Next Generation of Common Rail Diesel Injection

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3rd Aachen Colloquium China Automobile and Engine Technology 2013 1 Next Generation of Piezo Common Rail Diesel Injection Systems to Manage all Upcoming Market Needs for Light Vehicles

Dipl.-Ing. Peter Rankl, Dr.-Ing. Detlev Schöppe, Dipl.-Ing. Stefan Lehmann, Dipl.-Ing. Nicolas Nozeran, Dipl.-Ing. Friedrich Kapphan Continental, Shanghai, China, and Regensburg, Germany

Summary Fun-to-drive autos with further reduction of CO2 and pollutant emissions will be the ongoing focus of the automotive industry. New worldwide, harmonized test cycles and off-cycle emission tests increase the challenge. But modern diesel engines do not only need to comply with upcoming emission legislations, they also compete against direct-injected, turbocharged gasoline engines so they must remain a synonym for “fun-to-drive” while keeping the unbeaten fuel efficiency.

The ongoing development of future diesel engines requires higher precision, flexibility and lifetime stability of FIE (Fuel Injection Equipment) systems. To fulfill these needs Continental is going to launch two new diesel piezo common rail engine management injection systems, for mainstream diesel engines the PCRs5 system featuring servo-driven injectors, the other one for high performance engines is called PCRd1 and features direct-driven piezo injectors.

Both systems include a new generation of single piston pumps and the next generation electronics platform called ECU14.

This report provides an overview about these two new diesel piezo common rail injection system solutions, the associated key components, the related functions and engine results.

1 Introduction Internal Combustion Engines (ICE) will remain the prevalent form of propulsion for automobiles throughout this decade and the next. Key challenges are to fulfill further legislation requirements concerning emissions and CO2 reduction, meaning efficiency of the engines and the vehicles have to be further improved. All key markets require CO2 limits around 100 g/km in the 2020 to 2025 time frame, see figure 1. 2 3rd Aachen Colloquium China Automobile and Engine Technology 2013 Fig. 1: CO2 legislation in key markets [reference 1] At the same time keeping the fun-to-drive feeling is one of the key desires of the end consumers. The modern diesel engine especially fulfills such requirements for lowest CO2 emissions and high engine performance, combined with the capability to cover long distances under any conditions, based on a fuel supply network that covers every corner of the earth.

So a good future can be predicted for modern clean diesel engines, well reflected in volume forecasts in the established diesel markets remaining stable for the upcoming years, see figure 2.

Fig. 2: Volume forecasts diesel (grey) in EU, India, Asean, China 3rd Aachen Colloquium China Automobile and Engine Technology 2013 3 In Europe the estimated volume in 2020 is 10.8 million. Having in mind on the one side the EU6 emission legislation and the 2020 fleet average requirement of 95 g/km for CO2 and on the other side the trend that the majority of diesel engines will be applied in heavier vehicles, a growing need for high performing diesel fuel injection equipment becomes obvious. As to diesels, South Korea is expected to follow the European legislation as before; for 2020 the forecast is that roughly one million vehicles will be equipped with diesel engines.

Do not let us forget to mention US; although there was not any remarkable success in promoting more diesel engines over the years, the 2025 CO2 reduction requirements and the desire of US consumers to own bigger cars, might open new potentials for clean diesel engines, especially in the heavy pick-up and van segments.

Other important diesel markets like India (2020: 3.9 million), China (2020: 3.0 million) and Asean (2020: 1.9 million with Thailand leading concerning volumes) will be also faced with CO2 regulations becoming more stringent; EU6 comparable regulations are expected to come into force there in the 2020 to 2025 time frame.

In order to support best all these diesel engine manufacturers for their development of high performing clean diesel engines with lowest possible CO2 and emissions output, Continental has developed these two latest generation diesel piezo common rail engine management systems covering in total the world market’s needs for vehicles up to 6 tons.

2 Continental piezo common rail systems overview The systems consist of the following key components: • Servo-driven piezo injector PCRs5 in the PCRs5 system • Direct-driven piezo injector PCRd1 in the PCRd1 system • Electronic control unit ECU14, versions for both systems • Advanced software functionality • Radial 1-piston pump family DHP1