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Sistema de Control
Electronico
History of Common-rail System
Common-rail Engines
1CD-FTV
1CD-FTV (D-CAT)
1KD-FTV
2KD-FTV
1ND-TV
2AD-FTV
2AD-FHV
History of Common-rail System
Different variations on Common-rail
3 Generations
1st-generation
1st-generation
Common-rail
Common-rail
HP2
HP2 Supply
Supply Pump
Pump 2nd-generation
Solenoid Injector 2nd-generation
Solenoid Injector
HP3
HP3 Supply
Supply Pump
Pump
Discharge
Discharge Valve
Valve 3rd-generation
3rd-generation
135 MPa
Injector
Injector Compensation
Compensation NSR
NSR + + DPNR
DPNR
Code
Code Piezo
Piezo Injector
Injector
Max. Common-
rail Pressure 135 - 160 MPa
160 - 180 MPa
History of Common-rail System
Different variations on Common-rail
1st-generation *: Data Matrix Code
Max. Injector
Number Discharge
Engine Model Pump Type Common-rail Compensatio
of SCV Valve
Pressure n
Pressure
NLP10 Bosch 1 Regulating 160 MPa A,B,C Mark
Valve
1ND-TV
Pressure
NDE120 Bosch 1 Regulating 160 MPa DMC*
Valve
CDT220, CLM20,
HP2 2 No 135 MPa Resister
1CD-FTV CDE120
CDT250, CUR10 HP3 1 Yes 160 MPa QR Code
1CD-FTV HP3 + Flow
CDT250 1 Yes 175 MPa QR Code
(D-CAT) Damper
KDJ90, KDJ12# HP2 2 No 135 MPa Resister
1KD-FTV KDJ12# (04 -) HP3 1 Yes 160 MPa QR Code
KUN#6 HP3 1 No 160 MPa QR Code
KLH1#,2#, KDN1##,
HP3 1 Yes 135 MPa Resister
KDY2#0
2KD-FTV
KUN1#,25,35,
HP3 1 No 160 MPa QR Code
KDH20#,212,22#
2AD-FTV ADT251 HP3 1 No 167 MPa QR Code
HP3 + Flow
2AD-FHV ADT251 1 Yes 180 MPa QR Code
Damper
System Overview
Common-rail System Diagram (for IMV)
NE Signal Engine
EDU
G Signal ECU
Other Injectors
Various
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail
Injector
Pressure
Switch
Fuel Cooler
Fuel
SCV Fuel SystemFilter
Supply Pump Fuel Tank
Warning Light
Fuel System
Features
Injector
Pressure
Switch
Fuel Cooler
Fuel
Fuel cooler
cooler
Fuel cools
cools return
return
SCV Filter fuel
Warning Element fuel
Supplylight
Warning light
Pump Fuel System Element
Fuel Tank
for
for fuel
fuel filter
filter WarningDetects
Light
Detects replacement
replacement
clogging
clogging and and filter
filter type
type
fuel
fuel sedimenter
sedimenter clogging
clogging
Common-rail System
General
This system realize high injection pressure in all speed
range of the engine
NE Signal EDU
Engine
(Operates injector
G Signal ECU at high-speed)
Various
Signals
Fuel Pressure Pressure
Sensor Limiter
Common-rail
Injector
(Injects high-pressure fuel)
SCV
Supply Pump Fuel Tank
(Generates high-pressure fuel)
EDU
Battery High
DC / DC Voltage
Converter
Command
Pulse
IJT
#1-4
Control
Circuit High-speed
IJF
operation
Confirmation
Engine Pulse Injector
ECU
ECD System Components (DENSO)
EDU (Electric Driver Unit)
0V Time
Voltage
Battery 0V
EDU Time
+B COM1
High
Voltage
Generation
Circuit
High
Voltage
IJT#1
INJ#1
IJT#2
Control INJ#2
IJT#3
Circuit INJ#3
IJT#4
Engine INJ#4
IJF
ECU
GND GND
ECD System Components (DENSO)
EDU
Injector drive signals
IJT#1
IJF
COM1
INJ#1
System Overview
Main Components for Common-rail System
Shown for the 1KD-FTV engine on the IMV
Engine
Front
Common-rail
Fuel Pressure Sensor
Supply Pump Pressure Limiter
SCV (Suction Control Valve)
Fuel Temp. Sensor
System Overview
Features of Common-rail System
System
SCV Governor
EDU Timer
ECU
Injection
Injector Pump
Supply Pump Nozzle
Injection Volume
ECU (Injector) Pump (Governor)
Control
Injection Timing
ECU (Injector) Pump (Timer)
Control
Injection Pressure According to rotational speed
Supply Pump (SCV)
Control and injection quantity
Pressurization Supply Pump Pump
Distribution Common-rail Pump
Injection Pressure Max. 160 MPa Approx. 15 MPa
Common-rail System
Injector
High pressure injection for higher atomization
Injector
Compensation
Code
Return to From
Fuel Tank Common-rail
0.14 mm
4.2. Product Information ( QR Code )
Upper Side
QR code
: Quick Response
0.14 mm
ECD System Components (DENSO)
Injector
Small injection hall (0.14
mm)
[Top of Injector]
0.14 mm
Influence on Injector caused by particulate (sand,dust) Fuel
Contamination Fuel Foreign Materials
Seizure of Valve
sliding sticking
surface
Piston Command
sticking
Needle Nozzle
sticking
Fluid Valve Seat
grinding poor seal
Orifice
change flow rate
Injection hole
change flow rate
Nozzle Seat
poor oil
tight
Clogging Injection hole
poor fuel spray
Refer to Case 1
4.2. Product Information ( Plunger Clearance )
X-Sectional
0.5 ~ 1 View of
Cylind m Human Hair INJECTOR
er (Magnification
)
Plunger 60 m
Case 1. Fuel Spray Change caused by Injection Hole Clogging
with Foreign Materials
Bottom view
Normal
Spray
Foreign material
Injection Hole
Clogging
Common-rail System
Injector
Construction
Solenoid Coil
Return to From
Fuel Tank Common-rail
Piston
Nozzle
Spring
Nozzle
Needle
Common-rail System
Injector
Controlled by engine ECU signal
Solenoid
Solenoid
TWV
Small
Orifice Return
From
Common-rail Large
Orifice
Common-rail System
Injector
Pilot injection reduces NOx and engine noise
Main
Injection Pilot
Volume
NOx and
engine noise
Heat
Release
Value
TDC TDC
Pilot Conventional
Injection Control Injection Control
System Overview
Sensors and Actuators
Intake Restrictor
Air Flow Meter Valve (Step Motor)
Camshaft
Position Sensor Glow Plug
Plunger
Feed
Pump
Fuel Temp.
Sensor
SCV (Suction
Control Valve)
ECD System Components (DENSO)
Supply Pump (HP3)
Construction
To fuel tank (return)
Ring Cam
Plunger
Eccentric
Cam
Common-rail System
Supply Pump
Supplies the high pressure fuel to the common-rail
Driven by crankshaft
To Common-rail
(Outlet)
From Fuel Filter
(Inlet)
To Fuel Tank
(Return)
SCV
(Suction Control Valve)
Common-rail System
Supply Pump
Fuel flow
To common-rail
From fuel
tank
Common-rail System
Supply Pump Fuel flow
ECD System Components (DENSO)
Supply Pump (HP3)
Suction and pumping operation
SCV
Plunger B
Click!
Movie
ECD System Components (DENSO)
Supply Pump (HP3)
Fuel control operation (SCV opening small)
SCV fixed opening during suction stroke
Fuel
Pumping
Mass
ECD System Components (DENSO)
Supply Pump (HP3)
Fuel control operation (SCV opening large)
Fuel
Pumping
Mass
ECD System Components (DENSO)
Supply Pump (HP3)
Fuel control operation (SCV opening small)
Click!
Movie
ECD System Components (DENSO)
Supply Pump (HP3)
Fuel control operation (SCV opening large)
Click!
Movie
ECD System Components (DENSO)
Supply Pump (HP3)
The SCV opening regulates the pumping volume to
control fuel pressure
Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU Position Sensor
ECD System Components (DENSO)
Supply Pump
SCV signals
HP3 HP2
ECD System Components (DENSO)
Common-rail
Stores high pressure fuel and supplies to injector
[Three kinds of common-rail]
Pressure
Fuel Pressure Limiter
Sensor
Pressure
Discharge
Valve
Common-rail
Common-rail
Pressure
ECD System Components (DENSO)
Common-rail
Fuel pressure sensor (PCR)
Output characteristic
1.0
0 160
Common-rail Pressure (MPa)
ECD System Components (DENSO)
Common-rail
Fuel pressure sensor (PR, PR2)
With 2 different circuits for
Solenoid Solenoid
Coil From Coil
Common-rail
Return to
Fuel Tank
Control
Chamber
Nozzle
Spring
Nozzle
Injector Hole 6 or 8 Spring
Engine
Engine EDU
ECU
ECU
Injection
Volume
Injection Volume
High
Long
Common-rail
Electricity Time Electricity Time Pressure
ECD System Components (DENSO)
Injector
Injection volume correction
Injector compensation code
Injector
Compensation Code
QR Code Compensation Code Type (QR Code)
Injection Quantity
Activation Pulse Correction TQ
Injection Quantity
Activation Pulse Correction TQ Activation Pulse Correction TQ
: Correction Point
ECD System Components (DENSO)
Overview ECU Inputs
Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters
Intake Air Temp. Sensor (THA)
EDU
Water Temp. Sensor (THW)
Fuel Temp. Sensor (THF)
EGR Valve
Air Flow Meter (VG) Engine
Turbo Pressure Sensor (PIM) ECU
Vehicle Speed Sensor (SPD)
Fuel Pressure Sensor (PCR)
Ignition Switch (STA)
Blower Switch (BLW) DLC3
A/C Amplifier (AC)
Alternator (ALT)
ECD System Components (DENSO)
Overview ECU Outputs
Glow Plug
EGR Valve
DLC3
ECD System Components (DENSO)
Crankshaft Position Sensor (Ne)
Magnets
Hall
ICs
ECD System Components (DENSO)
Air Flow Meter [Hot Wire Type] (VG)
Temp.
Sensing
Element
Intake Air
Temp. Sensor
Platinum Hot
Wire Element
ECD System Components (DENSO)
Turbo Pressure Sensor (PIM)
Turbo Pressure
Sensor
Engine
ECU
Vacuum
Damper
EGR Valve
E-VRV
(for EGR valve control)
Engine
ECD System Components (DENSO)
EGR System
EGR valve (Step Motor Type)
EGR Valve
(Step Motor)
To Intake
Manifold
EGR
Valves
From
Exhaust
Manifold
ECD System Components (DENSO)
EGR System
EGR valve (Linear Solenoid Type)
EGR Valve
Position
Sensor
Linear
Solenoid
To Intake
EGR Manifold
Valves
From
Exhaust
Manifold
ECD System Components (DENSO)
EGR System
Intake Restrictor Valve (Step Motor Type)
Air Out
Intake
Reduction Gears Restrictor Valve
Air IN
Step Motor
Throttle Valve Fully Opened Switch
ECD System Components (DENSO)
EGR System
Intake Restrictor Valve (Rotary Solenoid Type)
A quick response and high precise are realized by
driving a direct valve shaft
Magnet
Steel Layer
Hall IC
Magnet
Magnet
ECD System Components (DENSO)
EGR System
Intake Restrictor Valve (Rotary Solenoid Type)
Intake restrictor shutter valve position sensor
Magnet
Hall IC 5
VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Valve
Valve Position Opening Angle (deg)
Sensor
ECD System Components (DENSO)
Variable Nozzle Vane Type Turbocharger
Nozzle Vane Position Sensor
Non-contact type position sensor
Hall ICs
Output characteristic of
main, sub sensor
n
Magnets Ope
Cross-section 2.5 VN
se
N Cl o
0 V
0.5
-55 55 -55 0 55
Sensor shaft rotation angle ()
Common-rail System
Diagnosis
DTCs for common-rail system
Injector Correction
P1601 Injector compensation code
Circuit Malfunction
(89) Engine ECU
(EEPROM)