TECHNICAL UNIVERSITY OF THE NORTH

FACULTY OF ENGINEERING IN APPLIED SCIENCES

AUTOMOTIVE MAINTENANCE ENGINEERING DEGREE

Members:

Ayala Cristian
Caiza Jhonatan
Enríquez Byron
Lema Edison

Instructor: Eng. Carlos Mafla MSc.

UPS INJECTION SYSTEM

Unit Pump System

Ibarra, 2018
OBJECTIVES.

General Objective.

Research and detail everything related to UPS (Unit Pump) injection systems.
System).

Specific objectives.

Describe the operation of a UPS injection system

To know the different technological advancements that the UPS system has had
relationship with diesel injection systems

Demonstrate the fields of application within the trademarks of the

tractor-trailers that use the UPS diesel injection system, BOSCH.

Determine the uses encompassed by an UPS injection system.

 1. OPERATION

The Diesel Engine

It is a self-igniting engine that only draws in air, subjecting it to high compression.

It is a combustion engine machine with the highest degree of efficiency. The performance
Reliable and economical diesel engines require injection systems that function
with high precision. With those systems, the fuel is injected into the cylinders of
motor under high pressure and at the right moment for the power to be achieved
(Bosch, Modern Diesel Injection Systems Complete Units and Their Breakdown,
2015, p. 3.

History
All BOSCH Injection Systems

Figure 1: Bosch injection systems.

Source: (Bosch, Modern Diesel Injection Systems Complete Units and Their Breakdown,
2015).
 Timeline

Figure 2: Timeline in Bosch innovation.

Source: (Bosch, Modern Diesel Injection Systems Complete Units and Their Breakdown,
2015.

Unit Pump System

Unit Pump System (UPS)
Description of Operation

The UPS is a robust system, different from conventional systems, as it contains

one pump for each cylinder of the engine. Each pump, injection pipe and injector
they are connected in a modular structure. The system is capable of analyzing with the
same precision and at the same time the conditions of the engine and the environment to provide
a perfect injection process. The drive shaft operates the pump, which is connected to the
injector through a short pressure conduit. How injectors are used
very small mechanics. The system is ideal for cylinders with a reduced diameter and
also for central injection technology with four valves. Each pump has
an electromagnetic valve that is controlled by the system's control unit, which
determine the amount and injection time - precisely calculated for each
rotation and load conditions, ensuring the best functioning of the engine (Bosch,
Modern Diesel Injection Systems Complete Units and Their Breakdown, 2015, p.
17).

Mechanical Operation Diagram

Figure 3: Schematic of parts of a UPS system.

Source: (Bosch, Modern Diesel Injection Systems Complete Units and Their Disassembly,
2015.

Components of the UPS pump system

Fuel supply system

Electronic regulation control
Sensors
Actuators

Description of services and products

Note: Staggered injector holder set.

 General operating scheme EDC

Figure 4: Bosch injection systems.

Source: (Virtual Mechanics, 2005, p. 31).

UPS systems are elements that control the injection time through a
solenoid valves that are integrated. The moment of activation of the solenoid valve,
determines the start of the injection as well as the time it is activated
solenoid valve, determines the injection flow. The moment and the duration of the
activation is determined by the electronic control unit according to the
characteristic fields that it has programmed in its memory and taking into account the
current service status of the engine through the different sensors

Figure 5: Bosch injection systems.

Source: (Virtual Mechanics, 2005).

Structure
The extremely short high-pressure pipes (6), of equal length for all the
pumps must permanently withstand the maximum pressure of the pump and the
pressure oscillations, partially high frequency, that occur during pauses
injection. For this reason, the pipes are made of seamless steel tubes, highly
resistant. They usually have an outer diameter of 6 mm and an inner diameter
of 1.8 mm.

Pump unit

The pump is directly driven by an injection cam located on the shaft.

motor leads (4). Communication with the pump piston is established through the
replacement spool (8) and the roller impeller (9). The pump is fixed with a flange
of the pump body in the engine block.

Figure 6: Operating sequence of Bosch injection systems.

Source: (Bosch, 2004).
The following table shows the utilization of injectors and injector holders according to the system.
injection used.

Figure 7: Injector table according to the injection system.

Source: (Virtual Mechanics, 2005).

Stepped injector port

It is especially in 4-valve engines for industrial vehicles, where

Due to space reasons, the assembly of the combination of holders is required to be in a vertical position.

injectors and injectors, in which stepped combinations are applied.

The structure and operation match the standard injector holder: The
the essential difference lies in the mode of connection of the pipe
combustible: while this is centrally screwed at the rear end of the
standard injector holder, in the stepped injector holder, it is joined to the body of
support through a pressure tab. With this arrangement it is possible
generally carry out very short injection pipe lengths,
which has a positive influence on the injection pressure level, due to its reduced nature
of dead volume.
 Characteristics of the Control Unit
The control unit takes into account

The crankshaft angle.

The number of revolutions of the camshaft.
The position of the accelerator pedal.
The boost pressure.
The temperature of the intake air, the coolant, and the fuel.
Walking speed.

Parameters and values of diesel injection systems.

Figure 8: Operating Parameters.

Source: (Bosch, 2004, p. 2).

Advantages over other systems

It is used in both tourism and in light commercial and industrial vehicles.

from up to 30 kW/cylinder and heavy industrial vehicles of up to 80
kW/cylinder. This system is also used in engines in locomotives and
boats.

High injection pressure up to 2050 bar.

Beginning of variable injection.

The possibility of a prior injection and in some cases a posterior injection.

It allows for greater flexibility in adapting to operations.

changeable motor, better than linear and rotary pumps.

EDC ensures the proper functioning of the engine with maximum performance.
minimal consumption, fewer harmful emissions, and silent operation

Main system failures

Failure: loss of injector strength

Solution: clean injectors

Failure: low fuel supply to the combustion chamber

Solution: check the electricity coming to the solenoid

Failure: low pressure in the feed pump

Solution: clean the fuel tank

Fault: black smoke in the exhaust

Solution: check the injectors and make the respective change upon detection.
the failure of any of them
 2. NEW DIESEL TECHNOLOGIES

The constant evolution of motor vehicles demands manufacturers to adapt.

increasingly divides the search for innovations and improvements in the systems and
diesel components, the automotive market is becoming more demanding every day regarding the
vehicle safety, to excellent performance, to comfort, to economy and to
caution with the environment, the new electronic diesel injection systems
they were developed for the new needs, always seeking lower emissions
of pollutant gases with greater fuel economy (Bosch, 2012).

The evolution of direct injection diesel engines has gone hand in hand with
development of injection systems that are increasingly precise and with injection pressures
increasingly higher.

The Unit Injector System UIS injection systems (also known as pump-unit)
injector, PDE), and Unit Pump System UPS (also called pump-pipe-injector,
(PLD), allow for achieving the highest injection pressures; the UPS system was a
innovation in diesel systems, we have a pump for each cylinder of the engine
of high pressure directly connected to the tool holder of the respective cylinder (Bosch,
Diesel injection systems, 2005.

This pump is operated by the engine's drive shaft, compressing the fuel.
through electronic actuation, the control unit operates the valve
electromagnetic that allows the passage of fuel under high pressure to the injector, the
the electronic command is precisely calculated for each condition of revolution and
loads ensuring the best operation of the engine

The following advancement obtained in injection systems was the UIS (unit system)
injector), where it integrates the high-pressure pump and the nozzle into a single compact unit.
and the nozzle in a single compact unit for each engine cylinder, the UIS system
replace the nozzle holder assembly of the conventional systems dispensing the use of
the high-pressure pipes, which allows for achieving higher pressure values (Bosch,
Diesel injection systems, 2005.

Each injector unit is installed in the engine head and performs the injection of
fuel directly in each cylinder, the fuel injection is controlled by
through a quick-action electromagnetic valve, which is in turn controlled by
the electronic control unit, which determines the best moment and the volume
suitable fuel that will be injected for each operating condition
of the engine, according to the information obtained through the various sensors
installed in the engine, providing efficient and safe operation

the unit injector (UI) systems and unit pump (UP), each cylinder of the engine
receive a pumping element of injection or an injection pump separately nearby
from the cylinder. Unit pump (UP) systems allow for short fuel lines
of high pressure placing the pump near the injector, the combination of the element of
pumping and the injector in a single assembly as in unit injector (UI) systems,
allows these lines to be completely removed Invalid source specified.

The elimination or reduction of the length of high-pressure fuel lines in the

UI / UP injection systems result in two benefits:

Reduction of line dynamics problems: the difficulties of dynamics

from the line in unit injectors / unit pump systems are fewer
problematic compared to their counterparts inpump-line-nozzle(PLN). The
possibility of wave superposition - which disturbed the PLN systems causing
post-injections and contributed to delays in the injection - is reduced
enormously. However, it should be mentioned that the dynamics problems of
lines generated within the narrow steps of the unit injectors can
modular the injection speed even more.

Higher injection pressure: the UI system has traditionally had the

highest injection pressure capacity among all types of system
injection. In the early 2000s, UI systems had
pressure capabilities of 200 MPa, compared to the 160 MPa of the
common rail systems. Since then, the maximum injection pressures of
UI / UP system has increased to 250 MPa in some applications of the year
model 2007.
Regarding fuel pressure, it should be noted thatthepressures of
fuel injection systemcommon rail alsohave increased and in some
systems have reached or exceeded the available pressures of the UI / UP systems. If
Well, there is no technical reason that prevents UI / UP pressures from increasing even more,
Motor manufacturers are increasingly using common rail systems in applications
traditionally dominated by UI / UP systems. For this reason, UI /
UP will likely see little evolution beyond their current maximum pressures of
approximately 250 MPa.

Both systems, UI and UP, are driven by the engine's camshaft. In a design
in a common mechanical system, fuel control was typically achieved through
the rotation of the pumping element (piston) in the same way as in the systems
PLN. With the introduction of electronics to diesel engines, systems were developed
of electronic unit injectors (EUI) and electronic unit pumps (EUP).

These use an electromagnetically operated overflow valve for control of

fuel

Possibly, the most advanced design of unit injector for light applications is
the PPD injector briefly produced by Volkswagen Mechatronic (a company
joint venture between Volkswagen and Siemens VDO) starting in 2004 for Euro applications
4 of the year 2006. This injector used a piezoelectric actuator and was capable of up to 2
pilot injections and 2 secondary injections in addition to the injection event
principal. However, it arrived at a time when common railway systems
They had already settled into lightweight applications and were gaining ground.
quickly. The PPD injector could not compete with common railway systems
and was removed shortly after its launch. Starting in 2007, it was replaced by
Common Rail for Euro 5 applications.
 3. SISTEMAS DE INYECCION UPS MARCAS

History and evolution

The commercial application of unit injectors began in the 1930s in

Winton (a subsidiary of GM) and GM diesel engines. Winton continued supplying
motors to Electro-Motive Corporation (EMC), while GM transferred production
from diesel engines to its Detroit Diesel Division, the two-stroke engine line of the
Detroit Diesel Corporation is one of the most well-known applications of technology.
unit injectors, from the 1930s to the mid-1980s,
Detroit Diesel used a mechanical unit injector design (Magdi K. Khair, 2010).

This system consists of a combination of holder nozzles connected by a line.

high-pressure cutoff with fuel injection pressures reaching 2200 bar.
It is made up of a high-pressure pump driven by direct motion of the
engine camshaft that provides a high fuel injection rate that
allows for a continuous increase in pressure throughout it. The UPS system is suitable
for commercial or heavy vehicle engines of up to 8 cylinders that can have
yields of 80 KW for each of them. It has the capacity to include a second
control unit for the injection to extend to the 16 cylinders (Bosch Worldwide,
2008).

Figure 9: Working pressures of the different injection systems.

Figure 9 shows the injection pressure curve achieved in relation to
at the engine RPM by the different injection systems. The injector system
A pump or UPS is one of the most reliable and powerful systems that achieves high pressures.
As the engine RPM increases, reaching up to 200 MPa, followed by
Common rail that when the engine reaches 2000 RPM injects with a constant pressure
of approximately 160 MPa, having an advantage over the other systems at low
revolutions.

The unit pump system (UPS) is also known by the designation type [Link].
for large-scale engines according to (Bosch, 2014), in the same way that the system
of unit injector, this system performs fuel injection through pumps
controlled by a timer, having applications in the engines below
mentioned:

Commercial engines of up to 6 cylinders (37kW per cylinder) – UPS System 12

Heavy commercial engines of up to 8 cylinders (65Kw per cylinder) - System

UPS 20.

Heavy commercial engines of up to 18 cylinders (92 kW per cylinder) - System

SP with plug-in pump or Steckpumpe.

Commercial engines of up to 6 cylinders (40 kW per cylinder) – SPS system with

small plug-in pump.

Engines for agricultural and construction machinery, railways, and ships with
powers of up to 20 cylinders (500 kW per cylinder) - UPS system.

Its robust system and modular structure with very small mechanical injectors is
ideal for cylinders with reduced diameter and also for central injection technology
with four valves.
Figure 10: Brand Classification
 4. APPLICATION

This system operates according to the same procedure as the pump-injector unit. It
This is about a modular structured high-pressure injection system.
Unlike the injector-pump unit, the injector and the pump are connected by a
short injection pipe. The UPS system has an injection unit for each
engine cylinder, which is driven by the engine's camshaft.

An electronic regulation by characteristic field of the beginning of injection and of the

injection duration (or injection flow rate) provides a significant reduction in the
pollutant emissions from the diesel engine. In combination with the electro-valve of
fast switching, electronically driven, the corresponding is determined.
characteristic of each injection process in particular (Garcia, 2008).

Structure

The extremely short high-pressure pipes, of equal length for all the pumps,
they must permanently withstand the maximum pressure of the pump and the oscillations of
pressure, in part of high frequency, that occurs during the injection pauses. By
For this reason, the pipes are made of seamless steel tubes, highly resistant.
They usually have an outer diameter of 6 mm and an inner diameter of 1.8 mm.

UPS pump-pipe-injector unit for industrial vehicles and buses

Figure 11: Types of vehicles by application

Fields of application of the UPS system

Figure 12: UPS application fields.

 5. CONCLUSIONS

The system is ideal for cylinders with a reduced diameter and also for the
central injection technology with four valves.

The next generation of UIS systems will offer better performance than the
UPS systems.

Although progress has been noticeable over the years for UPS pumps and
subsequently, manufacturers prefer to use UIS systems.
Common Rail today

The reduction of electronically driven elements has allowed the use of

common rail systems, putting aside the UPS system.

This injection system was one of the most used in agricultural machinery and
ships, because it provided a greater efficiency of potential, pressure of
flammable, at the moment of performing their work, being able to vary their potential of
agreement with the number of cylinders that the engine has.

6. RECOMMENDATIONS

UPS systems are very characterized systems and there are several characteristics.
what to pay attention to when it comes to the injection system of a diesel engine, the reason

the same diesel in most injection systems is

used as a lubricant.

These systems, being mostly almost entirely electronic, need a

constant review of your currents and voltages as failures will be caused by
energy losses or lack of it.
Currently, the use of common rail systems is on the rise, which makes employing
UPS systems would increase their costs in the market.

Currently, it is recommended to use another injection system, the same one that
can help achieve greater powers to perform the same work, that
it can be more efficient than the UPS due to the reduction of elements in
system.
 7. REFERENCES

Bosch. (2004). DIESEL INJECTION SYSTEMS, BOSCH. Obtained from Mechanics

virtual
The provided input is a URL and does not contain any translatable text.
20diesel, bosch(2).pdf

Bosch. (2005). Diesel injection systems. In R. Bosch.

Bosch. (2012). Zexel diesel injection systems. In R. Bosch.

Bosch. (2014).

Bosch. (2015). Modern Diesel Injection Systems Complete Units and their
[Link], 42.

Bosch Worldwide. (2008). Bosch autoparts. Obtained from

The URL provided does not contain translatable text.
1/diesel_

Garcia, A. J. (2008). Maintenance of auxiliary systems of the diesel engine. Madrid:

Elearning.

Magdi K. Khair, H. J. (2010). Unit Injector & Unit Pump Systems. Retrieved from
DieselNet.

Virtual Mechanics. (2005). Virtual Mechanics. Retrieved from Virtual Mechanics:

No translatable text provided.