control UnitDBV: Pressure limiter valve

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High Pressure System

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High Pressure System

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CR-Injector / Variants

• 4-Valve-Injektor • 2-Valve-Injektor

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CR-Injector / FunctionCross Section of a BOSCH-CRIN 2nd Generation Injector

Features:• Injector just opens when current is on• A leakage occurs during opening which is systematically caused (dependend on rail pressure and

injection duration)• Spring is just applied to keep the injector closed against compression pressure in combustion chamber• Exchange of nozzles is not permitted ! The whole injector has to be removed !• Service concept is in progress

Magnet coil

Magnet core Armature Control chamber High pressure channel Pressure piece

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Rail

• High pressure storage of injection system

• Rail contains pressure relieve valve (DBV) and rail pressure sensor (RDS)

Pressure relieve valve (integrated)

Pressure sensor

• The system is adjusted that after each injection a corresponding fuel quantity is delivered by the pump always before the next injection occure

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Pressure Relieve Valve (DBV)

Features:

• Pressure relieve valve is a mechaninical safety device, which opens at 1950(-100) bar and protects the system concerning over pressure caused by any malfunction

• If opened the rail pressure remains in the range of 650 - 850 bar (dependend on speed and load). The engine keeps running but if necessary with decreased performance (limp home mode)

• Under usual conditions the DBV will not open during engine operation

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Rail Pressure Sensor (RDS)

• Input variable for rail pressure controller

• If any malfunction is detected the ECU may force the DBV to open by putting over pressure onto the system

0 V

5 V

4,5 V

0,5 V

0 bar 1800 bar

Pressure

Signal voltage

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High Pressure Pump (PF 45)HD-connector

ND-connector

I/O-Ventil keeps two functions:

• Hydraulic separation of high pressure side during suctioning

• Filling of pumps is just possible at a minimum pressure of approx. 1.7 bar

I/O-Valve (integrated)

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High Pressure Pump (PF 45)

• Pump housing is common for all engines

• Roller tappet is common for all engines

• Spring cup seat differs between engines

- short seat: TCD 2012

- long seat/1 TCD 2013 L4/6 2V

- long seat/2 TCD 2013 L4/6 4V

TCD 2013 TCD 2012

02.1

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FCU (Fuel Control Unit):

To high pressure pump

From feed pump

back to tank

Fuel Control Unit (FCU)

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Fuel Control Unit (FCU)

• FCU controlles filling of high pressure pumps

• It is just delivered as much as needed to reach or keep the rail pressure setpoint

Inlet

to PF 45

Outlet

M-Prop

0

0,5

1

1,5

2

2,5

3

3,5

4

300 500 700 900 1100 1300 1500

Current [mA]

Fu

el

flo

w [

l/m

in]

• Supplier: BOSCH

• FCU for all DCR systems usable

• Tested Part from Supplier

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Characteristic of Overflow Valve

4

4,5

5

5,5

6

6,5

7

7,5

8

0 500 1000 1500 2000 2500 3000

Engine speed [rpm]

Pre

ssu

re [

bar

, ab

solu

te]

Low Pressure vs. Engine Speed

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Gear Pump - New Requirements

pgegen [bar] nMotor [1/min] Q [L/min]3 100 0,333

10 1000 1,8310 2300 2,92

Specifications: 2014 pumpgear driven

Suction pressure: p = 0,5 – 1.0 bar abs

4-7L Tier III belt driven

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Prefilter Requirements

• Prefiltration of Particle 30 m

• Water seperation of > 98 %

• Fuel preheating by means of a thermostatic valve

• Water storage with water level sensor

• Mechanical water draining (optional magnetic valve)

• integrated primer pump

• 1000 h exchange interval