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Delphi_Diesel_CRS_FAW_Presentation_Chinese.pdf

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DELPHI_DIESEL_CRS_FAW_PRESENTATION_CHINESE
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Delphi Confidential 1 Delphi Common Rail System 德尔福高压共轨系统 [Dec.21, 2006 2006年12月21日] Johnson Wu – Delphi Diesel Calibration Engineer 吴忠佐-德尔福柴油标定工程师Delphi Confidential 2 Delphi Diesel Products Overview 德尔福柴油系统产品一览表 Car / LCV’s 轿车/轻型车 Epic / DPC Common Rail tubular / spherical EUI 100 EUI 200 EUI E1 EUP E1 DP 200 DP 210 Medium Duty 中型 Trucks 卡车 EUI 200 Common RailDelphi Confidential 3 Expertise in fuel injection 燃油喷射系统技术 In diesel injection we have the key technologies which enable the advance of Fuel Injection Equipment (FIE) product design: 在柴油喷射技术方面,众多关键技术使我们的 燃油喷射系统产品设计处于领先 – Combustion 燃烧 – Controls 控制 – Stress 应力 – Materials 材料 – Noise 噪声 – Hydraulics 液力 0.75 msec/Div 0.75 msec/Div Transducer Pressure 57.3 MPA/Div Experimental Results Needle lift 0.1 mm/Div Experime ntal Trace Computed Results Experimental 试验 Computed 计算分析 Hydraulic System Model 液力系统模型 Electromagnetic Simulation 电磁模拟 Nozzle Stress Analysis 喷嘴应力分析 Rate of injection simulation 燃油喷射模拟 Spray analysis 喷射分析Delphi Confidential 4 Diesel Engineering Presence 柴油系统技术中心Delphi Confidential 5 Barcelona, Spain Troy, Michigan Gillingham, England Sudbury, England Saltillo, Mexico La Rochelle, France Blois, France Izmir, Turkey Cotia, Brazil Chennai, India Changwon, Korea Delphi Diesel System Manufacturing Presence 德尔福柴油系统工厂分布 Stonehouse, England TBD, ChinaNeed to create capacity for Asia Pacific from 2007 有必要从2007年开始在亚太地区生产 USA & SA serviced from Brazil & Mexico 巴西和墨西哥供应美国和南美市场 European Capacity kept full, Asia/Pacific customers transition to region, replaced by new Business 随着 新项目的增加使欧洲能力趋于饱和,亚太地区转 为本地生产 A/P expected to grow to 1m systems/year by 2010.预 计 到2010年亚太地区的供应量 会增加到一百万套/年Delphi Confidential 7 Diesel engines/vehicles fitted with DDS fuel injection products 配有德尔福系统的柴油发动机/汽车厂商Delphi Confidential 8 Delphi Diesel Common Rail Committed Customers 德尔福柴油共轨系统的配套客户 New 2 China New 4 China New 3 US More than 6 Million systems delivered by 06 Development programs started with 18 VM’s worldwide 截止到2006年,德尔福已销售超过6百万套系统,与18个汽车制造公司开展开发项目 Year年 Annual Prod. Vol 年销售量 Customers/brands客户/品牌 Engines发动机 Vehicles整车 2001 350k 4 4 6 2002 1 000k 6 5 11 2003 1 200k 8 6 20 2004 1 300k 10 7 25 2005 1 400k 14 11 34 2006 1 500k 17+ 16+ 41+Delphi Confidential 9 Delphi Diesel Systems Summary 德尔福柴油系统总结 Delphi launched Multec Common Rail in 2000, more than 6 million systems in field 从2000年开始,德尔福开始Multec共轨系统生产,已有超过六百万套系统投入使用 Euro IV has been achieved / demonstrated on several applications 已经在多个项目中达到欧四排放 Euro V type of systems has been demonstrated (solenoid based systems) 基于电磁阀的欧五系统已经经过验证 Direct piezo high performance system (Euro V) is well under development 正在顺利开发高性能压电晶体直接驱动型系统(欧五)Delphi Confidential 10 Win-Win strategy in China 在中国的双赢策略 Deliver latest diesel technology to Chinese Customers 为中国客户提供最新柴油技术 Cost-effective strategy in technical proposal 在技术应用中选择最经济策略 Potential capability for next tier emission legislation 有适合更高排放法规的潜力 Customized technical proposal 基于客户要求的技术应用 Continuous effort on cost reduction 长期致力于降低应用成本 Strong aftermarket service support 强大的售后服务支持 Extended strategic long-term relationship with the customer 与客户保持长期合作 – Transfer application capability to customers’ engineering team 与客户共享应用能力Delphi Confidential 11 Diesel Engine Management System 柴油发动机管理系统Delphi Confidential 12Delphi Confidential 13Delphi Confidential 14 Delphi Diesel Common Rail Features 德尔福柴油共轨系统特点 Injector喷油器 - best packaging with pencil dia 17 mm 外径仅17mm,安装方便 - balanced valve with 12V 应用12V平衡阀 - fastest switching of servo valve 响应最快的伺服阀 High pressure pump高压油泵 - modular pump design 0.6 to 1.2 cmm/rev 每冲程0.6到1.2毫升的泵油设计 - Inlet Metering Valve 进油计量阀 removes need for expensive fuel cooler 不用昂贵的燃油冷却器 - integrated transfer pump 集成燃油提升泵 does not require electrical feed pump 不用电动提升泵 - good standard packaging 安装方便 Rail and pipes 油轨与高压油管 - tubular rail available 直管状油轨 Software 软件 - advanced control strategies 先进的控制策略 Improved Individual Injector Characterization 改进的I2C策略 which reduces injector to injector deviations 喷油器的喷油散差缩小 Accelerometer Pilot Control APC 策略 ?listens? to the engine and corrects minimum drive pulse over the life of the engine 监听发动机缸体振动,在发动机整个使用过程中调 整喷油脉宽使喷油量更精确Delphi Confidential 15 Delphi Diesel Fuel Injector DFI 1 德尔福DFI1喷油器Delphi Confidential 16 DFI 1.2 / 1.3 Solenoid 电磁阀 1400 – 1600 bar Simple & Low cost design Best packaging – 17mm Fastest switching Balanced Servo Valve 12 Volt Bobbin Actuator Advanced Control Strategies, APC/ I2C 简单,低成本设计-17mm外 径装配方便。12V电磁线圈驱 动,最快的响应速度。先进 的控制策略APC/I2C CR Injector Technology Evolution 高压共轨喷油器技术发展历程 DFI 1.4 Solenoid电磁阀 1800 bar Pilot control Multiple injection Reliability with DLC Valve I3C 预喷控制更精确,多次喷射 可靠性更好。应用DLC阀控 制。I3C。 DFI 1.5 Solenoid 电磁阀 1800 – 2000 bar Injection rate Multiple injection Minimum separation CVA Valve Low Cost Worldwide fuels Competitive performance vs Last generation Indirect Piezo products 喷射控制更好,多次喷射能力更强, 最小喷射间隔角更小,经济性好,CVA 阀成本低,油品适应性好,性能可比 非直接式压电晶体产品。 Euro 3 Euro 4 Euro 5 Euro … DFI 3 Direct Acting Piezo 1800 – 2000 bar Performance enhancement Square injection rate Close to zero separation Variable Opening Nozzle capability 性能更优,喷射控制更直接,接近于0的喷 射间隔角,可变针阀开启特性。Delphi Confidential 17 Pulse Pulse 脉冲 Duration脉冲长度 Given injector给定喷油器 Injection rate喷油率 Target injector目标喷油器 Opening开启 Closing 关闭 Delay延迟 Delay 延迟 Delivery 喷油量 Q 2 Offset 2 偏移 2 Given injector 给定 喷油 器 Target injector 目 标喷油器 Q 1 Offset 1 偏移 1 Drive pulse duration 驱 动 脉冲长 度 Injector drive pulse and rate of injection 喷油器驱动脉冲及喷射率 Injector gain curve 喷油器喷油增长曲线 ? The final injectors assembly is followed by a 100% test on an automatic test line.喷油器100%经过下线自动检测。 ? Delivery measurements are made at a selected range of pressures.在选定的压力下进行喷油量检测。 ? Individual injector characteristics are derived from this data and recorded on the injector body.在测试中得出喷油器个性 化特征并记录于喷油器体。 I2C-Individual Injector Characterization I2C-个性化喷油器特性Delphi Confidential 18 What does I2C Strategy ? 什么是I2C策略? Study of complete delivery curve – 1600 bar 喷油器喷油量曲线研究-1600巴 Without I2C 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) With I2C 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) Correction area with less efficiency 修正区域,效 果欠佳 Without I2C 无I2C With I2C 有I2CDelphi Confidential 19 Simulation on a batch of 90 pieces – 1600 bar 90件样品的模拟测量值-1600巴 I2C to I3C evolution ,Comparison of the two methods 由I2C向I3C的改进,两种方法的对比 Without I2C 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) With I2C 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) Without I2C With I2C M1 With I2C M1 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) With I2C M2 0 10 20 30 40 50 60 70 80 90 200 400 600 800 1000 1200 1400 1600 Drive Pulse Length ( ) 祍 Delivery (mg/sh) 0 1 2 3 4 5 6 7 8 9 Line to Line / 3 Sigma (mg) With I2C M1 用I2C策略 With I3C 用I3C策略Delphi Confidential 20 I3C: Improved Individual Injector Characterization I3C: 新一代喷油器特性 Process Flow 过程示意 I3C allows for superb injection accuracy while optimizing the total manufacturing system I3C 的应用使燃油喷射控制更精确,同时优化了整个制造系统。Delphi Confidential 21 Principle:原理 The accelerometer sensor detects the combustion of the pilot injection which makes the engine structure vibrate at a frequency between 4 to 8 kHz depending on the engine 加速度传感器探测缸内预喷燃烧引发的缸体振 动信号,此振动频率在4到8千赫兹(随发动机 不同而有差异) Learning: 自学 习 The pilot pulse is increased until a knock sensor signal is detected 预喷脉冲不断加长,直到加速度传感器检测 到需要的信号。 The difference between this pulse and a nominal one is then used to compensate all pilot injection pulses 实际的脉冲长度与名义值的差即可被用来作 为脉冲长度补偿 Filtered accelerometer signal Drive pulse Cylinder Pressure Pilot pulse =260 us Pilot pulse =200 us The Minimum Drive Pulse corresponds with about 0.3 mg 大 约0.3mg 的最小驱动脉冲 Multec DCR APC : Principle & Learning Multec DCR APC: 原理及其自学习功能Delphi Confidential 22 DFP1 HP Pump DFP1 高压油泵Delphi Confidential 23 Product Description 产品描述 – up to1600 bar operating pressure 高达1600巴的工作压力 – integrated pressure sensor 集成轨压传感器 – tubular rail available 可供直管型油轨 – Hydraulic optimization 液力优化 Status 状态 – tubular rail in production 直管型油轨已生产 – Different volumes 不同的内腔容积 Multec DCR Spherical / Tubular High Pressure Rail Multec 共轨系统球形/直管状油轨Delphi Confidential 24 ECU Technology Evolution ECU 技术发展历程Delphi Confidential 25 Product Description 产品描述 – Compact plastic design with quick fit connectors紧凑的外形设 计,利用快速接头接插 – Water drain with large capacity and smart sensor 油水分离能 力强,接有专门传感器 – Low pressure drop over long mileages 长时间使用后低压油 路压降依然较小 – In-depth filtration media, retention capacities ( ?-ratios ) meeting ISO 14/8 target 纵深滤清介质,滤清能力强,符合ISO 14/8 目标 – Integrated fuel diverter for efficient fuel de-waxing after cold start 在低温时改变燃油流向,减少结腊 Customer Benefits 优点 – Extended filter element service ( 60000 km) with fuel complying with European standard CEN 590 level 如使用符合CEN 590标准的燃油,滤清器使用可达60000km. – Easy and tool free servicing 无需工具,拆装方便 – Flexible packaging 安装布置容易 Status 状态 – in Production 在产 – manufactured at DDS Sudbury (UK) plant 在德尔福英国Sundbury生产。 DDS Filtration Control Unit 德尔福柴油系统滤清燃油滤清控制Delphi Confidential 26 00 01 02 03 04 05 06 07 08 09 10 MULTEC DCR 1600 Bar MULTEC DCR 1400 Bar MULTEC DCR 1800 Bar DIRECT ACTING CR Start Tier 2 (by HP Rating) EURO4 EURO4 Incentive US Tier 2 / EURO5 Year CR System Roadmap 共轨系统发展历程 MEDIUM DUTY CR LD MD Start Tier 3 (by HP Rating) EURO 3Delphi Confidential 27 Injector and nozzle design parameters optimisation :喷油器及喷油嘴设计参数优化 – Improved spray symmetry,喷油更均匀 – Improved atomisation (High Cd, K factor),雾化更好(高Cd及K常数) – Reduced minimum pilot quantity,更小的最小预喷量 – Improved shot to shot and line to line difference,更小的喷油量差异 Multiple Injection - Capability up to 5 injections 多次喷射-可多达5次 – System hydraulic stability and strategies optimisation for multiple injection.为达到多次喷射,系统液 力稳定性及策略经过优化 System pressure 1600 bar / 1800 bar (up to 2000 bar ?) 系统压力1600巴/1800巴(甚至高 达2000巴) Small system variation to comply to in-field emission standards and tougher emission standards. I3C and APC strategies. 得益于I3C以及APC策略,系统差异更小,可满足正在执 行的以及将来更高的排放法规要求。 High sophisticated DCM for full flexibility including active aftertreatment devices 更全面更 复杂的管理系统使控制更灵活(包括后处理装置) CR System Requirements for Euro4 / 5 针对欧IV以及欧V排放法规的共轨系统Delphi Confidential 28 Particulate Trap颗粒捕集器 ? Catalyzed Particulate Filter 催化型颗粒捕集器 ? Electrically Assisted Turbo 电动涡轮 Part [g/km] 0.05 0.04 0.03 0.02 0.01 0 0 0.1 0.2 0.3 0.4 0.5 0.6 EURO IV ‘05 EURO III ‘00 DeNOx System 降NOx系统 ? High Conversion 更高转换率 ? NOx Adsorber NOx吸附装置 NOx [g/km] 1400 Bar ?2 v a l v e2阀 ?( c o o l e d ) E G R中冷EGR ?Ox i-Ca t氧化型催化器 1800bar (2000bar) ? multiple injection多次喷射 ? Combustion System燃烧系统 ? HCCI / VVT JAPAN NST ‘02 US NLEV ‘01 JAPAN NLT ‘05? EURO V? US Tier II Bin 5 1600 Bar ?4 v a l v e4阀 ? multiple injection 多次喷射 ? high (cooled) EGR 高EGR率 ? inlet throttle 进气阀门 ? PM trap (EU) option 颗粒捕集(可选) Decreasing nozzle flow 降低喷油嘴流量 Increasing number of holes增加喷孔数 Passenger Car and light duty truck Emission Strategy 轻型载客与载货车排放控制趋势
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