IQA - Injector Quantity Adjustment

! Why IQA?
! What does IQA do?
! Operating principles
! IQA Adjustment Map
! EOL programming
! IQA accuracy
! Perspective
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 1
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Why IQA?
0,12

Euro 2
0,10

Euro 2 - Application
0,08
Particle [g/km]

+/- 1 mm³/Str
0,06 Euro 4 - Application
Euro 3

0,04
Euro 4
+ 0,5 mm³/Str (PI)
0,02
+/- 1 mm³/Str (MI)
- 0,5 mm³/Str (PI)
0,00
0 0,2 0,4 0,6 0,8 1,0 1,2
NOx + HC [g/km]

•The actual fuel quantity must be as exact as possible to reach the

emission limit values
•High technical effort to reduce the production line tolerances
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 2
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Advantage of IQA is
! To reach the emission limit values of the future
! Equal injection fuel quantity for each cylinder
! To increase the injector first pass yield (FPY) by widening the
production tolerances

What is IQA not able to do?

! Correction of the PI within the „plateau“ (i.e. CRI2)
! Correction of the start of the injection
! Correction of the drift of the injector (no closed-loop control)

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 3
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Operating principle IQA

Characteristics
! Correction of the fuel quantity of new injectors
! Individual correction of tolerances at each point in the
characteristic map for each cylinder (injector)
! Influence on the fuel quantity by px

adjusting the energizing time (ET) MV characteristic

desired fuel quantity

inj.tolerance for
correction
p2
actual fuel
Q (mm³)

quantity of inj. p1

ET (µs)
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 4
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

The energizing time map in the ECU

characterises the behaviour of mean
value injectors in the engine. P = const.
Quantity
[mm³] QCRI(ET) QMV(ET)

Test Point
QTP
∆QIMA = QMV - QTP Precondition:
QMV
∆QIMA dQCRI dQMV
=
d ET d ET
∆ET

ETIQA ETTP ET [µs]

DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 5
copying and passing on to third parties.
 IQA - Determination of the adjustment map

! Definition of the 4 inspection points ID, PI, EP, FL in agreement with the
customer and the injector development
! Definition of a control duration map from the average of a batch of 25 injectors

- Additional pressure lines may be required

! Definition of the additional measuring points for the available quantity values
80
Example 1600 bar 1200 bar

70
Inspection Points
Additional Points FL 800 bar
Fuel Quantity [mm³/stroke]

60

50

400 bar
40

30
250 bar

20 EP
10 ID
PI
0
0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5
DS/P-IMA (EAC) 382 9973d_Wh IQA training ET [ms]
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 6
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

! Selection of the most suitable matching points between inspection points and additional points

80 PP VL 1600bar/900µs - 250bar/1280µs
1600 bar 1200 bar
Inspection Points y = 0,4248x
R2 = 0,1663
2
70 1,5
Additional Points 1
FL 800 bar

250bar / 1280µs
60 PP LL 250bar/810µs _ 250bar/1280µs 0,5
Fuel Quantity [mm³/str.]

3,00
0
y = 1,9841x -2 -1,5 -1 -0,5
-0,5
0 0,5 1 1,5 2
50 2,00
R2 = 0,9576
-1
1,00
250 bar/1280 µs

40
-1,5 400 bar
0,00 -2
-3,00 -2,00 -1,00 0,00 1,00 2,00 3,00 PP VL
30 -1,00
250 bar

20
-2,00
EP
-3,00
PP LL ID
ID
10
PI
Chosen
0 inspection point ID
0,1 quantity
•Fuel 0,2 0,3 tolerance
0,4 0,5 at0,6 0,7
additional0,8measuring
0,9 1 point
1,1 1.98
1,2 * 1,3 1,4 1,5
correction
value ID ET [ms]
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 7
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Operating principle IQA Adjustment Map

IQA Adjustment Map

0 250 400 800 1600 Rail Pressure [bar]

0 0 0 0 0 0
Fuel Quantity [mm3]

PI 0 0,42*∆ID 0,42*∆ID 0 0
ID 0 ∆ID 0,83*∆ID 0,45*∆EP 0,9*∆EP
EP 0 1,98 *∆ID 1,65 *∆ID ∆EP 1,3 *∆EP
PL 0 1,98*∆ID 1,65*∆ID 0,84*∆EP 1,2*∆EP

FL 0 1,98*∆ID 1,65*∆ID 0,4*∆FL ∆FL

Weighting Factors Inspection Points

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 8
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Operating principle in ECU

Dynamic Interrupt
∆q
q_desired
+
p_Rail Calculation of ET
90 1600 bar
85
80
75
70
65
60 800 bar
Flash PROM t ET
55
50 600 bar
45
40

InjVlv_stQntAdj_Map 35
30
25 250 bar
20
15
Mengenwert der Prüfpunkte [mm3]

10
0 250 400 800 1600 Raildruck [bar] 5
0
0 0 0 0 0 0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5
PI 0 0,42*∆ID 0,42*∆ID 0 0
ID 0 ∆ID 0,83*∆ID 0,45*∆EP 0,9*∆EP
EP
x*FL
0 1,99*∆ID
1,99*∆ID
1,65*∆ID
1,65*∆ID
∆EP
0,84*∆EP
1,3*∆EP Control duration map
0 1,2*∆EP
FL 0 1,99*∆ID 1,65*∆ID 0,4*∆FL ∆FL

shared for one type of *

injector

E²PROM
Correction Value
∆ EP / ∆ID / ∆FL / ∆ PI /QS
individual for each injector

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 9
copying and passing on to third parties.
 IQA - Operating Principle

Quantity energizing time map - without IQA

64
1600
62 1200
60
58 FL
VL
56
54 +- 2,1 mm³
800
52
50
48
46
44
42
40
Quantity [mm³]

38
36
34
32
400
30
28
26
24
22
20
18 EP
EM
16
14 +- 3,0 mm³ 250
12
10
8
6
LLID
4
2 +- 1,0 mm³
0

ET [µs]
Ansteuerdauer [µs]
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 10
copying and passing on to third parties.
 IQA - Operating Principle

Quantity energizing time map - with IQA

64 1600
62 1200
60
58
56 VL
FL
54
52
+- 1,1 mm³ 800
50
48
46
44
42
40
Quantity [mm³]

38
36
34
32
30 400
28
26
24
22
20
18 EP
EM
16
14
+- 1,25 mm³
12 250
10
8
6
4
ID
LL
2 +- 0,5 mm³
0

ET [µs]
Ansteuerdauer [µs]
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 11
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Influences on IQA accuracy

! accuracy of measuring process
" reproducibility of measurement (RM)

" accuracy of measuring device

" stability of injector:

i.e. sensitivity to backflow config., temperature,

test sequence, clamping ...
" differences between test stations within one production

line and between different production lines (DTS)

! accuracy of injector
" quantity stability over lifetime

" slope variation in the Quantity-ET map (DQ

CRI ≠ DQMV) (SV)
" maximum required correction value (RCV
max)
! compatibility of the production quantity deviation to the
engine quantity deviation
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 12
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Implemented process for EOL-Programming

IQA - Coding
Labeling of injectors with alpha-
numeric and Data-Matrix-Code

Mounting of injectors and

reading of the IQA Code

Transmission of IQA Code into

ECU

Reduction of emission dispersion Bosch

in the engine
Customer Code - Input

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 13
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Perspective
! IQA will be introduced in passenger cars in all future projects

! The inspection points will be determinated by IQA (requirement for

high correlation to additional points)

! Further optimisation of the IQA algorithm

" correction of the slope variation

" multi linear IQA coding

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 14
copying and passing on to third parties.
 IQA - Injector Quantity Adjustment

Summary
! The IQA functionality is assigned to correct the injector quantity of
each injector of a Common-Rail-System individually and across the
complete range of the Q(ET) - map.

! The input of the function are the ECU correction values. They
represent the difference to the nominal values of the respective test
point and will be encoded and labeled on top of each injector.

! At the end of the automobile manufactur line, the ECU adjustment

values of the mounted injectors and the allocated cylinders are
programmed into the ECU.

DS/P-IMA (EAC) 382 9973d_Wh IQA training

© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as 15
copying and passing on to third parties.
 IQA - Flow Chart for an application

Flow Chart for IMA applications

Presentation IMA Handling Service, EOL programming and after market
First application with IMA for this customer
D: 1 day; R:DS/VXY, DS/P-IMA; 1 1/2 year before customer SOP
(Responsibility in Europe, to be defined at RBAJ)
EMI reference map of CRI in digital Preparation
form to DS/EAC, DS/P-IMA
R:DS/EIM, DS/EIP
Determination of IMA addtional measuring
points for the IMA adjustment map
R:DS/P-IMA, DS/EAC2

Information about the relevant

working range of the engine
Determination of check
to DS/P-IMA and DS/EAC2
sequence with addtional
R:DS/Vxy
measuring points
R:DS/ECR-Ba
Measurement of CRIs
R:DS/ECR-Ba
Calibration of map
Measurement data to
Selection of 100 CRIs to Measurement data to
DS/P-IMA
measure the quantity at the DS/P-IMA D: 1 w.;
R:DS/EIM, DS/EIP
additional points R:DS/ECR-Ba
R:DS/P-IMA, DS/EAC2 Validation
C- & D-sample lot
EMI curves of 5 nominal injector with high Calculation of the IMA
R:BaW,HoW,RBTR
pressure config. of customer adjustement map Check of the IMA
R: DS/EAC4 R:DS/EAC2, DS/P-IMA adjustement map with 25
Determination of extrem CRIs
average value R:DS/EAC4, DS/EAC2
R:DS/EIM, DS/EIP

Determination of Comparison ET map

Delivery of nominal injector to customer with EMI reference map Engine test with injector set
ET map
R:DS/Vxy, DS/EIM, DS/EIP R:EAC2, DS/P-IMA R:customer, DS/EAC2,
R:customer
DS/Vxy
Customer
DS/P-IMA (EAC) 382 9973d_Wh IQA training
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as Time 16
copying and passing on to third parties.