(Bosch professional automotive information) Gasoline Engine Management Systems and Component 2015

Sách nói về công nghệ động cơ ô tô hiện đại của Bosch, Công nghệ phun xăng trực tiếp, phun xăng trước đường ống nạp. Chia ra các phần cụ thể từ hệ thống động cơ, hệ thống cung cấp nhiên liệu, chế độ hoạt động, chế độ cháy, chế độ phun, phương pháp hình thành hỗn hợp cho các loại động cơ,...

Bosch Professional Automotive Information Konrad Reif Ed Gasoline Engine Management Systems and Components Bosch Professional Automotive Information Bosch Professional Automotive Information is a definitive reference for automotive engineers The series is compiled by one of the world´s largest automotive equipment suppliers All topics are covered in a concise but descriptive way backed up by diagrams, graphs, photographs and tables enabling the reader to better comprehend the subject There is now greater detail on electronics and their application in the motor vehicle, including electrical energy management (EEM) and discusses the topic of intersystem networking within vehicle The series will benefit automotive engineers and design engineers, automotive technicians in training and mechanics and technicians in garages Konrad Reif Editor Gasoline Engine Management Systems and Components Editor Prof Dr.-Ing Konrad Reif Duale Hochschule Baden-Württemberg Friedrichshafen, Germany reif@dhbw-ravensburg.de ISBN 978-3-658-03963-9 DOI 10.1007/978-3-658-03964 -6 ISBN 978-3-658-03964 -6 (eBook) Library of Congress Control Number: 2014945106 Springer Vieweg © Springer Fachmedien Wiesbaden 2015 This work is subject to copyright All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer Violations are liable to prosecution under the German Copyright Law The use of general descriptive names, registered names, trademarks, etc in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use Printed on acid-free paper Springer is part of Springer Science+Business Media www.springer.com Foreword ▶ Foreword The call for environmentally compatible and economical vehicles necessitates immense efforts to develop innovative engine concepts Technical concepts such as gasoline direct injection helped to save fuel up to 20 % and reduce CO2-emissions Descriptions of the cylinder-charge control, fuel injection, ignition and catalytic emission-control systems provides comprehensive overview of today´s gasoline engines This book also describes emission-control systems and explains the diagnostic systems The publication provides information on engine-management-systems and emission-control regulations Complex technology of modern motor vehicles and increasing functions need a reliable source of information to understand the components or systems The rapid and secure access to these informations in the field of Automotive Electrics and Electronics provides the book in the series “Bosch Professional Automotive Information” which contains necessary fundamentals, data and explanations clearly, systematically, currently and application-oriented The series is intended for automotive professionals in practice and study which need to understand issues in their area of work It provides simultaneously the theoretical tools for understanding as well as the applications V VI Contents ▶ Contents History of the automobile 101 Mixture formation Development history 105 Ignition of homogeneous air/fuel mixtures Pioneers of automotive technology 106 Electromagnetic fuel injectors Robert Bosch’s life’s work (1861–1942) 110 Gasoline direct injection Basics of the gasoline (SI) engine 110 Overview Method of operation 110 Method of operation 12 Cylinder charge 111 Combustion process 16 Torque and power 114 Operating modes 18 Engine efficiency 117 Mixture formation 20 Specific fuel consumption 119 Ignition 22 Combustion knock 120 High-pressure injector 24 Fuels 122 Operation of gasoline engines on 24 Fuels for spark-ignition engines (gasolines) 29 Alternative fuels natural gas 122 Overview 124 Design and method of operation 32 Cylinder-charge control systems 125 Mixture formation 32 Electronic throttle control (ETC) 127 Natural-gas injector NGI2 36 Variable valve timing 130 Natural-gas rail 39 Dynamic supercharging 130 Combined natural-gas pressure and 42 Mechanical supercharging temperature sensor 44 Exhaust-gas turbocharging 131 DS-HD-KV4 high-pressure sensor 47 Intercooling 132 TV-NG1 tank shutoff valve 48 Controlled charge flow 133 PR-NG1 pressure-regulator module 49 Exhaust-gas recirculation (EGR) 136 Ignition systems over the years 50 Gasoline injection systems over the years 136 Overview 50 Overview 138 Early ignition evolution 52 Beginnings of mixture formation 146 Battery ignition systems over the years 60 Evolution of gasoline injection systems 152 Inductive ignition system 76 Fuel supply 152 Design 76 Fuel delivery with manifold injection 153 Function and method of operation 78 Fuel delivery with gasoline direct injection 155 Ignition parameters 79 Evaporative-emissions control system 159 Voltage distribution 80 Electric fuel pump 160 Ignition driver stage 83 Gasoline filter 161 Connecting devices and interference 85 High-pressure pumps for gasoline suppressors direct injection 92 Fuel rail 162 Ignition coils 93 Pressure-control valve 162 Function 94 Fuel-pressure regulator 163 Requirements 95 Fuel-pressure damper 164 Design and method of operation 170 Types 96 Manifold injection 174 Ignition-coil electronics 96 Overview 175 Electrical parameters 97 Method of operation 177 Simulation-based development of 100 Instants of injection ignition coils Contents 178 Spark plugs 268 Catalytic emission control 178 Function 268 Overview 179 Usage 269 Three-way catalytic converter 180 Requirements 272 NOX accumulator-type catalytic converter 181 Design 274 Catalytic-converter configurations 184 Electrode materials 276 Catalytic-converter heating 185 Spark-plug concepts 280 Lambda control loop 186 Electrode gap 187 Spark position 284 Emission-control legislation 188 Spark-plug heat range 284 Overview 190 Adaptation of spark plugs 286 CARB legislation (passenger cars/LDTs) 194 Spark-plug performance 289 EPA legislation (passenger cars/LDTs) 196 Types 291 EU legislation (passenger cars/LDTs) 203 Spark-plug type designations 294 Japanese legislation (passenger cars/LDTs) 204 Manufacture of spark plugs 294 US test cycles for passenger cars 206 Simulation-based spark-plug development and LDTs 207 Handling spark plugs 296 European test cycle for passenger cars and 212 Electronic Control 297 Japanese test cycle for passenger cars and LDTs 212 Open- and closed-loop electronic control LDTs 218 Motronic versions 224 System structure 298 Exhaust-gas measuring techniques 226 Subsystems and main functions 298 Exhaust-gas test for type approval 300 Exhaust-gas analyzers 234 Sensors 303 Evaporative-emissions test 234 Automotive applications 235 Temperature sensors 304 Diagnosis 236 Engine-speed sensors 304 Monitoring during vehicle operation 238 Hall-effect phase sensors 240 Hot-film air-mass meter 243 Piezoelectric knock sensors 244 Micromechanical pressure sensors (on-board diagnosis) 307 On-board-diagnosis system for passenger cars and light-duty trucks 324 Diagnosis in the workshop 246 High-pressure sensors 248 Two-step lambda oxygen sensors 326 ECU development 252 LSU4 planar broad-band lambda 326 Hardware development oxygen sensor 330 Function development 332 Software development 254 Electronic control unit (ECU) 336 Application-related adaptation 254 Operating conditions 343 Quality management 254 Design 254 Data processing 260 Exhaust emissions 260 Combustion of the air/fuel mixture 261 Main constituents of exhaust gas 262 Pollutants 264 Factors affecting untreated emissions VII VIII Authors ▶ Authors History of the automobile Dr rer nat Winfried Langer, Dipl.-Ing Karl-Heinz Dietsche, Dr.-Ing habil Jürgen Förster, Dietrich Kuhlgatz Dr.-Ing Jens Thurso, Jürgen Wörsinger Basics of the gasoline (SI) engine Dr rer nat Dirk Hofmann, Ignition systems over the years Dipl.-Ing Bernhard Mencher, Dipl.-Ing Karl-Heinz Dietsche Dipl.-Ing Werner Häming, Dipl.-Ing Werner Hess Inductive ignition system Dipl.-Ing Walter Gollin Fuels Dr rer nat Jörg Ullmann, Ignition coils Dipl.-Ing (FH) Thorsten Allgeier Dipl.-Ing (FH) Klaus Lerchenmüller, Dipl.-Ing (FH) Markus Weimert, Cylinder-charge control systems Dipl.-Ing Tim Skowronek Dr rer nat Heinz Fuchs, Dipl.-Ing (FH) Bernhard Bauer, Spark plugs Dipl.-Phys Torsten Schulz, Dipl.-Ing Erich Breuser Dipl.-Ing Michael Bäuerle, Dipl.-Ing Kristina Milos Electronic Control Dipl.-Ing Bernhard Mencher, Gasoline injection systems over the years Dipl.-Ing (FH) Thorsten Allgeier, Dipl.-Ing Karl-Heinz Dietsche Dipl.-Ing (FH) Klaus Joos, Dipl.-Ing (BA) Andreas Blumenstock, Fuel supply Dipl.-Red Ulrich Michelt Dipl.-Ing Jens Wolber, Ing grad Peter Schelhas, Sensors Dipl.-Ing Uwe Müller, Dr.-Ing Wolfgang-Michael Müller, Dipl.-Ing (FH) Andreas Baumann, Dr.-Ing Uwe Konzelmann, Dipl.-Betriebsw Meike Keller Dipl.-Ing Roger Frehoff, Dipl.-Ing Martin Mast, Manifold injection Dr.-Ing Johann Riegel Dipl.-Ing Anja Melsheimer, Dipl.-Ing Rainer Ecker, Electronic control unit (ECU) Dipl.-Ing Ferdinand Reiter, Dipl.-Ing Martin Kaiser Dipl.-Ing Markus Gesk Exhaust emissions Gasoline direct injection Dipl.-Ing Christian Köhler, Dipl.-Ing Andreas Binder, Dipl.-Ing (FH) Thorsten Allgeier Dipl.-Ing Rainer Ecker, Dipl.-Ing Andreas Glaser, Catalytic emission control Dr.-Ing Klaus Müller Dr.-Ing Jörg Frauhammer, Dr rer nat Alexander Schenck zu Schweinsberg, Operation of gasoline engines on natural gas Dipl.-Ing Klaus Winkler Dipl.-Ing (FH) Thorsten Allgeier, Dipl.-Ing (FH) Martin Haug, Emission-control legislation Dipl.-Ing Roger Frehoff, Dipl.-Ing Bernd Kesch, Dipl.-Ing Michael Weikert, Dipl.-Ing Ramon Amirpour, Dipl.-Ing (FH) Kai Kröger, Dr Michael Eggers Authors Exhaust-gas measuring techniques Dipl.-Phys Martin-Andreas Drühe Diagnosis Dr.-Ing Matthias Knirsch, Dipl.-Ing Bernd Kesch, Dr.-Ing Matthias Tappe, Dr.-Ing Günter Driedger, Dr rer nat Walter Lehle ECU development Dipl.-Ing Martin Kaiser, Dipl.-Phys Lutz Reuschenbach, Dipl.-Ing (FH) Bert Scheible, Dipl.-Ing Eberhard Frech and the editorial team in cooperation with the responsible in-house specialist departments IX 340 ECU development Application-related adaptation Example of calibration Exhaust-gas temperature control The following aspects play an essential role in operating a modern gasoline engine: ¼ Exhaust-gas emissions ¼ Fuel consumption and ¼ Thermal stresses on engine components In order to minimize the stresses to which the engine is subjected, a low exhaust-gas temperature has to be aimed at (e.g peak temperature below 1050 °C and continuous temperature below 970 °C) This is a particularly important consideration in the case of turbocharged engines because the turbocharger has to be protected against thermal damage The exhaust-gas temperature can be reduced by enriching the air-fuel mixture by manipulating the optimization parameters, for example Unfortunately, the negative side of enriching the mixture is that both fuel consumption and exhaust-gas emissions (CO and HC) are raised This means that the mixture need only be enriched by the absolute minimum amount required Engine operation generally follows a dynamic pattern, which is why the exhaustgas temperature is subject to fluctuations Therefore, a physical model to take account of heat capacities, heat transfer and response times is required to determine exhaust-gas temperature Such complex models can generally only be configured with the aid of optimization tools This involves performing tests under all relevant operating conditions in which all essential input and output variables are recorded In the case of exhaust-gas temperature control, the optimizer then adapts the optimization parameters until the modeled temperature matches the measured temperature as closely as possible The accuracy of the modeled temperature is equivalent to that achieved with a temperature sensor if the choice of parameters is appropriate The advantages are obvious – the temperature sensor, sensor wire and installation position layout can be dispensed with on the production model In addition, this removes the risk of the component failing over the life of the vehicle It means that the faultdiagnosis function for the component is not required either Other adjustments Safety-related adaptation As well as the functions that determine emission levels, performance and userfriendliness, there are also numerous safety functions that require adaptation (e.g response to failure of a sensor or actuator) Such safety functions are primarily intended to restore the vehicle to a safe operating condition for the driver and/or to ensure the safe operation of the engine (e.g to prevent engine damage) Communication The engine ECU is normally part of a network of several ECUs The exchange of data between vehicle, transmission, and other systems takes place via a data bus (usually a CAN) Correct interaction between the various ECUs involved cannot be fully tested and optimized until they are installed in the vehicle, as the process of basic configuration on the engine test bench usually involves only the engine-management module on its own A typical example of the interaction between two vehicle ECUs is the process of changing gear with an automatic transmission The transmission ECU sends a request via the data bus to reduce engine torque at the optimum point in the gear shifting operation The engine ECU then initiates actions independently of the driver to reduce engine torque output and thus facilitate a smooth and judder-free gear change The data that result in torque reduction has to be adapted Electromagnetic compatibility The large number of electronic vehicle systems and the wide use of other electronic communications equipment (e.g radio telephones, two-way radios, GPS navigation systems) make it necessary to optimize the Electro-Magnetic Compatibility (EMC) of ECU development the engine ECU and all its connecting leads in terms of both immunity to external interference and of emission of interference signals A large proportion of this optimization work is carried out during the development of ECUs and the sensors concerned, of course However, the dimensioning (e.g length of cable runs, type of shielding) and routing of the wiring harnesses in the actual vehicle has a major impact on immunity to and creation of interference As a result, testing and, if necessary, optimization of the complete vehicle inside an EMC room is absolutely essential Fault diagnosis Due to legal requirements, the capabilities demanded of fault-diagnosis systems are very extensive The engine ECU constantly checks that the signals from all connected sensors and actuators are within specified limits It also tests for loose contacts, short circuits to ground or to the battery terminal, and for plausibility with other signals The signal range limits and plausibility criteria must be defined by the application developer These limits must firstly be sufficiently broad to ensure that extreme conditions (e.g hot or cold weather, high altitudes) not produce false diagnoses, but secondly, sufficiently narrow to provide adequate sensitivity to real faults In addition, fault response procedures must be defined to specify whether and in what way the engine may continue to be operated if a specific fault is detected Finally, detected faults have to be stored in a fault memory so that service technicians can quickly locate and rectify the problem Testing under extreme climatic conditions Testing procedures include trials under extreme climatic conditions that are normally only encountered under exceptional circumstances during the service life of the vehicle The conditions that are encountered during these trials can only be simulated to a limited degree on a test bench because the sub- Application-related adaptation jective judgement of the test driver and long experience play an important part in such tests Temperature itself can easily be simulated on a test bench, but using a chassis dynamometer to assess a vehicle’s response when pulling away, for example, is very difficult compared to making the judgement under real driving conditions In addition, road tests generally involve longer distances and several vehicles This enables testing of calibration parameters across the spread of the vehicles tested and, therefore, allows wider conclusions to be drawn than with calibration based on a single test subject Another essential aspect is the impact of variations in fuel grade from one part of the world to another The chief effect of such variations in fuel grade is on the engine’s starting characteristics and warm-up phase Vehicle manufacturers go to great lengths to ensure this a vehicle will run properly on all the fuels on the market Cold-weather trials Cold-weather trials cover the temperature range from approx °C to – 30 °C Preferred locations for cold-weather trials are places such as northern Sweden and Canada The primary function is to assess starting and pulling away During the starting sequence, every individual combustion process is analyzed and the appropriate parameters optimized where necessary Correct configuration of parameters for every individual injection sequence is a decisive factor in engine start time and smooth increase of engine speed from starter speed to idle speed Even a single imperfect combustion process with resulting reduced torque development during the startup phase is perceived as a deficiency – even by inexperienced customers 341 ECU development Application-related adaptation Hot-weather trials Hot-weather trials cover the temperature range from approx + 15 °C to + 40 °C These trials are carried out at locations such as southern France, Spain, Italy, the U.S., South Africa and Australia Despite the great distances involved and the corresponding high cost of equipment transportation, South Africa and Australia are of interest because they offer hot-weather conditions during the European winter Due to the ever increasing demands to shorten development times, such possibilities have to be considered Altitude trials Altitude trials involve testing at altitudes between and approx 4000 meters It is not only the absolute altitude that is of importance to the tests but, in many cases, a rapid change in altitude within a short space of time Altitude trials are generally carried out in combination with hot or cold-weather trials Once again, an important component is testing the start characteristics Other aspects examined include mixture adaptation, tank ventilation, knock control and a range of diagnostic functions Hot-weather trials test such things as hot starting, tank ventilation, tank leakage detection, knock control, exhaust-gas temperature control and a wide variety of diagnostic functions Recording cold-starting response in the cold room æ UMS0697-1Y 342 ECU development Quality management Quality assurance measures accompany the entire development process, and subsequently the production process as well Only in that way can consistent quality of the end product be guaranteed The quality requirements placed on safety-related systems (e g ABS) are particularly strict Quality assurance systems All elements of a quality management system and all quality assurance measures have to be systematically planned The various tasks, authorities and responsibilities are defined in writing in the quality management handbook International standards such as ISO 9001 to 9004 are also adopted In order to regularly monitor all elements of a quality management system, quality audits are carried out Their purpose is to assess the extent to which the requirements of the quality management system are being followed and the effectiveness with which the quality requirements and objectives are being met Quality assessment On completion of specific stages in the development process, all information available up to that point about quality and reliability is subjected to a quality assessment and any necessary remedial action initiated FMEA FMEA (Failure Mode and Effects Analyzis) is an analytical method for identifying potential weaknesses and assessing their significance Systematic optimisation results in risk and fault cost reduction and leads to improved reliability FMEA is suitable for analyzing the types of fault occurring on system components and their effects on the system as a whole The effect of a fault can be described by a causal chain from point of origin (e.g sensor) to system (e.g vehicle) Quality management The following types of FMEA are distinguished: ¼ Design FMEA: assessment of the design of systems for compliance with the specifications It also tests how the system reacts in the event of design faults ¼ Process FMEA: assessment of the production process ¼ System FMEA: assessment of the interaction of system components FMEA assessments are based on theoretical principles and practical experience Example: a direction indicator fails The effects in terms of road safety are serious The likelihood of discovery by the driver is small, however, since the indicator is not visible from inside the vehicle As a means of making the fault obvious, the rate at which the indicators flash must be made to change if an indicator fails The higher flashing rate is discernible both visually on the instrument cluster and audibly As a result of this modification, the effect of the fault can be reduced Review The review is an effective quality assurance tool in software development in particular Reviewers check the compliance of the work produced with the applicable requirements and objectives The review can be usefully employed as a means of checking progress made even at early stages of the development process Its aim is to identify and eliminate any faults at as early a point as possible 343 344 Index ▶ Index AAS diode 167 alternation 37 ABB 228 alternative fuels ABC 228 altitude trials abnormal operating states AC ACA 194 29, 30 342 ambient pressure 232 AMR sensors 232 244 237 analog input signals 254 accelerator-pedal module 32, 35 angle-of-rotation sensor accelerator-pedal sensors 33 application-related adaptation accessory control 232 232 AS accessory control electrical machines accessory control steering 233 233 233 ASIC ATC 257 326 228 ACE 233 auto-ignition ACS 233 automatic test ACT 233 AVC activation arc suppression 194, 195 335 228 167 Ba(NO3)2 278 273 bag mini diluter 236 300 actuator diagnosis 325 barium oxide, BaO actuator triggering 214 barium nitrate adaptation of spark plugs ADC 273 273 barrier effect 190 84 battery ignition systems over the year 228 additive ignition-angle corrections additives 155 28 adjustable camshaft adjustments AIC 38 battery ignition Benz Motor Cariage 54 Benz, Carl Friedrich 222 bifuel-motronic fuel system 228 bifuel-motronic system 215 air conditioner bill of materials 320 air consumption BMD 14 BOBD 97 air system 327 307 27 air system boost control 228 boost-pressure control 42 air system brake booster 228 Bosch battery ignition 137 air system determination of charge air system intake manifold control air system throttle control air system valve control air/fuel mixture air/fuel ratio 228 brake-booster vacuum control brake-fluid pressure sensor 222 246 breaker-triggered transistorized ignition brush carburetor 10, 264 aircraft engine Bosch, Robert broad-band lambda oxygen sensor 97 aircraft carburetors air-flow 228 228 228 124 223 300 boiling curve 215, 228 B-specimen 56 53 326 burner system 56 279 104 air-gab concept air-gab spark 185 air-mass readings α/n system 30 15 177 calibration tools calibration 241 air-temperature sensor alcohol fuels CAE 186 235 146 136, 143 bifuel-motronic 340 air channel air mass 257 228 A-specimen accessory control thermal management active speed sensors 336 application specific integrated circuit accessory control air condition active heating 34 calorific value camshaft 336, 337 340 25 36 camshaft phase adjustment 36 K Reif (Ed.), Gasoline Engine Management, Bosch Professional Automotive Information, DOI 10.1007/978-3-658-03964-6, © Springer Fachmedien Wiesbaden 2015 252 148 Index camshaft-lobe control camshaft sensors canister-purge valve capacitance combustion knock 80 combustion process communication 286 carbon dioxide carbon particle 232, 258 communication user interface 262 compact coil 50, 52 268 170 compact-ignition-coil design competition spark plug catalytic-converter concepts 269 compiler catalytic-converter configurations catalytic-converter diagnosis catalytic-converter heating 330 312, 313 compound electrodes 184 comprehensive components CE 268 ceramic monoliths 71 222 161 connection adaptor 334 continuous-delivery system 244 charge-flow control valve charge-flow control controlles charge flow 48 101 conversion of pollutants conversion rate 327 212 COP 232, 262 235 226 coordination engine states 30, 123 226 171 corporate average fuel economy CO2 emissions 293 288, 291, 294, 296 271 corrosion inhibitors coil designations 169 COS 171 COU 232 cold starting 98 COV 232 197 crankshaft drive cold-starting problems cold-weather trials 99 C-specimen combustion chamber 17 crankshaft-synchronized channel 341 326 current control combustion-air temperature 28 232 coil on plug combustion 270 coordination engine closed-loop control 146 269 coolant temperature sensor 302 269 48 conventional coil ignition 302 281 79 continuously operating catalysts 48 chemiluminescence detector circuit diagram 299 242 continuous-action lambda control 15 charge-air pressure cold starts 182 connecting devices contamination protection 215 177 331 Constant Volume Sampling charge recording coating 10 44 conical seal seat 147 271 charge component CO 9, 10 compression ratio concept 226 changeover CNG compression 321 123 Computer Aided Engineering centrifugal advance adjustment CLD compressed natural gas compressor 183 central injection unit CIFI 314 226 center electrode CES 99 272 catalytic-converter quality factor catalytic emission control 333 component packages catalytic-converter-heating phase catalytic-converter poisoning 170 202 276 276 232 166 compact ignition coil catalytic converters 232 232 communication vehicle interface 263 260 111, 113 communication security access 261 carbon monoxide 314, 315 combustion of the air/fuel mixture 168 CARB legislation 22, 194, 195 combustion-miss detection 175 capacitive load carburetor 37 238 47 10, 11, 102, 112 current shunt Cutter FID 149 188 302 215 345 346 Index CVS dilution method CVS 299 distributorless (stationary) voltage 299 distribution cylinder charge 12 cylinder-charge control systems 32 D-Jetronic cylinder-individual fuel injection 101 driver stage cylinder pressure curve 195 data memory data processing DBV DSM 254 DSV 18 77, 79 28 duration of the spark 2, 136 development process 330 DVAL 156 dwell-angle control 304 diagnosis in the workshop 310 dynamic supercharging 319 E2PROM diagnosis of engine cooling system 320 EAF diagnosis of exhaust-gas recirculation system 319 diagnosis of fuel system 318 diagnosis of lambda sensors 318 313 diagnosis of NOx accumulator-type catalytic 314 diagnosis of variable valve timing 312 320 231 ECU 254 ECU functions EDM diagnostic system management diagnostic system manager 257 efficiency chain 19 49 31 electrical faults 310 electrocal parameters 309 electrode gab electrode shapes differential hall-effect sensor 237 electrodes 84 194, 199 electromagnetic compatibility 299 electromagnetic fields 220 200 electromagnetic testing 332 distributorless (fully-electronic) ignition electronic control 151 329 212 electronic control unit 340 329 electromagnetic fuel injectors direct-injection gasoline engines distributed development 184 183 183 electrode wear 255 175 186 electrode materials Diesel, Rudolf Christian Karl DI-Motronic 328 electrically heated catalytic converter 95, 244 dilution systems 80, 81 321 electrical testing 233 233 digital input signals 326 214 electric fuel pump 311 138 231 electric drive 311 diagnostic function scheduler diagnostic-tester ECT EGR 304 diagnostic system early ignition evolution EEPROM diagnosis of primary catalytic converter diagnosis validator 257 231 ECU development diagnosis of main catalytic converter diagnosis system 176 39 324 diagnosis of crankcase ventilation diffusion effect 149 dynamic internal resistance diagnosis fault path management converter 169 162 311 dwell period 310 diaphragm 169 dual-spark ignition coil development history diagnosis 109 dual-plug ignition 25, 126 detergent additives DFPM 327 93 dual spray demand-controlled system density 311 233, 310 D-specimen 93 deal cycle 174 16 233 DSCHED 256 171 60 drivetrain DS Daimler, Gottlieb 159 distributorless voltage distribution 254 106 278 Index electronic diagnosis electronic ignition 216 exhaust-gas turbine 150 electronic throttle control EMC 32 exhaust pipe 340 329 emission limits 286 exhaust system description and 286, 289, 294, 308 emission-control laws 284 catalyst 335 external EGR 18 external residual 235 fault detection 236 26 306 fault information 231 fault storage EoL programming EPA legislation 258 309 306 fault-memory entries 289 FEL 256, 257 essential properties of gasolines 26 32 FFC 229 FID 302 257 filter fineness 84 83 ETC 32 filter medium ETF 231 filtration effects 231 84 finger-type sensor 291 324 229 FEPROM 231 EU legislation 13 306, 341 fault handling enhancing knock resistance ETM 233 49 23 engine-speed sensors ETC system 231 extended monitoring engine-oil temperature sensor EPROM 231 exhaust system 334 engine efficiency ES exhaust system three-way front 331 engine knock 231 exhaust system NOx main catalyst 335 emulator module ENM modeling 284 emission-control legislation emulator mode 249 Finite Element Method 177, 206 Euro 291 FIT Euro 291 flame propagation Euro 291 flame-front propagation Euro 291 flame-ionization detector European On-Board Diagnosis European test cycle 224 296 flat seal evaporative-emissions test excess-air factor 79 303 20, 248 9, 253 exhaust emissions 277 exhaust-gas analyzers exhaust-gas branch 102 81, 82 300 343 fossil fuels 268 exhaust-gas recirculation 286 29 four-stroke prinicple 290 4-stroke spark-ignition exhaust-gas measuring techniques 298 49 exhaust-gas temperature sensor 298 229 formaldehyde exhaust-gas categories exhaust-gas test 288, 290 flow-type pump Ford, Henry 261, 270 FPC 229 fresh gas 235 153 182 flow of mixture FMEA 260 11 256, 257 fleet averages FMA exhaust-camshaft adjustment exhaust gas 229 flasch-EPROM evaporative-emissions control system exhaust 231 exhaust system control of temperature emission categories encoding 15, 44 249 exhaust system air fuel control EMC tests emulator 44 exhaust-gas turbocharging 12 frictional losses 19 front electrode 186 8 302 231 231 347 348 Index FS FSS 229 hall-effect angle-of-rotation sensor 229 hall-effect phase sensors fuel-cell power supply 31 hall-effect rod sensors fuel-consumption map 21 hall-effect sensor element fuel delivery 76 hall vane switch fuel-injection systems fuel outlet 50 fuel pressure 244 HC 95 fuel-pressure regulator heat range 76 fuel supply 25 fuel-supply modules fuel supply system 88, 90 HFM 82 194 high voltage properties high-pressure circuit fuel system evaporation leakage detection fuel system feed forward control fuel system injection timing 229 229 229 fuel system mixture adaptation fuel system purge control 229 24 176 78 high-pressure fuel injector high-pressure generation high-pressure injector 229 fuel-temperature sensor fuel-vapor generation 315 120, 121 85 high-pressure sensor 131, 246 history 38 202 automobiles homogeneous 331 function development 141 138 history of compressor-engine fully-shielded spark plugs function monitoring high-voltage vibrator ignition 80 fully variable valve timing function definition 164, 165 high-voltage magneto ignition 235 fuel-vapor management 120 110 high-pressure pumps high-voltage generation fuel-tank leakage diagnosis 99 15, 240 high oil consumption 229 229 function test 189 heating up the catalytic converter fuel-supply control valve fuel system 191 heat-range code number 76 168 189 heat-range adaption fuel standards fuels 92 heat generation in the coil 92 fuel return 326 326 262 HDEV 94 237 237 hardware specimens fuel-pressure damper fuel rail 238 hardware development 107 34 238 43 114 homogeneous air/fuel mixtures 330 105 homogeneous combustion process 233 homogeneous knock protection 331 homogeneous lean 111 116 115 homogeneous mixture distribution gamma angle 109 homogeneous mode gas exchange 13 homogeneous operation gas mass flow gasoline 126 homogeneous split 24 14, 78, 92, 110, 282 gasoline direct-injection system gasoline engine 122 83 hot-soak losses 50, 60 hydrogen 323 ground electrodes group fuel injection 303 139 hot-weather trials hydrocarbons hysteresis 183, 195 101 115 15, 240 342 hydrocarbon molecule structures 302 global service hot-film air-mass meter hot-tube ignition gasoline injection systems GC-FID 111 gasoline engines on natural gas gasoline filter 12 116, 277 homogeneous stratified charge gasoline direct injection 11 114, 117, 222 262 31 166 hysteresis curve 166 24 Index ID 232 intermittently operating ideal fuel consumption IGC 21 catalysts 230 ignition internal EGR 11, 105, 119 internal residual ignition advance adjustment ignition cables 161 ignition circuit 152 174 172 IS 191 ignition distributor japanese legislation 150 jet-nozzle carburetor 157 KE-Jetronic 66 ignition parameters 155 knock control ignition probability 197 knock recognition 198 153, 158 knock sensor 230 243 334 LabCar 162, 186, 199 lambda closed-loop control 230 lambda control loop impact effect 84 283 lambda (λ) inductive ignition system inductive speed sensors inductive trigger 10, 11 152 98 linker 107 LNG 100, 103 335 low-pressure circuit 37 intake-manifold model 30, 123 long-term compliance 188 LPG 15 intake-manifold pressure 287 78 30 L3-Jetronic 68 244 intake-synchronous injection 103 magnetic circuit 47 interference suppressors 30 66 logic analyzer 181, 204 intake camshaft 123 liquefied petroleum gas 254 insulator nose 306 333 L-Jetronic instants of injection 12 69 liquefied natural gas 106 108 intercooling LH-Jetronic limp-home function injection-duration correction input signals 114 learn-burn operation 115 injector operation 181 lean-burn mode 285, 289, 291, 293 injection duration 184 328 lead-free glaze 236 150 in-field monitoring layout 248 10, 248 laser-welded pins induction-mixture distribution injection points 280 lambda oxygen sensors individual-cylinder control insulator 243 knock-sensor signals 20, 187, 276 ignition voltage injectors 23 25 136, 230 ignition timing induction 23, 154 knock resistance ignition system knock control IKC 54 62 K-Jetronic 156 ignition systems 297 160 ignition energy balance ignition reliability 294 japanese test cycle ignition driver stabe ignition spark 190 230 162, 169 230 ignition energy 81 ionic-current-measurement 162, 164, 171, 177 ignition control 13 internal-combustion engine ionic current ignition-coil modules ignition coils 147 internal-gear pump ignition-coil electronics ignition-coil types 269 49 166, 172 magnetization curve 161 interference-suppression resistors magneto 161 166 136 magneto ignition 140 248, 282 349 350 Index magneto-electric low-voltage snap-release ignition main channel MOX 226 natural gas major-leak detection 316 manifold injection 308 manifold-injection system Maybach, Wilhelm sensor 204 15, 42 NDIR analyser NDIR 271 256 NMOG 233 micromechanical diaphragm NO 241 NO2 micromechanical pressure sensors 244 mixture control mixture formation mixture ignition M-Motronic 232 301 273 NOx accumulator-type catalytic converter 273 NOx storage catalyst 112 101, 117, 125, 264 157 NSC 272 NTC 235 272 NTC temperature sensor 218 N2O 296 286 262, 272 NOx removal 248 mixture distribution 235 262 233 Modified New European Driving Cycle modularity module 296 OBD II 333 OBD system 233 OBDI 153, 155, 265 OBV 26 monitoring concept 35, 216, 233, 257 monitoring of ECU communication monitoring of input signals 306 monitoring of output signals 305 232 OEP 306 25 232 off-board tester OMI 325 244 232 on-board diagnosis 304 on-board-diagnosis system 70 motor-sport- applications motronic system structure 212 on-engine measures 202 open-loop control 225 motronic systems in motorsport motronic systems 304, 308 307 oil pressure 305 monitoring of internal ECU functions Mono-Jetronic 308 octane number 304 311 307 OBD limits 233 monitoring 307 OBD OBD functions 330 moment of ignition MON 271 NOx accumulation 316 misfire detection irregular running MOM 262 noble metal NOx minor-leak diagnosis MOF 286 262 non-methane organic gases 239 235 262, 272 Non-Dispersive InfraRed 247 308 miniaturzation MOC 301 nitrous oxides microcontroller monitoring MNED 123 301 negative temperature coefficient 126 micromechanics 124 natural-gas vehicles 218 microcontroller 130 natural-gas system metallic monoliths 130 natural-gas rail 29 mechanical supercharging ME-Motronic 125, 127 natural-gas pressure and temperature 97 manufacture of spark plugs 123 natural-gas injectors 76, 92, 96, 100 manufacturing paths 30, 122 natural-gas drives malfunction indicator lamp MIL 218 233 215 main functions mfng motronic versions 140 217 operating data 307 98 212 212, 232 operating data battery voltage 232 272 Index operating data engine position management operating data temperature measurement operating data vehicle speed operating modes 232 220 114 220 operating-mode coordination 319 165 primary-droplet spray 102 4, 53 program code 258 316, 317 oxygenates 25 p/n system 15 Pt 235 pump cell paramagnetic detector parameter definition 302 336 pump current 253 pump pistons 85 253 339 pump voltage particulates 263 pumping losses pedal-travel sensor 34 172, 173 performance of electronic control units periodic emission testing peripheral pump 293 planar lambda sensor 243 rac 250, 251 platinum electrodes 184, 249 321 204 57 84 radial vee-form filter 83 rail-pressure sensor 246 RAM 257 ram-tube supercharging 262, 270 ram-tube systems positive temperature coefficient positive-displacement pump post-ignition 81 192 post-start phase 235 17 9, 16 192 random testing 257 285 321 rationality checks 321 read only memory 256 readiness code 310 real p-V-diagram 18 real-world fuel economy pre-intake injection 103 reduction of emissons pressure attenuator 87, 88, 90 reference vacuum pressure curve 39 41 random access memory range checks 98 176 power output 343 343 radial vee-form element 302 pre-ignition 343 12 radial engine 184, 271 power loss 258 243 piezoelectric knock sensors pollutants PWM signals 259 quality management piezoceramic element plug core 18, 19 quality assurance systems 286, 290 plausibility errors 14, 19 p-V diagram quality assessment 81 255 253 parameters platinum 324 184 pulse-shaped input signals 271 pencil coil 332 prompted troubleshooting PTC palladium 331 256 programming language 28 214 333 programm memory 232 oxidation stabilizers power 25 program version delivery overpressure method PMD 328 processing of gasolines processing of operating data output signals phase-in 133 18 primary-current curve printed-circuit board 220 232 Otto, Nikolaus August OVS 93, 94 pressure-regulator module primary sensor operating-mode selection OTM pressure-limiting valve pressure-volume diagram 114 operating-mode changeover operating-mode map 232 232 154 pressure-control valve 244, 245 reformulated gasoline 93 refueling test 303 135 98 28 351 352 Index regenerative fuels 29 single-spark coils relative air charge 12 single-spark ignition relative fuel quantity remote version 12 SMD 171 SO2 171 169 254 262 requirement 330 software calibration process residual gas 13 software development resistance software process improvement 175 returnless system review rfq 77 343 software quality 332 software sharing 332 software testing station 12 rhodium solenoid armature 271 rod sensors 256 RON 26 solenoid coil 238 roller-cell pump ROM soot rotating high-voltage distribution running-loss test 333 162 spark duration spark energy 303 spark gab safety-related system 267 spark current 159 153 162, 168 190 spark-generation properties 35 spark head 226 308 spark-ignition engines screening 161 spark-ignition 178 spark plasma 105 226 seal seat 182 secondary mixture preparation secondary sensor 100, 277, 278, 317 243 sensor ceramic element sensor diaphragm 249 234 setpoint generation SFTP schedules 101 signal testing silver 167 188 spark-plug installation 207 spark-plug performance 192 178, 193, 200 202 172 spark position 187 153, 156 special-purpose spark plugs 186 specific fuel consumption 255 specimen assembly 214, 255 speed of sound 325 spit-back test 184 328 simultaneous fuel injection 101 single-plunger/barrel pump spray formation spray shapes 87, 90 86 303 spray targeting 109 109 103 202 20 126 spiral vee-form element 184 silver-center electrodes single-barrel pump 188 194 208, 209 spark-plug selection spark tail 182, 204 signal processing 197 spark-plug heat range spark-plug well signal conditioning 206 181 spark plugs with resistors 295 295 side electrode spark plug design spark plugs 212 shear in magnetic circuit shell 185 spark-plug profiles 212, 234 sequential fuel injection SFTP 205 spark-plug concepts spark-plug operating range 240 sensor integration levels sensors spark-plug assembly spark-plug efficiency 101 seismic mass 24 spark-plug development 319 secondary-air injection SEFI 104 176 153, 156 scan tool SD 334 128 263 source code 42 332 129 soot emissions 81 rotary-screw supercharger SC 338 332 83 Index spray-guided combustion process starting phase 113, 119, 201 98 tester steel terminal stud 181 story of fuel injection stratified charge test procedures 285 309 testing station 51 333 thermal aftertreatment 11, 114, 222 thermal auto-ignition stratified-charge combustion process 112 99 191 thermal conduction paths stratified-charge concept 11, 20 thermal efficiency stratified-charge mixtures 119 thermal loading capacity stratified-charge mode 114, 117 stratified-charge starting 116 stratified-charge/catalyst heating substrates thermal losses 188 18 thermocouple spark plug 116, 277 271 subsystems 189 18 thermographic picture thermography 226 190 328 329 three-barrel pump 85 sulfur content 28 three-sensor control sulfur dioxide 262 three-way catalyst sulfur loading 274 three-way catalytic converter supercharging 14 throttle device supplemental federal test procedure surface-air-gab concepts surface-air-gab spark surface carburaetor 186 295 throughflow curve 16 torquebased system structure 186 torque conversion surface-mounted devices 15 134 227 torque 185 254 269 33 throttle-valve model TMO 54 surface-gab concept surface-gab-spark 185 283 268 215 227 torque coordination 227 swell matting 271 torque demand auxiliary functions swirl air flow 113 torque demand cruise control switching signals 258 torque demand driver switch-on sparks 167 torque demand idle speed control SYC 226 227 226 226 226 torque demand signal conditioning system control 226 torque demand system documentation system structure 226 224 226 226 torque modeling 227 torque structure 215, 227, 231 transistorized ignition with hall-effect tank shutoff value 132 trigger tank-leakage diagnosis 82 tank-ventilation losses 303 tapered spray 148 transistorized ignition with induction-type pulse generator 109 trigger conditions TCD 227 TS TCV 227 tumble air flow TD 226 150 335 227 113 tuned-intake pressure charging TDA 227 tuned-intake-tube system TDC 226 turns ratio TDD 226 two-sensor control TDI 226 temperature sensors tendency to knock terminal stud test cycles 176 two-step control temperature measurement 235 22 181, 204 285, 296 190 282 280 two-step lambda oxygen sensors type approval type tests 40 40, 41 285, 292 292 248 353 354 Index unscheduled testing 289 untreated CO emissions untreated emissions wall- and air-guided combustion wall/air-guided combustion process 265 warming-up phase 264 untreated HC emissions 112, 119 untreated NOx emissions US test cycles 267 vacuum advance adjustment 147 316 27 variable valve timing 36, 320 variable-geometry intake-manifolds variation coefficient 187 vehicle management 216 26 voltage distribution 159 volumetric efficiency VTG turbocharger 320 workshop 324 yoke plate 172 308 27 variable turbine geometry of turbocharger VVT workshop tester 27 vapor-lock index (VLI) volatility workshop diagnostic functions 9, 13 vapor/liquid ratio 59 59 working cycle 315 vacuum-relief diagnosis method vapor pressure 45 wood-gas generator system wood-gas valve timing 98 wastegate supercharger 294 vacuum method 46 200 266 14, 40 40 46 zero-emission vehicles 289 325 ... (EEM) and discusses the topic of intersystem networking within vehicle The series will benefit automotive engineers and design engineers, automotive technicians in training and mechanics and technicians...Bosch Professional Automotive Information Bosch Professional Automotive Information is a definitive reference for automotive engineers The series is compiled by one of the world´s largest automotive. .. ignition and catalytic emission-control systems provides comprehensive overview of today´s gasoline engines This book also describes emission-control systems and explains the diagnostic systems