Cr Injector Pkw Ps
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Component Orientation – CR Injector
Common Rail Injector
A brief overview by
Prashanth S, Mico/ECC11 MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Common Rail System Overview
Pressure Control Valve (DRV)
High Pressure Pump
Common Rail
Rail Pressure Sensor (RDS)
Metering Unit
Fuel Filter
Injector ECU
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Overview
High pressure fitting
Body Magnet group Armature group Valve group Nozzle
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function
Low Pressure
High Pressure
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Electro Magnet Valve spring Armature plate Stopper plate Armature spring
Armature bolt Ball guidance Ball MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Electro Magnet Valve spring Armature plate Stopper plate Armature spring
Armature bolt Ball guidance Ball MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Nozzle needle
Ball A-throttle
Valve piston Nozzle MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Nozzle needle
Ball A-throttle
Valve piston Nozzle MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Mounting • Injector guided at two different diameters (Ød1 & Ød2) • Ød1 = Guidance diameter at the Nozzle retaining nut
5min
• Ød2 = Guidance diameter at the Injector body. As high as possible, below clamping but minimum of 57.0mm between two guidance.
12min
57 min
• An axial force of 7000 – 9000N to be ensured on injector clamping by customer.
d2
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
d1
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Handling – Key points • Clamping saddle – Not to be removed • Caps – To be removed only shortly before assembly process • HP Connector – Hold during disassembly / assembling of HP pipe. • Magnet head – No tool (wrench) should be used.
• Copper washer – Replace even when injector is loosened. • Nozzle shaft – Not to be cleaned by wire brush. Only by Ultrasonic bath MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Identification of Injector:
Daily Production Amount
Manufacturing date
Shfit/Line/Clamping station
Production plant code
IQA - Data Matrix Code (for EOL use) IQA – Alpha Numeric Code (for field use) Bosch part number
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Characteristic Map - Representative 120 10
9
8
100 Quantity( mm3/stroke)
7
Quantity( mm3/stroke)
80
6
5
4
3
2
VE2 1200bar ~240µs
VE1 600bar ~290µs
1
0 0.1
60
0.15
0.2
0.25
0.3
0.35
0.4
VL 1600bar ~800µs
Energising Time (ms)
40
1450 bar 1300 bar 1200 bar 1100 bar 1000 bar 900 bar 800 bar 700 bar 600 bar 500 bar 400 bar 300 bar
20
0 0
EM 600bar ~630µs LL 300bar ~620µs 0.2
0.4
0.6
0.8
1
1.2
1.4
Energising Time (ms)
Main Injection test points
Additional Injection test points
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
1.6
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Benefits of CRI Î
Electronically controlled device
Î
Better control of Injection quantity
Î
Possibility of multiple injections
Î
Injection pressure is independent of Engine speed
Î
Possibility of Software correction function like IQA
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector
Thank You
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Common Rail Injector
A brief overview by
Prashanth S, Mico/ECC11 MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Common Rail System Overview
Pressure Control Valve (DRV)
High Pressure Pump
Common Rail
Rail Pressure Sensor (RDS)
Metering Unit
Fuel Filter
Injector ECU
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Overview
High pressure fitting
Body Magnet group Armature group Valve group Nozzle
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function
Low Pressure
High Pressure
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Electro Magnet Valve spring Armature plate Stopper plate Armature spring
Armature bolt Ball guidance Ball MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Electro Magnet Valve spring Armature plate Stopper plate Armature spring
Armature bolt Ball guidance Ball MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Nozzle needle
Ball A-throttle
Valve piston Nozzle MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector function Nozzle needle
Ball A-throttle
Valve piston Nozzle MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Mounting • Injector guided at two different diameters (Ød1 & Ød2) • Ød1 = Guidance diameter at the Nozzle retaining nut
5min
• Ød2 = Guidance diameter at the Injector body. As high as possible, below clamping but minimum of 57.0mm between two guidance.
12min
57 min
• An axial force of 7000 – 9000N to be ensured on injector clamping by customer.
d2
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
d1
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Injector Handling – Key points • Clamping saddle – Not to be removed • Caps – To be removed only shortly before assembly process • HP Connector – Hold during disassembly / assembling of HP pipe. • Magnet head – No tool (wrench) should be used.
• Copper washer – Replace even when injector is loosened. • Nozzle shaft – Not to be cleaned by wire brush. Only by Ultrasonic bath MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Identification of Injector:
Daily Production Amount
Manufacturing date
Shfit/Line/Clamping station
Production plant code
IQA - Data Matrix Code (for EOL use) IQA – Alpha Numeric Code (for field use) Bosch part number
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Characteristic Map - Representative 120 10
9
8
100 Quantity( mm3/stroke)
7
Quantity( mm3/stroke)
80
6
5
4
3
2
VE2 1200bar ~240µs
VE1 600bar ~290µs
1
0 0.1
60
0.15
0.2
0.25
0.3
0.35
0.4
VL 1600bar ~800µs
Energising Time (ms)
40
1450 bar 1300 bar 1200 bar 1100 bar 1000 bar 900 bar 800 bar 700 bar 600 bar 500 bar 400 bar 300 bar
20
0 0
EM 600bar ~630µs LL 300bar ~620µs 0.2
0.4
0.6
0.8
1
1.2
1.4
Energising Time (ms)
Main Injection test points
Additional Injection test points
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
1.6
Component Orientation – CR Injector Contents:
¾
Overview
¾
Injector Function
¾
Mounting of Injector on Engine
¾
Injector handling and identification
¾
Testpoints & Measurement
¾
Summary
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector Benefits of CRI Î
Electronically controlled device
Î
Better control of Injection quantity
Î
Possibility of multiple injections
Î
Injection pressure is independent of Engine speed
Î
Possibility of Software correction function like IQA
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector
Thank You
MICO/ECC1 Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.
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