[Hubei Cheng Lixin] In order to meet the country's three emission standards, most domestic truck and diesel engine companies set the technical route to high pressure common rail, and the current high pressure common rail technology is mainly controlled by Bosch, Delphi, Denso and other companies, among which Bosch's high The rail system occupies most of the market share.
The technical upgrade is accompanied by changes in the use of vehicles, etc. In order to better spread the knowledge of the 3rd Electronic Control Common Rail System and make everyone use it better, we have found on the official website of the Bosch Common Rail System. The basics of some common rail systems are now sorted out and shared with everyone.
â— Â Common diesel system composition
The diesel common rail injection system consists of a hydraulic system and an electronic control system. The hydraulic system is divided into low pressure hydraulic system and high pressure hydraulic system.
Common rail system schematic
 Hydraulic system
Low pressure hydraulic system:
— Fuel Tank — Fuel Pump — Fuel Filter — Low Pressure Tubing
High pressure hydraulic system:
— High pressure pump — High pressure fuel rail — Injector — High pressure tubing
 Electronic Control System (EDC)
- Sensors - Electronic Control Unit (ECU)
- Actuators, including fuel injectors with solenoid valves, pressure control valves, glow plug control units, boost pressure regulators, exhaust gas recirculation regulators, throttle valves, etc. - wiring harness
â— Â The four core components of the common rail system
Among them, injectors, high pressure pumps, high pressure fuel rails, and electronic control units are the four core components of diesel common rail systems.
 Injector
Injectors are components that atomize and distribute fuel in the engine's combustion chamber. The injection time and duration of the common rail injectors are calculated by the electronic control unit and then given signals, which are then controlled by solenoid valves.
 2. High pressure pump
The role of the high pressure pump is to compress the fuel from the low pressure state to a high pressure state through the plunger to meet the fuel injection pressure and fuel injection requirements of the system and the engine.
 3. High pressure fuel rail
The role of the high-pressure fuel rail is to store the fuel, while suppressing the pressure fluctuations caused by the high-pressure pump oil supply and injector fuel injection to ensure that the system pressure is stable. The high pressure fuel rails are common to all cylinders, which is a sign of the common rail system.
 4. Electronic control unit
The electronic control unit is just like the brain of the engine. It collects the parameters of the operating conditions of the engine, calculates and processes the stored characteristic maps, and transmits the signals to the actuators to achieve functions such as engine operation control and fault diagnosis.
There are two kinds of commercial vehicles for Bosch common rail system products: CRSN2-16 and CRSN3-18.
â— Â CRSN2-16: The most widely used, the maximum pressure of 1600 bar
Based on Bosch's global platform R&D and optimized for the Chinese market, it is currently Bosch's most widely used platform in China. It can simultaneously meet various national, national, and national emission standards. Applicable to mid- and heavy-duty commercial vehicles, specifically for the characteristics of commercial vehicles for life-enhancement.
By going home, even if the system fails, it can still be driven without affecting the safety to meet the special needs of commercial vehicles.
Modular design, suitable for different power torque and number of cylinders. A variety of high-pressure pump combination solutions to meet different customer needs, including CP3, CPN2-16 for the development of a global platform, CB28 for the localization of efficient and reliable development and more competitive prices.
The optional EDC17CV electronic control unit of Bosch's latest generation of globalization platform is specially optimized for Bosch Denoxtronic 2.2 system. It can integrate all the functions of the urea injection control unit (DCU) to simplify the system and reduce costs.
 Features
Common rail system tailor-made for medium and heavy commercial vehicles Â
Globalized platform optimized for the Chinese market Â
Modular design for different power torque and number of cylinders Â
Homecoming function Â
Low fuel consumption Â
High reliability, higher design life Â
Self-diagnosis to quickly and efficiently resolve faults Â
System pressure up to 1600 bar Â
Can meet the national three, four and higher emission standards
â— CRSN3-18: Upgraded version, maximum pressure 1800 bar
Based on Bosch's global platform R&D, it is particularly optimized for the Chinese market. Applicable to mid- and heavy-duty commercial vehicles. It is designed to enhance the lifespan of commercial vehicles.
By going home, even if the system fails, it can still be driven without affecting the safety to meet the special needs of commercial vehicles. Modular design, suitable for different power torque and number of cylinders.
The entire system can be directly upgraded based on the CRSN2-16 system, simplifying the development and matching cycle. System pressure up to 1800 bar.
 Features
Common rail system tailor-made for medium and heavy commercial vehicles Â
Globalized platform optimized for the Chinese market Â
Modular design for different power torque and number of cylinders Â
Homecoming function Â
Can be upgraded directly on the CRSN2-16 Â
High reliability, higher design life compared to passenger car systems Â
Self-diagnosis to quickly and efficiently resolve faults Â
System pressure up to 1800 bar Â
Can meet the national IV and higher emission standards
â— Â Diesel common rail system characteristics
In traditional diesel injection systems, the pressure and fuel injection are related to the cam and the plunger. The injection pressure increases with the increase of engine speed and fuel injection. This diesel system has been unable to meet the increasingly stringent emission regulations and desire to reduce fuel consumption.
The common rail system (CRS) stores fuel in a pressure accumulator (high pressure oil rail) under high pressure, which essentially overcomes the defects of traditional diesel injection systems. Its characteristics are:
· The injection pressure does not depend on the engine speed and system fuel injection. It can flexibly control the injection pressure and oil quantity according to the different working conditions of the engine so as to realize low injection speed, high injection pressure, low speed and high torque, low emission and optimized fuel oil. Economical purpose.
· Through the electronic control unit to calculate the ideal fuel injection and injection time, and then accurately injected by the injector, or even multiple injections.
· Higher system pressure, better discharge capacity, and lower fuel consumption.
â— Â The advantages of Bosch common rail technology
The purpose of diesel engine electronic control of high pressure diesel is to improve the fuel economy and emission pollution of the diesel engine. At the same time, from the aspects of power, fuel consumption, and drivability, the electronically controlled diesel system is increasingly accepted by the market. The main advantages are shown in the figure.
The current Bosch electronically controlled high pressure common rail system on the market has the following advantages:
· Compared with the same power gasoline engine, the diesel engine fuel consumption saves 25%-30%;
Strong dynamics, mainly in the torque, fast acceleration at low speed, good drag and drop performance;
· The precise control of the electronic control unit refines the injected diesel oil, improves combustion, and effectively suppresses particulate matter and NOx generation.
· Can achieve precise control of fuel injection
· Better smoke control ability and low emission capacity;
· CO2 emissions are about 30% lower than gasoline vehicles, and HC emissions are also significantly lower;
· Complete self-diagnosis system, complete failure protection mode and security control strategy.
â— Â Selective Catalytic Reduction System Overview
Selective Catalytic Reduction (SCR) is used to remove nitrogen oxides from diesel engine emissions. In the high temperature environment, the urea injection unit injects urea aqueous solution into the exhaust pipe, urea liberates ammonia gas at high temperature, ammonia reacts with the nitrogen oxides in the exhaust gas in the SCR catalyst, and regenerates nitrogen and water. In order to reduce the emission of nitrogen oxides from diesel engines, the reaction equation is:
NOX+CO(NH2)2 Â =>N2+H2O
Its features are:
· Wide range of applications, widely used in diesel passenger cars, commercial vehicles and non-road construction machinery;
· Can effectively reduce the engine's fuel consumption rate, to achieve the purpose of vehicle energy saving;
· Good oil compatibility (better sulfur resistance);
· Relatively simple engine structure (for EGR engines) for ease of maintenance.
 System composition
The selective catalytic reduction system consists of a urea supply unit, a urea injection unit, a control unit and a catalyst.
 Urea supply module (Supply Module)
- Urea supply pump - Urea and urea tank heating and level assembly - Urea tube
 Dosing Module (Dosing Module)
— Urea injection valve and gasket — cooling water pipe
 control unit
- Sensors, including ambient temperature and urea tank temperature sensors, level sensors, nitrogen oxygen sensors, etc. - The urea injection control unit (DCU) can be integrated in Bosch EDC17CV electronic control units - actuators, including heating relays, Urea box solenoid valve
 Selective catalytic reduction system catalyst box
- Catalytic converters for selective catalytic reduction - silencers
 Urea supply unit
The urea supply unit sucks the urea solution from the urea tank into the urea pump and delivers the urea pump to the injection unit with a certain pressure. When the urea supply unit is stopped or the system fails, the urea solution is emptied.
 Urea spraying unit
The urea injection unit atomizes and sprays the urea aqueous solution into the exhaust pipe.
 Urea injection control unit
The urea injection control unit knows the status of the vehicle in real-time through the sensor and accurately controls the operation of each actuator in real time through software calculations, realizing accurate control of each vehicle system.
â— Â Bosch Selective Catalytic Reduction System Products
 Denoxtronic 2.1
Denoxtronic 2.1 is the second generation of Bosch's selective catalytic reduction system developed for diesel commercial vehicles and non-road construction machinery.
 System Features
· High nitrogen oxide conversion efficiency
· Effectively reduce engine fuel consumption
· The system can be thawed by itself to achieve normal operation in low temperature environment
· Direct cooling of the injection valve with aqueous urea
· Modular design for easy installation on vehicles
· Can meet the national four, country five and higher emission requirements
 Denoxtronic 2.2
Denoxtronic 2.2 is an upgraded version of Bosch's second generation selective catalytic reduction system Denoxtronic 2.1, developed for diesel commercial vehicles and off-highway construction machinery. The urea injection control unit (DCU) can be integrated in the Bosch EDC17CV electronic control unit.
 System Features
· The urea injection control unit (DCU) can be integrated into the Bosch EDC17CV electronic control unit to simplify the system and reduce costs
· High nitrogen oxide conversion efficiency
· Effectively reduce engine fuel consumption
· The system can be thawed by itself to achieve normal operation in low temperature environment
· Cooling injection valve with engine cooling water
· Modular design for easy installation on vehicles
· Can meet the national four, country five and higher emission requirements
â— Â Daily use points
1. The engine start time generally does not exceed 5 seconds; if the start is not successful, the key must be turned off for 30 seconds before starting.
2. After the cold start, run at idle or low speed for a few minutes before accelerating.
3. When starting the vehicle, it must be powered on to complete the self-test of the indicator light and start again.
4. After the engine is running, check whether the warning light is on, whether the fuel temperature and water temperature are normal, and whether the engine runs abnormally.
5. The driver should always pay attention to the indicator light, such as water temperature, oil pressure, engine fault light, etc. If there is any abnormality, please check the relevant system promptly; when the fault light is on, you must go to the repair station in time for processing.
6. Avoid emergency stop after a long period of high speed and high load operation.
7. When starting at a low temperature, wait until warm-up is complete before starting.
When the key is placed in the ON position, the engine warm-up lamp will light, and the warm-up lamp should be started as soon as it goes out.
8. The diesel engine must not exhaust the refueling of diesel fuel because the engine fuel system sucks air in this condition and can damage common rail components.
9. The oil-water separator in the fuel filter should be checked and drained regularly.
â— Â Fuel Saver
1. Let the engine run as far as possible in a reasonable speed area (usually the green area marked with a tachometer) to get the best power, economy and emissions.
2. Select the appropriate gear. Avoid high-speed low-speed driving, or low-speed high-speed driving.
3. During normal driving, avoid rapid acceleration and rapid deceleration.
4. Choose economic speed.
5. When the vehicle is running, when the engine speed is higher than 1500 rpm, do not use neutral gliding, otherwise it will be more fuel-consuming.
â— Precautions for diesel use
Please select the diesel that meets the emission regulations at the regular gas station. From July 1, 2009, all the diesel engines for commercial vehicles and passenger vehicles have already been implemented with the National III emission regulations. The state issued the standards for GB19147-2009 on vehicle diesel fuel on June 12, 2009 and was not promulgated on January 1, 2010.
In different regions and in different seasons, suitable diesel should be selected according to the ambient temperature.
 It is forbidden to incorporate gasoline, water or other additives into diesel fuel!
Diesel fuel quality is an important factor affecting engine emissions, performance and service life. Inferior diesel fuel has a serious impact on the normal use of common rail systems, and even causes significant losses:
· Poor lubrication causes common rail components to wear out;
· Particles cause dictatorship, card retention, and wear;
· Water and additives cause rust and corrosion;
· The presence of elements such as copper, zinc, lead, and tin in diesel fuel can cause carbon deposits in the nozzle, affecting the corresponding functions.
â— Â Maintenance points
1. Replace the three filters (oil filter, diesel filter, air filter) according to the maintenance manual of the host machine.
2. Replacement filter specifications must meet the OEM requirements, such as filtration efficiency, and are not free to use low s
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