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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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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)

Common Rail

Rail Pressure Sensor (RDS)

High Pressure Pump

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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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 (d1 & d2) d1 = Guidance diameter at the Nozzle retaining nut d2 = Guidance diameter at the Injector body. As high as possible, below clamping but minimum of 57.0mm between two guidance. An axial force of 7000 9000N to be ensured on injector clamping by customer.
57 min 5min

d2

12min

d1

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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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

Shfit/Line/Clamping station

Manufacturing date

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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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

100
Quantity( mm3/stroke)

80

Quantity( mm3/stroke)

VE2 1200bar ~240s


0.1 0.15 0.2 0.25 Energising Time (ms)

VE1 600bar ~290s


0.3 0.35 0.4

60

VL 1600bar ~800s

40

20

0 0

1450 bar 1300 bar 1200 bar 1100 bar 1000 bar 900 bar 800 bar 700 bar 600 bar 500 bar 400 bar 300 bar
0.2 0.4 0.6

EM 600bar ~630s LL 300bar ~620s


0.8 Energising Time (ms) 1 1.2 1.4 1.6

Main Injection test points


MICO/ECC1

Additional Injection test points

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: Overview Injector Function Mounting of Injector on Engine Injector handling and identification Testpoints & Measurement 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 Electronically controlled device Better control of Injection quantity Possibility of multiple injections Injection pressure is independent of Engine speed 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.