Bosch DNOx 2.

2 AdBlue Dosing System

System Description

Version 5.0

H.Hagin
Aftertreatment Systems
05.12.2011
 Supply module

Pressure compen-
sation membrane Coolant water
connector
Electrical connector
Tyco

AdBlue connector

Fixation points

Cover

Water heater

Hagin / System Description DNOx-2.2_05 2

 Supply module: View inside

Coolant AdBlue inlet AdBlue backflow

connector (tank  SM) (SM  tank)

AdBlue outlet
(SM  DM)

Reverting valve
(4/2 Way valve)

Membrane Pump
Pressure sensor

Lead frame Main filter

Hagin / System Description DNOx-2.2_05 3

 Supply module: Coolant heater

Water circuit

Cover
Plastic part

Heating plate
Aluminium part

Coolant water
connector

Hagin / System Description DNOx-2.2_05 4

 Supply module assembly

Hydr. Connectors
Coolant SAE J2044 3/8”
Adblue (Low press.) SAE J2044 3/8”
Cover Adblue (High press.) SAE J2044 5/16”

Membrane Pump
Main filter
Lead frame

Filter cover
Housing

Connectors Heating plate

Reverting valve

Water heater

Hagin / System Description DNOx-2.2_05 5

 Dosing module

Hydr. Connectors
Coolant SAE J2044 3/8”
Coolant connector
Adblue SAE J2044 5/16”

Valve keeper
Adblue connector

Electrical connector
Heat shield

Cooling adapter

Hagin / System Description DNOx-2.2_05 6

Dosing module

Hold down bracket

Coolant connector
Valve keeper

Heat shield

Dosing valve

Cooling adapter

Sealing plate

Hagin / System Description DNOx-2.2_05 7

 Dosing valve

Inj. Inj. Inj.

Operation Mode PWM controlled
ON Break Nominal pressure 9 bar
Dosing quantity Min. 36 g/h
Max. 12000 g/h.
t
EV- OVERMOLD Dosing frequency 1 – 4 Hz
T T Spray angle 23°
OFF
Time Spray holes 3
BLADE TERMINAL

TERMINAL CLIP
ADJUSTMENT SLEEVE
FILTER

O- RING
SUPPORT TUBE
COIL
O- RING
ELECTROMAGNET ARMATURE HOUSING

VALVE NEEDLE

VALVE BALL
TUBE
EXTENSION TUBE
VALVE SEAT

COVER
ORIFICE PLATE
COMPRESSION SPRING

SUPPORTING DISK SEAL RING

Hagin / System Description DNOx-2.2_05 8

 Further components of AdBlue system
 General concept and basic requirements for the following components is remaining unchanged
compared to Euro-V systems

 AdBlue tank
 Multifunctional-Tank-Unit (=´ Wema ´)
 Pipes
 Hydraulic connectors
 Sensors

Hagin / System Description DNOx-2.2_05 9

Dosing Module installation in Euro-VI muffler

Hagin / System Description DNOx-2.2_05 10

 Hydraulic layout: with heating by engine coolant

Coolant

AdBlue (low pressure)

AdBlue (high pressure)

Engine

DM
Tank heater valve
Dosing Module
Thermal insulation
(Avoid Heat-up of AdBlue in
condition <Heating Off> )

Supply Module

Condition: Heating Off

Engine coolant is used to

• Cool Dosing Module

AdBlue Tank
Hagin / System Description DNOx-2.2_05 11
 Hydraulic layout: with heating by engine coolant

Coolant

AdBlue (low pressure)

AdBlue (high pressure)

Engine

DM
Tank heater valve
Dosing Module
Thermal insulation
(Avoid Heat-up of AdBlue in
condition <Heating Off> )

Supply Module

Condition: Heating On
Engine coolant is used to
• De-freeze AdBlue tank
AdBlue pipes
Supply Module

• Cool Dosing Module

AdBlue Tank
Hagin / System Description DNOx-2.2_05 12
 Hydraulic layout: with electrical heating

Coolant

AdBlue (low pressure)

AdBlue (high pressure)

Electr. heating

Engine

DM
Tank heater valve
Dosing Module
Thermal insulation
(Avoid Heat-up of AdBlue in
condition <Heating Off> )

Supply Module

Condition: Heating On
Engine coolant is used to
• De-freeze AdBlue tank

• Cool Dosing Module

AdBlue Tank
Hagin / System Description DNOx-2.2_05 13
 Hydraulic layout: without heating

Coolant

AdBlue (low pressure)

AdBlue (high pressure)

Engine

DM
Dosing Module

Supply Module

Engine coolant is used to

• Cool Dosing Module

AdBlue Tank
Hagin / System Description DNOx-2.2_05 14
 DNOx-2.2 Filtration concept
Component Function Service-Requirement Comment

No regular service planned

Tank Pre-Filter Protect tank during filling
(Cleaning, if required)
Silencer
SM Pre-Filter Protect SM from dirt coming from tank tbd

No regular service planned

SM Inlet-Filter Protect SM during 1st start-up Very limited filtration surface
(Replacement, if required)

SM Main-Filter Protect DM On-Highway: 300‘000 km Off-Highway: tbd

Protect throttle in backflow connector from

dirt coming from pressure line or dirt No regular service planned
SM Backflow-Filter Very limited filtration surface
introduced during change of SM Main- (Replacement, if required)
Filter

Dosing Valve Filter Protect DM during 1st start-up Cannot be serviced Very limited filtration surface

Dosing Module

DM SM Pre-Filter Tank Pre-Filter

SM Backflow-Filter 100 μm 200 μm
100 μm
Dosing Valve Filter

SM Inlet-Filter
36 μm
100 μm

SM Main-Filter

Part.size Filtr.rate
>10 μm 43%
>15 μm 87%
>20 μm 99% Supply Module
AdBlue Tank
>30 μm 100%

14-04-2011 Hagin / System Description DNOx-2.2_05 15

 DNOx 2.2 System Function overview (1/11)

Standby
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode
Standby
State after initialization or in case
MeteringControl of errors

Hagin / System Description DNOx-2.2_05 16

 DNOx 2.2 System Function overview (2/11)

NoPressureControl
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode
NoPressureControl
This state will be reached if no
MeteringControl errors are found in the system

Hagin / System Description DNOx-2.2_05 17

 DNOx 2.2 System Function overview (3/11)

PressureControl – Refill
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

Refill
PressureBuildUp Ventilation This state is entered if engine is
running and exhaust temperature is
above threshold
DetectionMode
Supply module, suction- and
pressure line are filled with AdBlue
MeteringControl

Hagin / System Description DNOx-2.2_05 18

 DNOx 2.2 System Function overview (4/11)

PressureControl – PressureBuildUp / Ventilation

ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp
PressureBuildUp Ventilation If the desired filling level of the pipe
is reached, system will switch to
PressureBuildUp
DetectionMode Dosing Valve remains closed

Ventilation
MeteringControl In case the desired pressure cannot
be reached, Dosing Valve will be
opened for a short time so that the
air can escape
Hagin / System Description DNOx-2.2_05 19
 DNOx 2.2 System Function overview (5/11)

PressureControl – DetectionMode
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation
DetectionMode
Pressure stabilization followed by
DetectionMode short opening of Dosing Valve (~
1 sec)

MeteringControl Check if lines are defrosted

and/or DV is not blocked

Hagin / System Description DNOx-2.2_05 20

 DNOx 2.2 System Function overview (6/11)

PressureControl – MeteringControl
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode

MeteringControl MeteringControl
Dosing release: ´Normal´ AdBlue dosing

Hagin / System Description DNOx-2.2_05 21

 DNOx 2.2 System Function overview (7/11)

Key-15 off: PressureReduction

ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode PressureReduction
Triggered by key-off (Terminal-15)

Opening of Reverting Valve to reduce

MeteringControl system pressure

Hagin / System Description DNOx-2.2_05 22

 DNOx 2.2 System Function overview (8/11)

Transition to Afterrun
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode
Transition to Afterrun
State transition from
MeteringControl PressureControl to Afterrun

Hagin / System Description DNOx-2.2_05 23

 DNOx 2.2 System Function overview (9/11)

Afterrun – Emptying
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode

Afterrun - Emptying
MeteringControl Emptying of pressure line an
Pump Module

Hagin / System Description DNOx-2.2_05 24

 DNOx 2.2 System Function overview (10/11)

Afterrun – PressureCompensation
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation
Afterrun - PressureCompensation
DetectionMode Pump is switched off.
After that, Reverting Valve is set to normal position and
the Dosing Valve is closed with a short delay, in order to
achieve pressure compensation to environmental
MeteringControl pressure

Hagin / System Description DNOx-2.2_05 25

 DNOx 2.2 System Function overview (11/11)

Afterrun – WaitingForShutoff
OFF
ON

Afterrun
Init
Emptying
p
Standby PressureCompens.

WaitingForShutoff

NoPressure Pressure
Control Reduction ECU
off
PressureControl
Refill

PressureBuildUp Ventilation

DetectionMode

MeteringControl Afterrun - WaitingForShutoff

Control unit will be shut down

Total time for hydr. Afterrun: 40 – 120 sec

Hagin / System Description DNOx-2.2_05 (…depending on diameter and length of AdBlue pipes…) 26
 Urea-Heating-Control (UHC)

Tasks of the AdBlue Heating Control functionality

 Defrost (thaw) the DNOX system components at cold temperatures
 Heat the DNOX system components after defrosting at cold temperatures

 Input to heating control

60
 Tank temperature
 Supply module temperature
50
- Supply module heater temperature

ea
40

ur
- Environment temperature

-
- Coolant temperature
- Tank Level 30
- Battery voltage

T [°C]
- Environment temperature 20
- Actual dosing quantity

a
re
-u
10


0

ea
H2O

-ur

-10
-11.5°C

0 10 20 30 40 50 60 70
Urea concentration [°C]
Hagin / System Description DNOx-2.2_05 27
Urea-Heater-Control (UHC) structure

C1: AdBlue Tank

C2: Supply Module

C3: Pressure Pipe

Hagin / System Description DNOx-2.2_05 28

 Defreezing thresholds summary (…preliminary…)

Defrosting
Signal Threshold Comments

On Off

C1 SCR_tUtnkT. < -10.0 °C > -8.0 °C

C2 SCR_tSMTFlt < -4 °C for 4 sec > -4 °C for 1 sec

C3 UHC_tEnvAir Timer: UHC_tiC3Dfrst_CUR As soon as state MetCtl is reached Example for timer duration: 600 sec @ -20°C

Heating
Signal Threshold Comments

On Off

C1 SCR_tUtnkT. < +15 °C > +17 °C

C2 UHC_tEnvAir < -2 °C > 0 °C Cold ambient: Heating is always active

C3 UHC_tEnvAir < -2 °C > 0 °C dto

Hagin / System Description DNOx-2.2_05 29