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A1commonrail
 

A1commonrail

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Common Rail

Common Rail

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    A1commonrail A1commonrail Presentation Transcript

    • System diagram for Common rail High pressure fuel rail Pressure Fuel return line limitation High pressure fuel line valveHigh pressure pump Low pressure fuel line Low pressure Pressure sensor Injector CMP Pressure Glow regulating valve relay Turbo chargerFuel filter WTS E/G ECU EGR Fuel tank valve CKP Waste gate CAN communication valve Scanner A/C switch Meter set APS BLS Clutch switch
    • Engine-FrontAlternator Timing chainAutotensioner High pressure pump Cooling fan clutch
    • Engine –Side view Glow plug One belt system CKP Turbo charger Oilcooler Oil filter Oil fan
    • Engine – side view High Pressure Pump Pressure regulating valve Low pressure pump
    • Engine – Top view Injector Common railPressurelimitation valve High pressure pipe Rail pressure sensor
    • Engine Turbo Injector charger Fuel rail Camshaft Rocker arm/HLA Chamber CrankshaftOil Balance shaftfilter Baffle plate Oil fan
    • Fuel system diagram Fuel pressure High pressure Fuel pressure sensor limitation valve fuel line Common rail Low pressure Fuel fuel line return line InjectorHigh pressure Fuel pressure pump regulator valve
    • Detail fuel line High pressure pumpCommon rail Fuel filter (water Gear pump seperator /fuel heater) Discharge Suction pressure pressureInjector (4-6 bar) (0.5-1bar) Pri. filter Fuel pressure (600㎕) regulator valve Fuel tank
    • Low pressure lineFuel remainingwarning lampconnector Fuel return line Fuel supply line Air breather (filter) Fuel tank
    • 연료 시스템- 연료센더 ASS’Y 3-5 ▷ 전원 커넥터:센더 및 경고등 관련 전원 회로 ▷ 연료호스: 연료공급및 리턴호스 ▷ 에어브리더 (공기휠터):연료탱크 ▷ 컷오프 밸브 : 액면 경사시나 차량 전복시 (에어브리더 하단) 연료가 유출되는 것을 방지. ▷ 연료센더 어셈블리:연료 탱크내 연료량을 감지. ▷ 1차 연료휠터:탱크로부터 유입되는 연료를 여과
    • 연료 시스템- 연료센더 ASS’Y 3-6 □ 연료 게이지 작동 : 유면에 따른는 저항치 변화를 연료유량게이지 작동 □ 연료 경고등 점등 : - 동일시스템을 이용 저항치가 경고등 점등 설정치 이상을 일정시간 지속시 연료 잔량 경고등 점등(지연회로 형식) 경고등 지연회로 경고등 지연회로 지연시간 : 60 초 ± 20 경고등플로트위치 FULL 1/2 EMPTY 점등시점기준저항치 3±2 31±2 79±2 110±2 (Ω)연료탱크 65 33 12 8용량(리터)
    • Fuel filter◆ Fuel filtering & water seperater – Feed pump for air◆ Fuel heating by fuel temp. switch Fuel temp. Feed switch pump out Fuel In heater Water detecting sensor
    • 연료휠터 - 연료가열 3-8♣ 디젤연료는 온도가 낮아지는 정도에 연료 온도 따라 연료성분의 일부에서 파라핀계 스위치 성분이 고체화 되는 현상이 있으며 이것은연료휠터 에서 연료흐름을 방해한다♣ 연료의 고체화로 인해 발생될수 있는 기타 현상을 막기위해 연료가열장치를 연료가열 적용하였다 히터◆ 연료의 가열은 냉간시 연료내 이물질 생성 및 응고 방지 (시동성/내구성 향상)◆ 연료온도 스위치 작동온도 영하 3도 에서 ON 상온 3도 OFF
    • Fuel filter heating circuit Fuse box Heater Battery Relay Fuel temp. IG switch Fuel temp. switch (Operating temp.: – 3℃ ON / 3 ℃ OFF) Fuel heater relay 가열히터 커넥터
    • Low pressure pump ◆ Attached type of high pressure pump ◆ Gear pump : Driven by timing chain ◆ Suction pressure 0.5-1.0 bar Discharge pressure : 4 .5 bar Discharge Q 2798 RPM 1.03 L Discharge pressure 2798 RPM 4.5 bar Max. discharge Q 80 liters/hour
    • Fuel pressure regulating valve■ Installed at high pressure pump■ Supply required fuel to high pressure pump for injection.■ Controlled by duty signal from ECUWhen defective, engine stops Low pressure pump Fuel pressure regulator High pressure pump
    • Fuel pressure regulating valve – close Fuel cut-off: ECU에서 연료압력 조절밸브 에전류를 최대치로가한 상태 이때 저압의 연료는 펌프 내부의 윤활역할만하고 저압 리턴부를 통해 연료탱크로 전량 리턴된다
    • Fuel pressure regulating valve – open Fuel supply : ECU에서 MPROP에 전류를 하나도 가하지 않은 상태 저압의 연료는 소량만 윤활에 이용되고 모두 고압실로 보내져 플런져의 왕복운동 에 의해 가압되어 연료레일로 보내진다.
    • Fuel pressure regulating valve – No load▷ Fuel pressure regulated according to engine rpm and load (F: 185Hz)▷ Ignition OFF : Valve opened / ▷ When defective, engine stops ◆ Idle 800rpm (No load) : Duty Approx. 45% Fuel pressure260bar Fuel pressure sensor 1.26V Accelerator pedal position sensor 0.66V Fuel pressure regulating valve 40% Injector 20 A
    • Fuel pressure regulating valve – load▷ More load, less duty value – Duty 100%(close) / Duty 0%(open) ◆ Full load (4500rpm) : Duty approx. 35 % (Fuel pressure : 1200 bar) ` Crankshaft position sensor 31 V Accelerator pedal position sensor 3.35V 3.97V Fuel pressure sensor Fuel pressure regulating valve 35%
    • A – 엔진 연료 시스템 연료 라인 전체구성도 저압의 연료 라인 고압의 연료 라인
    • 연료 시스템-고압펌프▶ 역할: 저압에서 이송된 연료를 고압으로 압축하여 고압의 연료를 생성함▶ 구동: 타이밍 체인 과 연동 저압연료 저압연료 공급부 리턴부▶ 장착: 연료를 흡입하는 고압 기어 펌프와 연료 연료유량제어밸브인 공급부 연료압력조절밸브와 연료를고압으로 만드는 고압 펌프 일체 고압 펌프▶ 구성부품: 구동샤프트 기어펌프 캠 연료압력 플런져-피스톤 조절밸브 저압 펌프
    • Structure of high pressure pump ▣ 캠축 1회전에 왕복 피스톤 1회씩 이송행정(기존 인젝션 펌프보다 낮은 부하) ▣ 설정압력은 1350 bar이며, 분사압력은 연료분사량에 영향줌(출력에 영향) Connector for Eccentric shaft return lineEccentriccamPlunger Pressure control valveInlet valve Gear High pressure spring pump
    • 고압펌프 작동 3-12토출량 0.677 cm3/Rev최대토출압 1600 bar기어비 0.67최대속도 4600 RPM구동토크 24(average)/28(peak) Nm 플런져 피스톤
    • 연료레일( COMMON RAIL ) 3-23♣ 고압펌프로부터 이송된 연료가 저장 & 축압되는 곳 (250 –1350 bar)♣ 연료가 분사 될때의 압력 변화는 레일체적과 내부압력으로 유지(volume : 25 ㎤)♣ 레일의 압력 변화는 ECU 제어에 따라 영향 고압연료부 레일압력센서 (TO INJECTOR) 고압연료부 (FROM PUMP) 저압연료부 (FROM INJECTOR RETURN ) 압력제한밸브 카먼레일(연료레일) 저압연료부(TO FUEL TANK)
    • 연료압력 제한밸브♧ 연료압력제한 밸브( Pressure Limiting Valve )- 연료 압력 과다 상승시 valve가 열려 연료 리턴- 개방압력(Opening Pressure) : 1750 bar▶ 유동이 가능한 플러져 밸브가 리턴스프링의 힘으로 레일 입구를 막고있다가 과도한 압력(1750 bar) 발생시 스프링이 밀리면서 밸브도 열린다.
    • 인젝터 ( INJECTOR ) 3-16고압의 연료를 실린더연소실 분사하는장치 저압연 전원커넥 리턴부위 터 솔레노이드 밸브 고압연료 공급부위볼트 클램프 O링 실린더 헤드 중앙 직립 형태로 장착 노즐 솔레노이드 밸브 / 니들(노즐) 밸브로 이루짐 엔진 ECU 에의해 제어됨 노즐 초기 작동전류 80 V 20 A
    • Operation of injector Injector closed Injector open Injector operate
    • Injection system Pre injection : To reduce noise and vibration Main injection : To get engine torque (APS.RPM.WTS.ATS adaptation) Post injection : To reduce emission especially NOx (Not doing at current) With pre injection Combustion pressure Pre injection Main injection Without pre injection Combustion pressure
    • Tighten injectorClamp Tightening torque: 2.5 – 2.9 kgfm Clamp bolt & washer ASS’Y - Torque : 3.1 ± 0.3 kgfm - Over tightening torque -> Fuel particles irregular Less power, Pour durability - Less tightening torque -> Lower compressionGasket pressure Less power, High emission Nozzle(6-holes)
    • Input/Output diagram 4-1 APS1, 2 연료 제어 Double brake sig. BOSCH /분사시기 /공전속도 CKP 제어 CMP ECU Fuel pressure sensor Fuel pressure control Hot film AFS EGR control Clutch switch Cooling fan control WTS, ATS Pre heater control Switch signal Glow plug control
    • Air flow sensor■ Hot film air flow sensor (ATS integrated) - Signal input for EGR control - Acceleration/Deceleration – Correction of fuel quantity - When defective – Limitation of E/G rpm Integrated sensor Protect GRID
    • Air flow sensor
    • Air flow sensor HFM Acceleration 5V1.5VAir temp. sensor
    • Accelerator pedal position sensor (APS)▶ Detect accelerator pedal position for injection quantity& injection timing ▷ Sensor 1 : Primary sensor ▷ Sensor 2 : Monitor sensor 1 for safety
    • Accelerator pedal position sensor (APS)▷ Sensor 1: Approx. 0.6 – 4.6 ▷ Sensor 2: Approx. 0.25– 2.5▷ When defective : Poor acceleration 4.08 V ▷ Sensor 1 0.72 V 2.10 V 0.36 V ▷ Sensor 2
    • Crankshaft angle sensor (CKP)◆ Inductive type : Injection timing◆ Teeth of target wheel (58)◆ Defective : does not cranking and engine dies #1 cylinder TDC after 114 degree
    • Crankshaft angle sensor (CKP) Shield wire
    • Camshaft position sensor (CMP)◆ Cylinder recognition signal◆ Injection timing adaptive◆ When defective : Restart not possible
    • Camshaft position sensor (CMP) Power supply 12V Sensor output ( 5-0V) Sensor ground
    • Rail pressure sensor◆ Detect fuel pressure of common rail and send signal to ECU◆ Signal used for controlling fuel quantity, injection timing◆ When defective : Engine die / Not starting
    • Rail pressure sensor 4-31
    • Rail pressure sensor Power supply 5 V Start the engine Sensor output Sensor GND
    • Water temperature sensor◆ Detect the water temperature - Injection timing/Injection quantity correction - Engine rpm control according to temperature. - Water temperature abruptly high – decrease fuel quantity
    • Double brake switches▶ ECU로 입력되는 브레이크신호가 2개 이며 BRAKE S/W 1.2 로 구분▶ 브레이크 스위치와 악셀페달 센서 연계해서 악셀페달센서 고장검출▶ BRAKE S/W 1 . 2 를 조합하여 브레이크 스위치 고장 검출▶ 악셀페달이 밟힌상태에서 나중에 브레이크 스위치가 밟힌상태이면 연료감량(엔진 회전수 제한)
    • Double brake switch circuit
    • Double brake switchesPower for s/w 1–12 V Switch 1Power for s/w 2–12 V Switch 2
    • Clutch switch□ smoke control during shifting□ Adaptive control of cruise control system
    • Injector◎ Peak current : 20±1A, Hold in current : 12±1A, Recharging current : 7A
    • Circuit of injector
    • Oscilloscope pattern of injector Pre-injection Main injection 21A
    • Fuel cut off during decelerating CPS RPS APS Injector
    • During starting CPS TDC RPS INJ
    • Glow relay operating time 1.PRE GLOW Water temp. -20℃ -10℃ 20℃ 50℃ Glow time 12 sec. 8 sec. 3 sec. 0.7 sec. 2. START GLOW 1) Before start the engine - Operate 15 sec. when not starting. 2) Glow during starting - Water temp. is below 30℃, operate 30 sec. before starting mode finished 3. POST GLOW - After starting, below 2500rpm and fuel quantity is below 75cc Water temp. -20℃ 0℃ 20℃ 40℃ Glow time 150 sec. 115 sec. 67 sec. 0 sec.※ When WTS is defective , fail safe temp. is -20℃
    • EGR system - To reduce NOx in exhaust gas - Temperature is dropped in combustion chamber.♣ EGR solenoid valve: PWM controlled by ECU EGR solenoid valve EGR valve
    • E G R System
    • E G R SystemEGR not operatingEGR operating
    • Pin lay out of ECU
    • ENGINE ECU