Engineering partner for common rail systems

Liebherr injection systems are designed using state-of-the-art tools based on decades of experience in the development and production of diesel engines. Qualified application engineers provide support for the integration of common rail components as well as for exhaust gas aftertreatment and the development of combustion systems. Liebherr thus offers its customers a reliable and complete state-of-the-art system.

State-of-the-art methods for stable power and high load capacity

Modern development tools such as the Finite Element Method (FEM) or Computational Fluid Dynamics (CFD) analysis contribute towards the constant optimization of the injection system and its modules.

Flow effects are inspected with CFD analyses

Flow effects are inspected with CFD analyses

Engineering methods

Many components of a fuel injection system are subjected to cyclic loads. When testing with FEM, particular emphasis is placed on determining and then optimization fatigue resistance.

All components are also inspected intensively by calculation engineers with CFD analyses. Flow effects inside the components are modeled and the findings are incorporated in the design.

Endurance testing of common rail systems

Endurance testing of common rail systems

Product validation

All components in Liebherr Common Rail systems are subjected to thorough and comprehensive validation program. This is oriented on excellent system reliability and availability under demanding environmental conditions, as well as towards a long product service life. Accelerated test procedures are used to investigate the ageing process of system and components. Field trials are also a key element of the validation process.

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Testing competence at Liebherr - how a prototype is built and thoroughly tested
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Testing competence at Liebherr - how a prototype is built and thoroughly tested View video
Testing competence at Liebherr - how a prototype is built and thoroughly tested
We need your consent This YouTube video is provided by Google*. If you load the video, your data - including your IP address - is transmitted to Google and may be stored and processed by Google inter alia in the USA. We have no influence over further data processing by Google. By clicking on "Accept", you consent to the transmission of data to Google for this video in accordance with Art. 6 (1) (a) GDPR and at the same time expressly consent to the transfer of data to the USA in accordance with Art. 49 (1) (a) GDPR. If you no longer wish to consent to each YouTube video individually in the future and wish to be able to load the videos without this blocker, you can also select "Always accept YouTube" and thereby consent to the associated data transmissions and transfers to Google and to the USA for all other YouTube videos which you open on our website in the future. Please note that, in the opinion of the European Court of Justice, there does not currently exist an adequate level of data protection in line with EU standards in the USA, and at present we cannot provide suitable safeguards to protect your data and offset this shortcoming. Possible risks to you of data transfer to the USA are that access by state authorities cannot be excluded and that your data could be processed for reasons of national security, criminal prosecution or for other purposes in the public interest of the USA, possibly without you being informed separately and without enforceable rights and effective means of redress being available to you. You can withdraw consent that you have given at any time with future effect via the settings. For further information, please see our Data Protection Declaration and Google's Privacy Policy. *Google Ireland Limited, Gordon House, Barrow Street, Dublin 4, Irland; Mutterunternehmen: Google LLC, 1600 Amphitheatre Parkway, Mountain View, CA 94043, USA

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Stable multiple injections

Stable multiple injections ensured with the 3-way servo valve

Stable multiple injections ensured with the 3-way servo valve

In the case of multiple injections, the pilot injection is crucial for the engine to run silently, the main injection ensures optimal power delivery and maximum torque, and the post-injection reduces emissions.

The 3-way servo valve ensures that the injection spray is established moderately. The injection process ends with very fast closure of the nozzle needle. This results in a very clear boundary for the individual injections and a precisely measured amount of fuel - both of which are decisive factors for an optimal combustion process, low fuel consumption and minimal raw emissions.

Minimal control leakage

Liebherr injectors are set apart by their very small amount of control leakage. In the case of system injectors for engines with a capacity of up to 2.7 liters per cylinder, at full load it is a maximum of 15 ml/min. This provides the following advantages:

  • higher degree of efficiency and therefore lower fuel consumption
  • lower leakage temperatures, therefore less cooling requirements
  • good tolerance of various fuel qualities

Injection timing control function

With the help of the injection timing control (ITC) function, even small quantities of fuel can be dosed more precisely. Each injector has the necessary hardware to determine the start and end of injection. Additional information gained from the start and end of the injection provides relevant condition monitoring data and the software regulates the amount of fuel to be delivered individually for each subsequent injection. This compensates for drift and keeps the injection quantity from the injector constant over the entire service life. The software-controlled Injection Timing Control (ITC) function works without an additional connector interface.

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Lifelong dependability

Liebherr uses an up-to-date computer-assisted quality management system that is implemented as early as the production process and covers the entire product life cycle. Efficient test benches, often specially developed for Liebherr, are used in testing the high precision components.

Extensive entry inspections

All purchased parts of the Common Rail fuel injection system are checked for their highest quality with the aid of highly modern measurement instruments.

These include for example, 3D coordinate measuring devices roughness and contour measuring systems as well as an optical surface scanner.

Series testing

Before delivering the fuel injection systems, the high-pressure pumps, injectors and high pressure connectors are tested 100% for functional and service life-relevant quality features such as flow, torque or leakage. The Data Matrix Code (DMC) is used to track the assembled parts and assign them to the corresponding system components.

Measurements and testing for injection systems

  • Leakage test of the injector
    A camera system is used to test the nozzle or nozzle needle to ensure that there is no leakage. In the process, the camera records any drop formation on the nozzle which is subjected to high pressure.

    Leakage test of the injector

    A camera system is used to test the nozzle or nozzle needle to ensure that there is no leakage. In the process, the camera records any drop formation on the nozzle which is subjected to high pressure.

  • Spray pattern test bench
    With the aid of a camera, the test bench measures the geometry of the spray pattern of the injector. Due to the very high speed of the injection process this places high demands on the measurement system as well as on the synchronization of the measurement and control loop.

    Spray pattern test bench

    With the aid of a camera, the test bench measures the geometry of the spray pattern of the injector. Due to the very high speed of the injection process this places high demands on the measurement system as well as on the synchronization of the measurement and control loop.

  • Geometry measurements
    Modern measurement instruments are used to measure the geometry of the Liebherr Common Rail system parts. The photo shows the evaluation of the round surface of the control valve.

    Geometry measurements

    Modern measurement instruments are used to measure the geometry of the Liebherr Common Rail system parts. The photo shows the evaluation of the round surface of the control valve.

  • Highest quality standards

    Quality assurance is certified according to DIN EN ISO 9001:2015 and complies with VDA standards (reliability control circuit). Statistical evaluations and FMEA (Failure Mode and Effects Analyses) are an integral part of the process, as well as the effectiveness testing of changes. In all our processes and operations, we follow the principle of PDCA and integrate Continuous Improvement (CI) in our daily work.

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