Fuel Injection Technology Trends

Edwin A. RiveraDelphi Powertrain Systems

John E. KirwanDelphi Powertrain Systems

February 25, 2014

Green Legislation Fuels Innovation & GrowthGlobal regulations are becoming more stringent

Regulation TrendsMore Stringent standards

d i i i tidriving innovation EPA 2025 proj.: 54.5 mpg

NHTSA Fleet avg: 2021: 40.3 – 41.0 mpgpg 2025: 48.7 – 49.6 mpg

GDi E iGDi Engines Projected to be the fastest

growing market segment over the next 10 years 80

100

120

Veh

icle

s Diesel

Alternative FuelsFuel Cell & Electric

the next 10 yearsWill become the dominant

internal combustion engine20

40

60

80w

ide

Ligh

t Dut

y V

(Mill

ions

)

PFI Gasoline

GDi Gasoline

GDi Hybrid PFI Hybrid

Diesel Hybrid

Fuel Injection Technology Trends – Feb. 25, 2014

0

20

2010 2013 2016 2019 2022 2025

Wor

ldw PFI Gasoline

Source: IHS Feb 2013

2

New Challenge for Gasoline Direct Injection EnginesParticulate Emissions

20

25Light Duty PM

Chart from: https://www.dieselnet.com/standards/us/ld_ca.php

10

15

20

g/m

ile) CA / US OBD Threshold

7.5 mg/mile difference Threshold = 1.75X Standard

LEV III 1 mg/mi Phase in0.75 mg/mile difference

Threshold = 1.75X standard

5

10

PM (m CA LEV /

US EmissionStandard

2.25 mg/mile differenceThreshold = 1.75X Standard

LEV III (& US Tier 3 Expected) 3 mg/mi Phase in

Fuel injection technology performance relative to particulate emission standards LEVIII d EURO6

02013 2015 2017 2019 2021 2023 2025

LEVIII and EURO6c: Particulate Mass is currently lower than proposed limits Particulate Number will remain a challenge

Fuel Injection Technology Trends – Feb. 25, 20143

GDi Fuel SystemHigh Level Functional Requirements

TIMINGTIMING

METERINGATOMIZATION METERINGATOMIZATION

TARGETING

Fuel Injection Technology Trends – Feb. 25, 20144

TARGETING

GDi Fuel SystemHigh Level Functional Requirements

METERING

TIMING

TARGETING

ATOMIZATION

TIMING

METERINGATOMIZATION METERINGATOMIZATION

TARGETING

Fuel Injection Technology Trends – Feb. 25, 20145

GDi Fuel System - MeteringTrend: Precise Fuel Mass Delivery

METERING

TIMING

TARGETING

ATOMIZATION

Part-to-part flow variation increases at shorter pulse widths

Injector Closed Loop Control

Measures injector electrical signals during operation to determine differences in dynamic response characteristics

– Detects injector-to-injector differences and injector aging effectsj j j g g

Adjusts individual injector pulse width to balance fuel delivery

Correction activatedICLC “ON”

4cyl. TGDi1200rpm / 3x 2mg / 200bar

Fuel Injection Technology Trends – Feb. 25, 20146

GDi Fuel System - MeteringTrend: Precise Fuel Mass Delivery

METERING

TIMING

TARGETING

ATOMIZATION

EDM Process• Improved coking resistance due to laser drilling

Laser Drilling

Improved deposit resistance due to smoother surface in flow holes

Sharp inlet for improved turbulence generation for lower deposit build-up and Laser Drillinggeneration for lower deposit build up and more effective removal

Flow Hole

Fuel Injection Technology Trends – Feb. 25, 20147

Counterbore

GDi Fuel SystemHigh Level Functional Requirements

METERING

TIMING

TARGETING

ATOMIZATION

TIMING

METERINGATOMIZING METERINGATOMIZING

TARGETING

Fuel Injection Technology Trends – Feb. 25, 20148

TARGETING

GDi Fuel System - TargetingTrend: Precise Spray Targeting

METERING

TIMING

TARGETING

ATOMIZATION

Fabrication of spray holes

• More consistent spray characteristicsR d d i ti i l l d l Reduced variation in spray plume angle and plume targeting

• Leads to increased precision in spray penetration and cone angle Patternation:

Single injector Reduced deposit build-up improves performance

over entire injector lifetime

Patternation: Center of plumes

Delphi: First to market with new non-thermal laser process

Center of plumes (280 injectors)

Fuel Injection Technology Trends – Feb. 25, 20149

Delphi ProductionExit Edge consistent

and no spatter

Thermal Laser process:Exit Edge Variation and

Spatter

GDi Fuel SystemHigh Level Functional Requirements

METERING

TIMING

TARGETING

ATOMIZATION

TIMING

METERINGATOMIZATION METERINGATOMIZATION

TARGETING

Fuel Injection Technology Trends – Feb. 25, 201410

GDi Fuel System - AtomizingTrend: Higher Fuel Pressure

METERING

TIMING

TARGETING

ATOMIZATION

• Motivation for increased fuel pressure: Thermodynamics

Delphi 400bar GDi fuel system available for MY2018

Thermodynamics• Better combustion efficiency due to

higher air utilization (improvements reported with fuel pressure up to 600 bar) Market info:600 bar)

• Trade-off versus increased parasitic losses requires careful assessment

Emissions

Market info: planned SOPs

• Improved cold start HC emissions due to better mixing and less wall wetting

• Lower particulates - mass andLower particulates mass and number emissions

Fuel Injection Technology Trends – Feb. 25, 201411

Homogeneous GDi Fuel SystemTrend: Non-Thermal Laser Spray Hole Manufacturingp y g High precision material removal provides greater

injector-to-injector targeting and metering consistency

Fuel Injection Technology Trends – Feb. 25, 2014

Homogeneous GDi Fuel SystemTrend: Non-Thermal Laser Spray Hole Manufacturingp y g High precision material removal provides greater injector-

to-injector targeting and metering consistency E ll t f lit d h d d ki Excellent surface quality and sharp edges reduce coking

to improve consistency over injector lifetime

EDMBefore Injector

Coking Test

Injector Spray Patternation

Laser Drilling

Fuel Injection Technology Trends – Feb. 25, 2014

Homogeneous GDi Fuel SystemTrend: Non-Thermal Laser Spray Hole Manufacturingp y g High precision material removal provides greater injector-

to-injector targeting and metering consistency E ll t f lit d h d d ki Excellent surface quality and sharp edges reduce coking

to improve consistency over injector lifetime

EDMAfter Injector Coking Test

Before Injector Coking Test

Injector Spray Patternation

Laser Drilling

Fuel Injection Technology Trends – Feb. 25, 2014

Homogeneous GDi Fuel SystemTrend: Non-Thermal Laser Spray Hole Manufacturingp y g High precision material removal provides greater injector-

to-injector targeting and metering consistency E ll t f lit d h d d ki Excellent surface quality and sharp edges reduce coking

to improve consistency over injector lifetime Non-conventional hole shape production capability

increases spray generation flexibilityincreases spray generation flexibility

Improved air-entrainment

Fuel Injection Technology Trends – Feb. 25, 2014Improved Air Entrainment

Advanced Combustion:Trend: Stratified Combustion Systems

• Future system scenario: stratified combustion in downsized turbocharged enginesin downsized, turbocharged engines Enabler for additional fuel consumption reduction

beyond homogeneous turbocharging and downsizing

• Outwardly opening Hollow Cone Spray Solenoid driven outwardly opening direct injector

with hollow cone spray for central mounting

Side view

Enables low particulate number due to low penetration, rapid spray evaporation, and excellent coking resistance

Enhanced minimum fuel control: < 1mg/pulse with Enhanced minimum fuel control: < 1mg/pulse with excellent atomization

Fuel Injection Technology Trends – Feb. 25, 201416

Bottom view

GDi Fuel SystemHigh Level Functional Requirements

METERING

TIMING

TARGETING

ATOMIZATION

TIMINGTIMING

METERINGATOMIZING METERINGATOMIZING

TARGETING

Fuel Injection Technology Trends – Feb. 25, 201417

GDi Fuel System - TimingTrend: Precise Timing with Multiple Injections

METERING

TIMING

TARGETING

ATOMIZATION

• Multiple injections can be effectively used to reduce particulate emissionsR lt

Single Cylinder Engine Total Particulate Number Single Cylinder EngineSingle Cylinder Engine Total Particulate Number Total Particulate Number • Results:

Improved overall mixture chamber homogeneity

Increased dilution tolerance via localTDC BDC TDC

S g e Cy de g eLow Load (NMEP < 2[bar]), 1200 [rpm]cold engine 1E+0 1E+2 1E+4 1E+6 1E+8

(#PN/ccm)

4.5E+6(COV >25%)

TDC BDC TDC

S g e Cy de g eLow Load (NMEP < 2[bar]), 1200 [rpm]cold engine

TDC BDC TDCTDC BDC TDCTDC BDC TDC

S g e Cy de g eLow Load (NMEP < 2[bar]), 1200 [rpm]cold engine 1E+0 1E+2 1E+4 1E+6 1E+8

(#PN/ccm)

4.5E+6(COV >25%)

1E+0 1E+2 1E+4 1E+6 1E+8(#PN/ccm)

4.5E+6(COV >25%)

Increased dilution tolerance via local enrichment and higher turbulence at the spark plug to support flame initiation and early propagationP t ti t l t i i i

TDC BDC TDC4.4E+4

(COV >15%)TDC BDC TDCTDC BDC TDCTDC BDC TDCTDC BDC TDC4.4E+4

(COV >15%)4.4E+4

(COV >15%)

Penetration control to minimize combustion chamber wall wetting to reduce particulate emissions and oil dilution

Reduced catalyst light-off time resulting from up to 5 injections with variable timing and mass split to reduce cold start emissions and fuel consumption

Fuel Injection Technology Trends – Feb. 25, 201418

p

GDi Fuel SystemSummary

METERING

TIMING

TARGETING

ATOMIZING

• Further reduction of emissions and CO2 is driving significant technology development for gasoline engines, subsystems and components

GDi i k bl th t t t t i t i t f• GDi is a key enabler that must meet stringent requirements for: Precise metering Precise targeting Fine atomization Accurate timing

• Longer term: Stratified DI alternative combustion systems and gaseous• Longer term: Stratified DI, alternative combustion systems and gaseous DI are potential candidates for further CO2 reduction.

Fuel Injection Technology Trends – Feb. 25, 201419

Recent Developments in Fuel Injector Technology for Alternative Fuels

• Compressed Natural Gas Port injection Direct injection

• E100 Heated Tip Injection

Fuel Injection Technology Trends – Feb. 25, 201420

Delphi’s Injector for Compressed Natural GasSmall Sized, Durable Port Fuel Injector – Multec® 3.5 CNG

• Functionality Port fuel injector for gaseous fuel

• Leverages CNG-fueled vehicle benefits:g 25% CO2 emissions reduction vs.

gasoline from reduced fuel carbon content

Reduced fuel cost vs gasoline Reduced fuel cost vs. gasoline Near-zero particulate emissions

Flow Performance: M3.5-CNG Injector8-Bar Nitrogen [SAE J1832 10 ms PRP]

g/s%linLL

05101520

1 52.02.53.03.5

ion.

%

g/s

8-Bar Nitrogen [SAE J1832, 10 ms PRP] LLUL

-20-15-10-5

0.00.51.01.5

0 5 10

Dev

iati

Flow

, g

Pulse Width ms

Fuel Injection Technology Trends – Feb. 25, 201421

Pulse Width, ms

For the Future:Delphi’s Injector for Direct CNG Injection

Global availability offers increased energy security and reduced fuel price

• Natural Gas Availability and Attractiveness is increasing

Significantly reduced CO2 (25%) due to fuel composition combined with lower ozone (smog) forming potential and reduced particulates

Increased octane offers potential compression ratio increase for impro ed comb stion efficiencincrease for improved combustion efficiency

• CNG Direct Injection Increases volumetric efficiency for improved 350

400

performance vs. PFI CNG vehicles Enables aggressive scavenging strategies offering

additional improvements to low-end torque utilized for further downsizing To

rque

[Nm

]

200

250

300 Manifold injection Direct injection

100

150

Engine Speed [rpm]1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Manifold and DI tests conducted on same engine. (2.0-liter 4-cyl)

(IAV 7th Gas Powered Vehicle Conference)

Fuel Injection Technology Trends – Feb. 25, 201422

Multec® PFI Heated Tip InjectorElectrically Heated Injector Tip Eliminates Secondary Gasoline Cold Start Fuel System

• Functionality Port fuel injector packaged with integrated heater

enhances vaporization of low volatility E100 fuel in Brazil

• Customer Benefits Enables E100 cold starts without gasoline supplement

down to -5ºC Heater located at injector tip to insure heating of first fuel

injections Eliminates secondary gasoline cold start system for

E100-fueled vehicles Significantly lower emissions (HC and CO) for any fuel

due to reduced fueling during cold starts

Fuel Injection Technology Trends – Feb. 25, 201423

Thank you

Homogeneous GDi Fuel SystemLow Noise InjectorjFuel Injector Decoupled armature mass design reduces impact energy during

operation to reduce injector noiseoperation to reduce injector noise

Fuel Injection Technology Trends – Feb. 25, 2014

Homogeneous GDi Fuel SystemLow Noise InjectorjFuel Injector Decoupled armature mass design reduces impact energy during

operation to reduce injector noiseoperation to reduce injector noise

D l d t

Fuel Injection Technology Trends – Feb. 25, 2014

Decoupled armature