DCR
Deutz Common Rail System
TE-TM1 05.02.04
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)
Medium Duty families: Situation today
E in s p r itz le it u n g
Deutz mech. UPS Best in class
Up to 1350 bar
(el. distr. pump)
Emission EU2,
E in s p r itz p u m p e
C&I stage 2
K u r b e lg e h ä u s e
System cost
Electronics on A u s g le ic h s c h e ib e
R o lle n s tö ß e l
Fuel consumption
demand N o c k e n w e lle Cold start
Electronic functions (EMR variant)
Deutz UPS Best in class
(Common Rail)
System cost
Fuel consumption
Low end torque
Up to 1600 bar Engine noise
Emission EU3
Options for the future
Unit Pump Systems Unit Injector System
DaimlerChrysler, Mack, DAF Volvo, Iveco, DDC, CAT
DEUTZ liquid cooled VW passenger car
• High peak pressure
• Favourable injection
rate
Common-Rail
Almost every • Pressure flexibility
passenger car • Multiple injection
RVI, JohnDeere, • Silent gear train
Cummins, CAT
DCR - System
ECU
1 Heater (optional)
2 Pressure sensor
Injector
3 MProp
pm in > 0,5 ÷ 1,0 bar
pm ax < 10,5 ÷ 13 bar
pSystem = 300 ÷ 1600 bar
Pressure
pback, m ax < 1,2 bar
sensor
Rail
DBV
3
Prefilter with HP-pump
water separator 1 2
FCU
Supply Main
pump filter
Thermostatic
Hand- valve
primer
ECU: Electronic Control Unit
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FCU: Fuel Control Unit
DBV: Pressure limiter valve
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 / Function
Cross Section of a BOSCH-CRIN 2nd Generation Injector
Magnet coil
Magnet core Armature Control chamber High pressure channel Pressure piece
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
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in combustion chamber
• Exchange of nozzles is not permitted ! The whole injector has to be removed !
• Service concept is in progress
Rail
• High pressure storage of injection system
• Rail contains pressure relieve valve (DBV) and rail pressure sensor (RDS)
Pressure sensor
Pressure relieve valve (integrated)
• The system is adjusted that after each injection a corresponding fuel quantity is delivered by
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the pump always before the next injection occure
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
Signal voltage
5V
4,5 V
0,5 V
0V Pressure
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0 bar 1800 bar
High Pressure Pump (PF 45)
HD-connector
I/O-Valve
(integrated)
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
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High Pressure Pump (PF 45)
TCD 2013 TCD 2012
• 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
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Fuel Control Unit (FCU)
FCU (Fuel Control Unit):
From feed To high
pump pressure
pump
02.12.02 TK-TM1
back to tank
Fuel Control Unit (FCU)
• FCU controlles filling of high pressure pumps
M-Prop
• It is just delivered as much as needed to reach or
keep the rail pressure setpoint
Inlet 3,5
Fuel flow [l/min]
to PF 45 2,5
Outlet 1,5
0,5
• Supplier: BOSCH
0
• FCU for all DCR systems usable 300 500 700 900 1100 1300 1500
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Current [mA]
• Tested Part from Supplier
Characteristic of Overflow Valve
Low Pressure vs. Engine Speed
8
7,5
Pressure [bar, absolute]
6,5
5,5
4,5
4
0 500 1000 1500 2000 2500 3000
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Engine speed [rpm]
Gear Pump - New Requirements
2014 pump Specifications:
gear driven
pgegen [bar] nMotor [1/min] Q [L/min]
3 100 0,333
10 1000 1,83
10 2300 2,92
4-7L Tier III
belt driven
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Suction pressure: p = 0,5 – 1.0 bar abs
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
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• 1000 h exchange interval
