Diesel engine management: systems and components

381 Pages·2014·12.967 MB·English

by  Reif, Konrad(Editor)

Bosch Professional Automotive
Information
Konrad Reif Ed.
Diesel Engine
Management
Systems and Components
Bosch Professional Automotive Information
Bosch Professional Automotive Information is a definitive reference for
automotive engineers. The series is compiled by one of the world´s largest
automotive equipment suppliers. All topics are covered in a concise but
descriptive way backed up by diagrams, graphs, photographs and tables
enabling the reader to better comprehend the subject.
There is now greater detail on electronics and their application in the motor
vehicle, including electrical energy management (EEM) and discusses the
topic of intersystem networking within vehicle. The series will benefit
automotive engineers and design engineers, automotive technicians in
training and mechanics and technicians in garages.
Konrad Reif
Editor
Diesel Engine Management
Systems and Components
Editor
Prof. Dr.-Ing. Konrad Reif
Duale Hochschule Baden-Württemberg
Friedrichshafen, Germany
[email protected]

ISBN978-3-658-03980-6 ISBN978-3-658-03981-3(eBook)
DOI10.1007/978-3-658-03981-3
LibraryofCongressControlNumber:2014945110
SpringerVieweg
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Foreword V
 Foreword
This reference book provides a comprehensive insight into today´s diesel injection
systems and electronic control. It focusses on minimizing emissions and exhaust-gas
treatment. Innovations by Bosch in the field of diesel-injection technology have
made a significant contribution to the diesel boom. Calls for lower fuel consumption,
reduced exhaust-gas emissions and quiet engines are making greater demands on the
engine and fuel-injection systems.
Complex technology of modern motor vehicles and increasing functions need a relia-
ble source of information to understand the components or systems. The rapid and
secure access to these informations in the field of Automotive Electrics and Electron-
ics provides the book in the series “Bosch Professional Automotive Information”
which contains necessary fundamentals, data and explanations clearly, systemati-
cally, currently and application-oriented. The series is intended for automotive
professionals in practice and study which need to understand issues in their area of
work. It provides simultaneously the theoretical tools for understanding as well as
the applications.
VI Contents
 Contents
2 History of the diesel engine 92 Unit injector system (UIS) and unit pump
3 Rudolf Diesel system (UPS)
4 Mixture formation in the first diesel engines 94 System diagram of UIS for passenger cars
5 Use of the first vehicle diesel engines 96 System diagram of UIS/UPS for commercial
8 Bosch diesel fuel injection vehicles
12 Areas of use for diesel engines 98 Unit injector system (UIS)
12 Suitability criteria 98 Installation and drive
12 Applications 99 Design
15 Engine characteristic data 102 Method of operation of UI for
passenger cars
16 Basic principles of the diesel engine 105 Method of operation of UI for
16 Method of operation commercial vehicles
19 Torque and power output 107 High-pressure solenoid valve
20 Engine efficiency
23 Operating statuses 110 Unit pump system (UPS)
27 Operating conditions 110 InstalIation and drive
29 Fuel-injection system 110 Design
30 Combustion chambers 112 Current-controlled rate shaping (CCRS)
34 Fuels 114 Overview of common-rail systems
34 Diesel fuel 114 Areas of application
41 Alternative fuels for diesel engines 115 Design
116 Operating concept
46 Cylinder-charge control systems 120 Common-rail system for passenger cars
46 Overview 125 Common-rail system for commercial
47 Turbochargers and superchargers vehicles
56 Swirl flaps
57 Intake air filters 128 High-pressure components of common-rail
system
60 Basic principles of diesel fuel injection 128 Overview
60 Mixture distribution 130 Injector
62 Fuel-injection parameters 142 High-pressure pumps
71 Nozzle and nozzle holder designs 148 Fuel rail (high-pressure accumulator)
149 High-pressure sensors
72 Overview of diesel fuel-injection systems 150 Pressure-control valve
72 Designs 151 Pressure-relief valve
78 Fuel supply system to the low-pressure 152 Injection nozzles
stage 154 Pintle nozzles
78 Overview 156 Hole-type nozzles
80 Fuel filter 160 Future development of the nozzle
82 Fuel-supply pump
86 Miscellaneous components 162 Nozzle holders
88 Supplementary valves for in-line 164 Standard nozzle holders
fuel-injection pumps 165 Stepped nozzle holders
166 Two-spring nozzle holders
90 Overview of discrete cylinder systems 167 Nozzle holders with needle-motion sensors
90 Type PF discrete injection pumps
Contents VVIIII
168 High-pressure lines 255 Serial data transmission (CAN)
168 High-pressure connection fittings 260 Application-related adaptation 1) of car
169 High-pressure delivery lines engines
264 Application-related adaptation 1) of
172 Start-assist systems commercial vehicle engines
172 Overview 269 Calibration tools
173 Preheating systems
272 Electronic Control Unit (ECU)
178 Minimizing emissions inside of the engine 272 Operating conditions
179 Combustion process 272 Design and construction
181 Other impacts on pollutant emissions 272 Data processing
183 Development of homogeneous combustion
processes 278 Sensors
184 Diesel fuel injection 278 Automotive applications
196 Exhaust-gas recirculation 278 Temperature sensors
199 Positive crankcase ventilation 280 Micromechanical pressure sensors
283 High-pressure sensors
200 Exhaust-gas treatment 284 Inductive engine-speed sensors
201 NOx storage catalyst 285 Rotational-speed (rpm) sensors and
204 Selective catalytic reduction of incremental angle-of-rotation sensors
nitrogen oxides 286 Hall-effect phase sensors
210 Diesel Particulate Filter (DPF) 288 Accelerator-pedal sensors
218 Diesel oxidation catalyst 290 Hot-film air-mass meter HFM5
292 LSU4 planar broad-band Lambda
220 Electronic Diesel Control (EDC) oxygen sensor
220 System overview 294 Half-differential short-circuiting-ring sensors
223 In-line fuel-injection pumps 295 Fuel-level sensor
224 Helix and port-controlled axial-piston
distributor pumps 296 Fault diagnostics
225 Solenoid-valve-controlled axial-piston and 296 Monitoring during vehicle operation
radial-piston distributor pumps (on-board diagnosis)
226 Unit Injector System (UIS) for passenger 299 On-board diagnosis system for passenger
cars cars and light-duty trucks
227 Unit Injector System (UIS) and Unit Pump 306 On-board diagnosis system for heavy-duty
System (UPS) for commercial vehicles trucks
228 Common Rail System (CRS) for passenger
cars 308 Service technology
229 Common Rail System (CRS) for commercial 308 Workshop business
vehicles 312 Diagnostics in the workshop
230 Data processing 314 Testing equipment
232 Fuel-injection control 316 Fuel-injection pump test benches
243 Further special adaptations 318 Testing in-line fuel-injection pumps
244 Lambda closed-loop control for passenger- 322 Testing helix and portcontrolled distributor
car diesel engines injection pumps
249 Torque-controlled EDC systems 326 Nozzle tests
252 Control and triggering of the remaining
actuators
253 Substitute functions 328 Exhaust-gas emissions
254 Data exchange with other systems 328 Overview
VIII Contents
328 Major components 349 European test cycle for passenger cars
330 Combustion byproducts and LDTs
349 Japanese test cycle for passenger cars
332 Emission-control legislation and LDTs
332 Overview 350 Test cycles for heavy-duty trucks
334 CARB legislation (passenger cars/LDT)
338 EPA legislation (passenger cars/LDT) 352 Exhaust-gas measuring techniques
340 EU legislation (passenger cars/LDT) 352 Exhaust-gas test for type approval
342 Japanese legislation (passenger cars/LDTs) 355 Exhaust-gas measuring devices
343 U.S. legislation (heavy-duty trucks) 357 Exhaust-gas measurement in engine deve-
344 EU legislation (heavy-duty trucks) lopment
346 Japanese legislation (heavy-duty trucks) 359 Emissions testing (opacity measurement)
347 U.S. test cycles for passenger cars
and LDTs
Authors IX
 Authors
History of the diesel engine
Dipl.-Ing. Nestor Rodriguez-Amaya,
Dipl.-Ing. Karl-Heinz Dietsche. Dipl.-Ing. Ralf Wurm.
Areas of use for diesel engines Overview of common-rail systems
Dipl.-Ing. Joachim Lackner, Dipl.-Ing. Felix Landhäußer,
Dr.-Ing. Herbert Schumacher, Dr.-Ing. Ulrich Projahn,
Dipl.-Ing. (FH) Hermann Gries haber. Dipl.-Inform. Michael Heinzelmann,
Dr.-Ing. Ralf Wirth.
Basic principles of the diesel engine
Dr.-Ing. Thorsten Raatz, High-pressure components of common-rail
Dipl.-Ing. (FH) Hermann Gries haber. system
Dipl.-Ing. Sandro Soccol,
Fuels, Diesel fuel Dipl.-Ing. Werner Brühmann.
Dr. rer. nat. Jörg Ullmann.
Injection nozzles
Fuels, Alternative Fuels Dipl.-Ing. Thomas Kügler.
Dipl.-Ing. (FH) Thorsten Allgeier,
Dr. rer. nat. Jörg Ullmann. Nozzle holders
Dipl.-Ing. Thomas Kügler.
Cylinder-charge control systems
Dr.-Ing. Thomas Wintrich, High-pressure lines
Dipl.-Betriebsw. Meike Keller. Kurt Sprenger.
Basic principles of diesel fuel injection Start-assist systems
Dipl.-Ing. Jens Olaf Stein, Dr. rer. nat. Wolfgang Dreßler.
Dipl.-Ing. (FH) Hermann Gries haber.
Minimizing emissions inside of the engine
Overview of diesel fuel-injection systems Dipl.-Ing. Jens Olaf Stein.
Dipl.-Ing. (BA) Jürgen Crepin.
Exhaust-gas treatment
Fuel supply system to the low-pressure stage Dr. rer. nat. Norbert Breuer,
Dipl.-Ing. (FH) Rolf Ebert, Priv.-Doz. Dr.-Ing. Johannes K. Schaller,
Dipl.-Betriebsw. Meike Keller, Dr. rer. nat. Thomas Hauber,
Ing. grad. Peter Schelhas, Dr.-Ing. Ralf Wirth,
Dipl.-Ing. Klaus Ortner, Dipl.-Ing. Stefan Stein.
Dr.-Ing. Ulrich Projahn.
Electronic Diesel Control (EDC)
Overview of discrete cylinder systems Electronic Control Unit (ECU)
Unit injector system (UIS) Dipl.-Ing. Felix Landhäußer,
Unit pump system (UPS) Dr.-Ing. Andreas Michalske,
Dipl.-Ing. (HU) Carlos Alvarez-Avila, Dipl.-Ing. (FH) Mikel Lorente Susaeta,
Dipl.-Ing. Guilherme Bittencourt, Dipl.-Ing. Martin Grosser,
Dipl.-Ing. Dipl.-Wirtsch.-Ing. Matthias Hickl, Dipl.-Inform. Michael Heinzelmann,
Dipl.-Ing. (FH) Guido Kampa, Dipl.-Ing. Johannes Feger,
Dipl.-Ing. Rainer Merkle, Dipl.-Ing. Lutz-Martin Fink,
Dipl.-Ing. Roger Potschin, Dipl.-Ing. Wolfram Gerwing,
Dr.-Ing. Ulrich Projahn, Dipl.-Ing. (BA) Klaus Grabmaier,
Dipl.-Ing. Walter Reinisch, Dipl.-Math. techn. Bernd Illg,