Amplified pressure CRS with hydraulic hybrid potential

Wieso bislang kein Druckverstärker (DV) ? Gründe / CRS-Vergleich :•kein pmax-Vorteil•höhere Kosten•falls zwei Magnetventile (APCRS für „Weltmotor“ Daimler-Actros):

• keine pmax-Nacheinspritzung (Steuergerät-Leistung zu gering)• aufwendiger Zylinderkopf (Injektor-Bauraum, Rücklaufanbindung)• Boot-Verlauf unnötig für hochaufgeladene Motoren (MAN,Volvo...) • schlechter Gesamtwirkungsgrad (3/2-Ventil, A/Z- und F-Drossel)

•falls ein (2/2-)Magnetventil als Servoventil für 3/2-Druckverstärker-Ventil :• Wirkungsgrad () verschlechtert , wegen :

• A/Z-Drosseln am 3/2-Ventil (Kurzschluss Rail/Rücklauf)• Kurzschluss Rail/Rücklauf beim Schaltvorgang des 3/2

• verlangsamte Öffnungsbewegung des Ventils notwendig:• wegen PI und Kleinstmengen => zusätzlich • flacher Ramp-Verlauf nachteilig für Nacheinspritzung

• DV-Kolben startet immer => • Druckschwingungen kritisch für PI und Kleinmengen• (DV-Rückbefüllung)

•falls ein 3/2-Magnetventil als Servoventil 2/2-DV-Ventil :vorteilhafte DV-Wiederbefüllung (über kleineres 3/2), jedoch weiterhinNachteile (s. o. : verlangsamte Öffnungsbewegung, DV-Kolben-Start)

Die obigen Nachteile entfallen bei den neuen Konzepten :•pmax : Düse mit zentralem Zulauf und Zwischenhub + DV-Maßnahmen•Kosten<CRS : hohes Druckübersetzer-Verhältnis => Pumpe… einfach•3/2-Magnetventil als Servoventil + DV-Maßnahmen =>

• ramp (für PI, Qmin) jedoch square mit pmax (für Nacheinspritzungen)• DV-Kolben „klebt“ zu Beginn (Druckflächenreduzierung oder 2 DV)

Weitere Vorteile:•wesentlich bessere Robustheit (T, Nadelschließkräfte , Dichtflächen)•System-Gesamtwirkungsgrad besser als CRS•Injektor-Bauraum wie CRS (optional: NKW-Düsenschaft- wieder 9mm)•optionale Hydraulikpumpe (ok: Trennung Kraftstoff/Hydrauliköl <-> CAT):

• Hydrauliköl, Öl-in-Wasser-Emulsion, Gasmembrandruckspeicher…• Bremsenergiespeicherung, Hilfsantriebe im Fahrzeug, Federung…

•Kraftstoff-Wechsel im Motorbetrieb, Fluid für Ansteuerung bleibt gleich•Kühlung/Heizung des Injektors umsetzbar (Cracken, Viskosität, Q)

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Amplified pressure CRS with hydraulic hybrid potential

2/2-valve needle:•hollow•coaxial to interlock=> big cross-section

control-holenozzle (pmax ):•central inlet •needle with upper and lower guide•guide washer to create 2 lifts

first lift

second lift

pressureless => pmax,nozzle

fuel-pump

back-pressure-valve (amplifier-refilling caused by 3/2-valve)

control-valve as (3/2-solenoid-valve)

moderation only at the beginning of amplifier-movement => coupled post injection with maximal pressure

multifunction interlock:-pressure separation-seatplate for 2/2-valve-fenceplate -> amplifier

amplifier control-chamber

2/2-valve control chamber

outer-area usefull as amplifier-delay for PI

sprayholes outside of needle-seat => more holes on bigger diameter lower guidance => optimal spray

New concept: 3/2-solenoid-valve commands amplifier-2/2-valve and nozzle

guide => better spring-stability => higher amplifier-lift

2. spring next to amplifier-cylinder => shorter injector

pressure-interlock (optional with seal) => inner and outer pressure-area

guide washer and spring optional

nozzle control-chamber

connection= optional

tank

delay-throttle

2Simulation of new concept see page 5

Amplified pressure CRS with hydraulic hybrid potential

New concept: Injector activated for postinjection (PI):

during the first lift -> needleseat-throttling decreases and gets smaler than the throttling at the delay-throttle => p2

second lift is still left

control-valve opens for PI (deactivation to finish the PI after nozzle-opening)

On outer-area acts only tank-pressure => hydraulic force

pressure in control-chamber => nozzle opens only at first lift, due to the spring/mass or/and the remaining pressure in control-chamber (s. page 8)

2/2-valve connectamplifier control-chamber with tank

delay-throttle becomes the squeeze after a certain nozzlelift => amplifier stays in start-position till: p2 (under the delay throttle) << p1 (upper the throttle)If 3/2 is deactivated before=> end of PI

p1

p2

~p2

3Simulation of new concept see page 5

Amplified pressure CRS with hydraulic hybrid potential

New concept: Injector activated for maininjection (MI):

control-valve opens again to activate the MI (after finishing PI by deactivation of the 3/2-valve)By maintained-activation of the 3/2 => amplifier starts working, leaves the pressure-interlock and moderation (with included ramp-function)After leaving:MI with pmax

To interupt MI: deactivation of the 3/2-valve

for coupled post injection: reactivation of the 3/2-valve. pmax immediatly because the pressure-interlock and moderation are not active (the piston has not returned yet at the start-position)

2/2-valve completely opened, due to amplifier movement and optional spring

Needle in fence, due to p-AMPLIFIER (pmax) under the nozzle-needle

MI-finish: the needle closes till contact (guide washer with lift-washer). Completly closed if p-amplifier => geometrically garanted safety

lift-washer

4Simulation of new concept see page 5

optional spring

5

Amplified pressure CRS with hydraulic hybrid potential

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Closed injector with hydraulic pump (only nozzle with diesel-fuel)If p-FUEL-PUMP > p-HYDRAULIC-PUMP => no polution of the fuel is possible

hydraulical reset-piston with bigger pressure surface than amplifier piston =>hydraulical reset => pmax (no springforce against piston-movement / spring = optional)

pressureless chamber, evacuation with many possibilities

distance sleeve

optional spring

Amplified pressure CRS with hydraulic hybrid potential

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Cooling (or heating) circuit for injector with hydraulical reset-piston

hydraulical reset-piston

Amplified pressure CRS with hydraulic hybrid potential

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Injector with hydraulic pump and two amplifiers (for smal pump pressure)If p-FUEL-PUMP > p-HYDRAULIC-PUMP => no polution of the fuel is possibleInjector is here activated for PI and/or smal Qhyd

If the plunger moves in cross-section => p2 and p-control (amplifier-valve opens) => big amplifier starts moving => pmax => nozzle opens completely

p2

important throttle (to generate p-control to keep the amplifier-valve intermeadiately closed)

Amplified pressure CRS with hydraulic hybrid potential

fuel

for example : hydraulic-oil or oil-in-water-emulsion

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Injector with hydraulic pump, only serving for the amplifier

…