Principle and Application of WEICHAI Electrical High Common Rail System

潍柴电控高压共轨系统原理及应用
Principle and Application of WEICHAI Electrical High Common Rail System
单位名称：国际业务协同部
时间：2020.10.12
1
PART 01 课程导入
2
高压共轨系统
1，高压共轨系统主要组成部分？
2，燃油品质差可能导致的故障？
3，常用的传感器有哪几类？
3
WP6 Engine
1×
6×
1×
1×
4
目录 CONTENTS
5
高压共轨系统概述
PART 02 Overview of high pressure common rail system
6
2.1 电控高压共轨系统的优势 HP CR System advantage
◼ 动力强劲
Powerful
◼ 电控单元精确控制，喷油精确控制
Precise control of fuel injection
◼ 较好的烟度控制能力及低排放能力
Excellent smoke control and low emission
◼ 完善的自诊断系统，完善的失效保护模式，
安全的控制策略.
Perfect self-diagnosis system, failure
protection mode and safe control strategy
◼ 实现需要的整车功能，比如发电的并网、转速调整，车机的巡航等等
Realize engine functions such as genset parallel, speed control, cruise control in vehicle, etc.
7
2.2 系统工作原理System working principle
CPN2.2高压油泵，提供最高电控单元,发动机控制中
心
1750bar燃油压力 ECU, control center
CPN2.2 high pressure pump,
Up to 1750bar
喷油器，喷油压力达1600bar
高压共轨管激光焊接、性能稳定
Injector，injection pressure up to
High pressure common rail , laser
1600bar
welding, stable performance
8
高压油泵功能原理
PART 03 High pressure pump
9
3.1 CPN2.2高压油泵High Pressure Pump
总体结构Structure 齿轮泵Gear pump 计量单元Metering Unit 溢流阀Overflow valve
高压油出口两缸高压油泵CPN2.2 可提供最大压力1750bar，实际

应用1600bar。
柴油进口（自滤器）柴油出口（到油箱）
M-PROP 燃油计量阀
燃料由齿轮泵从油箱中吸出，经燃油过滤器过滤后进
溢流阀
入高压油泵。
油量计量单元安装在高压油泵的进油位置，用于调整
凸轮轴
燃油供给量和燃油压力值。
Two-cylinder high pressure oil pump cpn5-22/2 provides a

maximum pressure of 17500bar, 1600bar for practical
柴油出口（到滤器） application.
The fuel is sucked out of the tank by gear pump and filtered
through the fuel filter into the high-pressure oil pump.
齿轮泵 ZP5 凸轮轴相位传感器: DG6 The fuel metering unit is installed at the inlet of the high
柴油进口（自油箱） pressure pump to adjust the fuel supply and fuel pressure.
10
总体结构Structure 齿轮泵Gear pump 计量单元Metering Unit 溢流阀Overflow valve
吸油过程：
当齿轮旋转时，右侧油腔的轮齿逐渐脱开，密封容积增大，
形成局部真空，燃油在大气压力作用下被吸到右边油腔，充
满齿槽，随着齿轮的旋转被带到左边。
压油过程：
由于齿轮逐渐进入啮合，左边油腔的容积逐渐减小，齿槽中
燃油受到到挤压，从出油口排出。
Fuel suction process:
When the gear rotates, the teeth of the fuel chamber on the right gradually detach, sealing
volume increases, forming a local vacuum, fuel is sucked to the right oil chamber due to
atmospheric pressure , and taken to the left with the rotation of the gear.
Fuel compress process:

使用含水或杂质过多的劣质燃油，会导致齿轮泵 As the gears are gradually engaged, the volume of the fuel chamber on the left is gradually
锈蚀，油泵无法供油，整车无法启动。 reduced, and the fuel is compressed and discharged from the fuel outlet.
The pump will be damaged if the fuel has too
much water or impurities.
11
总体结构Structure 输油泵Gear pump 计量单元Metering Unit 溢流阀Overflow valve
最大工作量电流: 0A Maximum delivery current: zero

Zero delivery current: 1.8A
零流量工作电流: 1.8A
工作电压 Working voltage 8~32V
线圈电阻 Coil resistance @20℃ 2.6~3.15Ω
工作电流范围 Working current 0.5~1.8A
开路电压 Open circuit voltage 3.5V/24V
油品质量较差会导致油量计量单元油道堵塞、活塞卡滞。
Poor quality fuel will block the fuel passage or piston,
WP4.6N以下（含WP4.6N）的是常闭 resulting in insufficient fuel supply.
WP4.6N以上的是常开
12
总体结构Structure 输油泵 Low pump 计量单元Metering Unit 溢流阀Overflow valve
油品质量较差会导致溢流阀卡滞，导致卸油不畅或供油不足。
Poor quality fuel will block the fuel passage or piston, resulting in
insufficient fuel supply.
13
3.2 系统结构示意图-WP6 System schematic diagram
ID≥
12mm
ID≥12mm
ID≥12mm
图中所示均为
内径值（ID） ID≥ ID≥
ID≥8mm
12mm 12mm
ID≥
4mm
燃油系统有三处回油：限压阀、
ID≥
喷油器、油泵 12mm
Fuel system has three

ID≥
backflow point: pressure limit 12mm
valve, injectors, pump.
14
高压油轨功能原理
PART 04 Common rail
15
4.1 WP6共轨管组成Common rail composition
主要参数Parameters 限压阀PLV
共轨管的功能是将其内部燃油保持在高压状态上下，因此共轨必须能够消除由高压油泵传来的压力波动和燃油喷射造成的压力
波动，这样，才能保证喷油器开启时，共轨管内的压力保持恒定。
The function of common rail is to keep the high fuel pressure stable, and eliminate the pressure fluctuation caused by high pressure pump and fuel
injection. In this way, pressure of the common rail pipe is constant when the injectors working.
正常系统压力 Normal pressure：1600bar Rail pressure sensor
限压阀开启压力PLV opening pressure：1850bar

PLV
限压阀打开限制PLV opening limit ：
累计打开次数Total opening times< 50次times

Body
累计打开时间Total opening time < 5小时hours
16
主要参数Parameters 限压阀PLV
限压阀是实现跛行功能的一个重要部件，它是机械阀，主要由阀体、 Body
O-ring
弹簧、密封活塞、O型圈等组成。
PLV(Pressure Limiting Valve) is an important part. It is a mechanical valve,

Adjust gasket
mainly includes valve body, spring, sealing piston, O ring, etc.
Spring
限压阀打开原因Cause of opening ： Sealing block Piston
1、被动打开 Passive open

回油背压过大、油量计量单元卡滞、溢流阀卡滞；
High backflow fuel pressure, metering unit blocked, overflow valve blocked
2、ECU主动打开 ECU control
轨压传感器相关故障、油量计量单元故障、供电模块故障、ECU重启故障；
Rail pressure sensor、metering unit, Power supply module failure, ECU restart failure
3、自身损坏 Damaged
17
主要参数Parameters 限压阀PLV Opening pressure
Leak pressure
Rail pressure
Pressure drop
Section Low power

increase output
High
flow
Pressure
drop Backflow fuel quantity
故障状态下，轨压升高，活塞打开，流通截面积改变，轨压迅速下降，
从而实现发动机保护。
Under failure condition, the rail pressure increases, the piston opens, the cross-
sectional area changes, and the rail pressure drops rapidly, so that to achieve
PLV关闭Close PLV打开Open engine protection.
18
共轨喷油器功能原理
PART 05 Injector
19
5.1 外形结构 Outline structure
喷油器的主要功能是按照发动机ECU喷射需求，定
时定量的喷射柴油，可实现预喷、主喷和后喷。
The injector will follow the injection timing and quantity

command from ECU, it can realize pre, main and post
injection.
① 高压连接High pressure connection

② 电器接插件Electrical connector
③ 回油连接Backflow connection
④ 气缸盖接头Interface to cylinder head, guides
⑤ 燃烧室连接面Interface to combustion chamber
类型Type 高压连接high pressure 回油backflow ⑥ 螺旋关节Screw joints
1 内进Internal 内回Internal ⑦ 低压密封Low pressure seal
2 外进External 外回External ⑧ 燃烧室连接面Interface to combustion chamber
3 外进External 外回External ⑨ 油嘴紧帽Fixation by clamp
4 外进External 内回Internal
20
5.2 内部结构 Internal structure
Control room 如果燃油品质较差，含水或颗粒会导致喷油器内部

Valve rod 结构腐蚀或磨损，丧失正常工作能力，此时发动机
Solenoid valve 工作粗暴，动力不足，且加油时有黑烟冒出。

If the fuel quality is poor, water or particles will lead to
Backflow connection armature
the internal structure of the injector corrosion or wear,
High pressure connection
then the engine will work rough, with insufficient power
or black smoke.
Needle valve
• 线圈电阻Coil resistance: 0.23Ω 禁止人为给喷油器加电，导致电磁阀的电磁线圈熔
• 最小工作压力Minimum operation pressure: 250bar 化，喷油器失效。

It is forbidden to add power to the injector artificially,
• 最大工作压力Maximum operation pressure: 1600bar
which will cause the electromagnetic coil of the solenoid
• 回油压力Backflow pressure: 0~1bar
valve melt and injector failure.
21
5.3 工作原理 Working principle
Nozzle position Nozzle open Nozzle close

Backflow
Coil
Armature
Ball valve
Release control
Supply control
Needle stem
HP pipe
Needle press. ring
Nozzle
High Pressure Low Pressure
关闭（无喷射）=>打开（开始喷射）=> 全开（喷射） => 关闭（喷射量减少） =>完全关闭（停止喷射）

Close(No injection) =>Opening(Start injecting)=> Full open(Injecting)=> Closing(Injection reduction) =>Close(Stop injecting)
22
高压共轨系统传感器
PART 06 Sensor
23
6.1 曲轴传感器 Crankshaft Sensor
外形结构Structure 工作原理Principle 连接方式Connection 检测方法Detection
曲轴传感器是一种磁电式传感器，件号不同，都安装在飞轮壳上，用于喷油时刻和喷油量计算、转速计算。
Crankshaft sensor is a kind of magneto electric sensor which installed on the flywheel housing, for injection timing and injection quantity
calculation, speed calculation.
电接头
Electric plug
安装螺栓孔
Mounting hole
O型圈
O-ring
内部感应线圈
Induction coil
24
曲轴传感器为一磁感应传感器，磁场的强度受触发轮与传感器间磁隙影响。曲轴传感
器与触发轮的布局如左图。
L为DG与触发轮之间的距离，为0.3mm~1.8mm。触发轮由58(60-2)个齿组成，每个
齿产生一个电脉冲，当曲轴转动时，发动机转速必须>50转，才能产生信号，信号由
曲轴传感器输出至ECU进行处理。
The crankshaft sensor is a magnetic induction sensor. The intensity of magnetic field is affected by
the gap between the trigger wheel and the sensor.
The layout of crankshaft sensor and trigger wheel is shown on the left.
L is the distance between DG and trigger wheel, which is 0.3mm~1.8mm.
The trigger wheel is composed of 58(60-2) teeth, each tooth generates an electrical pulse. When
the crankshaft rotates, the engine speed must be >50 to generate a signal, which is output by the
crankshaft sensor to the ECU for processing.
25
WP6发动机，WISE15控制器的曲轴传感器接线。
Crankshaft sensor wiring diagram of WP6 engine with WISE15 ECU.
26
 万用表测电阻：断开所有线束连接，测传感器两针脚间电阻，线圈电阻在20℃时860±86Ω
Measure resistance by multimeter: Disconnect all related connections, check if the coil resistance of 2 pins is about 860±86Ω at 20℃.
 万用表测量针脚开路电压：两个针脚都是2.5V.
Unplug the connector, measure the voltage of the pins on harness: 2.5V for both pins.
 示波器测电压波形：让发动机运行，转速须>=50rpm，用示波器测量两针脚输出波形。无论传感器是否连接线束，测量
波形都应如下图
Measure voltage waveform by oscilloscope : Keep the engine speed>=50 rpm, measure the output waveform of the pins by oscilloscope.
No matter whether the sensor is connected, the measured waveform should be as shown below
曲轴传感器正弦信号
Crank shaft sensor sinusoidal signal
27
6.2 凸轮轴转速传感器Camshaft Speed Sensor
详情参考前述曲轴传感器。
Refer to the crankshaft sensor for details.
28
6.3 轨压传感器 Rail Pressure Sensor
轨压传感器安装在油轨的一端或高压油泵上，主要是测量共轨压传感器接头损坏或内部电路板腐蚀，造成轨压信号异常
轨管中的燃油压力，最高共轨压力可达2150bar，能保证油，此时限压阀打开，发动机工作于跛行模式。
压控制稳定，属于闭环控制。 If the rail pressure sensor joint is damaged or the internal circuit board
Rail pressure sensor is mounted at one side of the common rail or high is corroded, the rail pressure signal will abnormal. In this case, the
pressure pump to measure the fuel pressure, it can ensure the stability pressure limit valve will open.
of the fuel pressure due to closed-loop control.
电插头
Electric plug
O型圈
O-ring
压力感应元件
Sensitive element
29
Signal range check
传感器元件测量轨中瞬间的燃油压力，把燃油压力转化为电
压。当轨压为0时，传感器输出电压为0.5V,当达到最大轨压
时，传感器输出4.5V。
Voltage The sensor measures the real-time fuel pressure in the rail and converts
into voltage. When the rail pressure is 0, the sensor output voltage is
0.5V. When the maximum rail pressure has reached max, the sensor
outputs 4.5V.
Signal range check

Pressure
电压值与压力值关系图
Voltage-Pressure relation chart
30
如图所示是轨压传感器的电路连接图
The connection of rail pressure sensor as shown below
针脚1接ECU X2-55针脚，接地；
Pin 1# is connected to ECU X2-55, grounded
针脚2接ECU X2-66针脚，作为信号输出；
Pin 2# is connected to ECU X2-66, signal output
针脚3接ECU X2-52针脚，5V供电
Pin 3# is connected to ECU X2-52, 5V power supply
31
1. T15上电，测量传感器信号线输出电压在轨压为0时是否为0.5V.
T15 power on, break the harness and measure if the output voltage of signal pin(2#) is 0.5V when the rail pressure is 0.
2. T15上电，用智多星监控轨压传感器电压是否为0.5V。
T15 power on, use DiagSmart to monitor if rail pressure sensor voltage is 0.5V.
传感器针脚1 - 连接地线
Pin 1#-Grounded
传感器针脚3 – 连接5V电
Pin 3#-5V power supply
传感器针脚2 – 用万用表检测输出电压是否为0.5V?
Pin 2#-Check if the output voltage is 0.5V by multimeter
32
6.4 水温传感器 Coolant Temperature Sensor
冷却液温度传感器测量冷却水温度，用于冷起动、目标怠速计算等，同时还用于修正喷油提前角、最大功率保护等。安
装在发动机的出水口上，其外形结构如图。
Coolant temperature sensor measures the coolant temperature for cold start, target idle speed calculation, etc. It is also used to correct the
injection advance angle, maximum power protection, etc. Installed on the water outlet of the engine.
感应元件
Sensitive element 怠速调整Idle adjustment
安装垫片当水温较低时候，会快速热车，发动机怠速会适当
Mounting gasket 提高。 When the water temperature is low, the
engine idle speed will increase appropriately to
warm up.
零件号
Part No.
过热保护Overheating protection
当ECU检测到温度超过标定限值，会减少发动机的
喷油量，防止过热。
线束连接头 When the ECU detects coolant temperature over
Connector set point, it will reduce the engine fuel injection
quantity, to prevent overheating.
33
冷却液传感器一般使用负阻系数的温度电阻（NTC），当外部温
度变化时，传感器的电阻值R随之发生变化，输入ECU内部的电压也
就不同，在ECU内部经过处理，得到正确的温度值。
Coolant temperature sensor is a negative temperature coefficient

resistor (NTC), when the external temperature changes, the
resistance of the sensor changes accordingly, so the voltage input
to ECU is different. After ECU internal processing, output the
correct temperature value.
34
如图所示是水温传感器的线路连接图：
Coolant temperature sensor wiring diagram as shown
below：
针脚1接ECU X2-27，接输出信号；
Pin 1# is connected to ECU X2-27, output signal
针脚2接ECU X2-33，接地。
水温传感器的安装扭矩为19.5~20 Nm
The mounting torque of the sensor is 19.5~20Nm.
35
电阻测量法：
在断开接线的前提下，测量传感器在不同温度（可参考给出的几个温度点）下的电阻值，
正常阻值与温度的具体值可参考表格。在检测相应温度下的电阻值时要把传感器六角环以下部
位全部放置到液体中，每次测量前应在液体中放置10分钟以上。
Resistance detection:
Disconnect the wiring, measure the resistance of sensor at different temperatures (can refer to the table below).
When detecting, place all parts of the sensor below the hexagonal ring into the liquid for more than 10 minutes
for each measurement.
件号*数量（Part No.*Qty）：612630060035*1
温度-电阻输出关系Temperature-resistance output
温度Temp.℃ 20 100
电阻Resistance(Ω) 2500 186
36
6.5 进气压力温度传感器 Air Intake PRESS-TEMP Sensor
进气压力温度传感器一般安装于增压器之后上，用于监测进气压力和进气温度，调节发动机喷油量和实现进气加热控制的功能。
Air intake press-temp sensor is generally mounted after turbocharger. It is used to detect intake air pressure and temperature, adjust fuel
injection quantity and control the intake air heating.
调整发动机喷油量Adjust engine fuel injection

产品标签
Product label
烟度限制：当检测到进气量过少时候，ECU会控制喷油器的喷油量，
防止排放超标。
安装螺栓 Smoke limit: when too little air is detected, the ECU will control the
fuel injection quantity to prevent excessive emission.
Mounting bolt
过热保护：当检测到进气温度超过标定限值时，会控制发动机喷油量
，防止过热。
线束连接头
Overheating protection: when the inlet temperature is detected more
Connector
than set point, ECU will control the engine fuel injection quantity to
prevent overheating.
O型圈
O-ring
进气加热控制Intake heating control
感应元件
Sensitive element 当ECU检测到温度低于标定限值，ECU控制进气加热继电器工作。
When the ECU detects temperature is less than set point, ECU will
control the intake air heating relay to work.
37
进气压力传感器由位于膜片表面的压敏电阻及硅膜片组成，当压力作用于压敏电阻上时电阻改变，再经过已设计的
电路，使最后传感器输出不同的电压。ECU再经过预设程序把收到的传感器电压转换成相应压力。
Intake air pressure sensor consists of a varistor located on the diaphragm surface and a silicon diaphragm. When the pressure apply on the
varistor, the resistance changes, the sensor outputs different voltages through designed circuit. The ECU converts the received voltage to the
corresponding pressure.
压力大小与电压
输出为线性关系进气温度传感器原理类似于水温传感器。
Voltage-Pressure Intake air temperature sensor principle is similar to
relation chart
coolant temperature sensor.
Absolute Pressure(KPa)
38
如图所示是进气压力温度传感器的线路连接图
Air intake press-temp sensor wiring diagram as shown below
针脚1接ECU X2-34，接地
针脚2接ECU X2-26，接NTC热敏电阻
Pin 2# is connected to ECU X2-26, NTC
针脚3 接ECU X2-64， +5V供电
针脚4 接ECU X2-68，为压力信号输出
Pin 4# is connected to ECU X2-68, pressure output
39
WP6 件号*数量（Part No.*Qty）：612630120004*1

Resistance value（Ω）
温度-电阻输出关系Temperature-resistance output
温度Temp.℃ 20 80
电阻Resistance(Ω) 2500 322

Temperature（℃）
压力-电压输出关系Temperature-resistance output
绝对输入压力Kpa
50 400
Absolute input pressure
输出电压
0.5 4.5
Output voltage(VDC)
40
6.6 机油压力温度传感器 Oil PRESS-TEMP Sensor
传感器通过压力测量芯片，将压力信号转化为电压信号，传
至控制单元ECU。
Through the pressure measuring chip, the sensor converts the pressure
signal into the voltage signal and transmits it to the control unit ECU.
41
如图所示是机油压力温度传感器的线路连接图
Oil press-temp sensor wiring diagram as shown below
针脚1接ECU X2-47，接地
针脚2接ECU X2-25，接NTC热敏电阻
Pin 2# is connected to ECU X2-25, NTC
针脚3 接ECU X2-63， +5V供电
针脚4 接ECU X2-67，为压力信号输出
Pin 4# is connected to ECU X2-67, pressure output
42
WP6
件号*数量（Part No.*Qty）
612600090460*1
压力-电压输出关系Pressure-voltage output
绝对输入压力Input pressure(Kpa) 100 500 1000
输出电压Output voltage(VDC) 0.71 2.395 4.5
43
44

Principle and Application of WEICHAI Electrical High Common Rail System

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Principle and Application of WEICHAI Electrical High Common Rail System

Uploaded by

Copyright:

Available Formats

潍柴电控高压共轨系统原理及应用

Principle and Application of WEICHAI Electrical High Common Rail System

高压油出口 两缸高压油泵CPN2.2 可提供最大压力1750bar，实际

Two-cylinder high pressure oil pump cpn5-22/2 provides a

Fuel compress process:

最大工作量电流: 0A Maximum delivery current: zero

工作电压 Working voltage 8~32V

线圈电阻 Coil resistance @20℃ 2.6~3.15Ω

工作电流范围 Working current 0.5~1.8A

开路电压 Open circuit voltage 3.5V/24V

Fuel system has three

正常系统压力 Normal pressure：1600bar Rail pressure sensor

限压阀开启压力PLV opening pressure：1850bar

累计打开次数Total opening times< 50次times

PLV(Pressure Limiting Valve) is an important part. It is a mechanical valve,

限压阀打开原因Cause of opening ： Sealing block Piston

1、被动打开 Passive open

Section Low power

The injector will follow the injection timing and quantity

① 高压连接High pressure connection

3 外进External 外回External ⑨ 油嘴紧帽Fixation by clamp

Control room 如果燃油品质较差，含水或颗粒会导致喷油器内部

Solenoid valve 工作粗暴，动力不足，且加油时有黑烟冒出。

• 线圈电阻Coil resistance: 0.23Ω 禁止人为给喷油器加电，导致电磁阀的电磁线圈熔

• 最小工作压力Minimum operation pressure: 250bar 化，喷油器失效。

Nozzle position Nozzle open Nozzle close

Needle press. ring

High Pressure Low Pressure

关闭（无喷射）=>打开（开始喷射）=> 全开（喷射） => 关闭（喷射量减少） =>完全关闭（停止喷射）

of the fuel pressure due to closed-loop control.

Signal range check

Signal range check

Coolant temperature sensor is a negative temperature coefficient

件号*数量（Part No.*Qty） ：612630060035*1

电阻Resistance(Ω) 2500 186

调整发动机喷油量Adjust engine fuel injection

WP6 件号*数量（Part No.*Qty） ：612630120004*1

电阻Resistance(Ω) 2500 322

绝对输入压力Input pressure(Kpa) 100 500 1000

输出电压Output voltage(VDC) 0.71 2.395 4.5

You might also like

高压油出口两缸高压油泵CPN2.2 可提供最大压力1750bar，实际

件号数量（Part No.Qty）：612630060035*1

WP6 件号数量（Part No.Qty）：612630120004*1