At the 26th Aachen Colloquium, Liebherr demonstrates its state-of-the-art technology in the area of fuel injection systems on the example of an in-house developed common rail system (CRS) 11.2 with a Liebherr-own diagnostics tool LiDIA from 9th to 11th October 2017.
With a maximal power output of 145 kW per cylinder, the evolved common rail system 11.2 offers an attractive alternative for engines with a displacement of up to three litres per cylinder. These are implemented in both medium- and heavy-duty ranges as well as in the field of industrial engines. The product range is supplemented by the CRS 11.5, a system for engines of up to six litres capacity per cylinder with a power output of up to 250 kW per cylinder. The 11.2 common rail system developed by Liebherr has now been in series production for more than four years, the CRS 11.5 for one year. The new 2,500 bar version is now under implementation.
The innovative common rail systems comply with the current and future emission standards for diesel engines, enabling high performance with the lowest possible fuel consumption. With precise multiple injections at pressures of up to 2,200 bar, constant performance and low emission values are guaranteed throughout the engine's service life.
The hydraulic components of both systems are designed for long service life of up to 25,000 hours and for working under harshest working conditions thanks to specific technical features like, for example, an oil-lubricated pumping mechanism.
In 2016, Liebherr opened a new production facility in Deggendorf (Germany). The main purpose thereby was to ensure a state-of-the-art production process for high-precision components, for example needle/ nozzle or complete injectors. The latter are developed for demanding applications in both off-road and heavy-duty on-road conditions and are used, for example, in mining, building construction and civil engineering, agricultural engineering or maritime environments. For such kinds of applications, robustness against aggressive fuels, high efficiency with a minimum fuel consumption as well as accuracy and stability of the injection volumes are of vital importance. High efficiency and accuracy are particularly guaranteed by the leakage-free design, which allows a minimal pressure loss between the pump and the nozzle tip. This, in turn, results in stable multiple injections with high precision of the pilot injection quantities.
For optimal integration in the widest variety of engines and applications, different types of housing geometries and nozzle variants are possible. Supreme flexibility for individual customer-specific adaptation and maximum quality is achieved through the in-house manufacturing of the nozzles, control valves and other function-relevant micro-precision parts.
Both common rail systems 11.2 and 11.5 are perfectly supplemented by Liebherr engine control units as well as a LiDIA diagnostics tool, which offers a rapid overview of the status of all systems, requires no configuration and reduces the complexity of diagnostic precedures to the bare essentials. The control units unite all control functions, including exhaust gas aftertreatment, in a single unit and are suitable for the toughest of environmental conditions as verified by ISO 15998, ISO 13849 and ISO 61508 SIL2.