Fuel Injection Technology Trends

Edwin A. Rivera
Delphi Powertrain Systems

John E. Kirwan
Delphi Powertrain Systems

February 25, 2014

Green Legislation Fuels Innovation & Growth

Global regulations are becoming more stringent
Regulation Trends
More Stringent standards
d i i iinnovation
driving
ti
EPA 2025 proj.: 54.5 mpg
NHTSA Fleet avg:
2021: 40.3 41.0 mpg
pg
2025: 48.7 49.6 mpg

120

Worldw
wide Light Duty V
Vehicles
(Millions)

GDi E
Engines
i
Projected to be the fastest
growing market segment over
the next 10 years
Will become the dominant
internal combustion engine

Fuel Cell & Electric

Alternative Fuels

100

Diesel
80

GDi Gasoline

60

GDi Hybrid
PFI Hybrid

40
20
0

PFI Gasoline
Source: IHS Feb 2013

2010
2

Diesel Hybrid

2013

Fuel Injection Technology Trends Feb. 25, 2014

2016

2019

2022

2025

New Challenge for Gasoline Direct Injection Engines

Particulate Emissions
Light Duty PM

25

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

20

PM (mg/mile)

CA / US OBD Threshold

15

10

LEV III 1 mg/mi Phase in

0.75 mg/mile difference
Threshold = 1.75X standard

7.5 mg/mile difference

Threshold = 1.75X Standard

CA LEV /
US Emission
Standard

2.25 mg/mile difference

Threshold = 1.75X Standard

5
LEV III (& US Tier 3 Expected) 3 mg/mi Phase in

2013

2015

2017

2019

2021

2023

2025

Fuel injection technology performance relative to particulate emission standards

LEVIII and
d EURO6c
EURO6 :

Particulate Mass is currently lower than proposed limits

Particulate Number will remain a challenge

Fuel Injection Technology Trends Feb. 25, 2014

GDi Fuel System

High Level Functional Requirements

TIMING

METERING

ATOMIZATION

TARGETING
4

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System

High Level Functional Requirements

METERING

ATOMIZATION
TARGETING

TIMING

METERING

ATOMIZATION

TARGETING

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System - Metering

Trend: Precise Fuel Mass Delivery

TARGETING

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

Injector Closed Loop Control

METERING

ATOMIZATION

Measures injector electrical signals during operation to determine

differences in dynamic response characteristics
Detects injector-to-injector
j
j
differences and injector
j
aging
g g effects

Adjusts individual injector pulse width to balance fuel delivery

Correction activated
ICLC ON

4cyl. TGDi
1200rpm / 3x 2mg / 200bar

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System - Metering

Trend: Precise Fuel Mass Delivery
Improved coking resistance due to
laser drilling

METERING

ATOMIZATION
TARGETING

EDM Process

Improved deposit resistance due to

smoother surface in flow holes
Sharp inlet for improved turbulence
generation for lower deposit build-up
build up and
more effective removal

Flow Hole

Counterbore
7

Fuel Injection Technology Trends Feb. 25, 2014

Laser Drilling

TIMING

GDi Fuel System

High Level Functional Requirements

METERING

ATOMIZATION

TARGETING

TIMING

METERING

ATOMIZING

TARGETING
8

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System - Targeting

Trend: Precise Spray Targeting

ATOMIZATION

METERING

TARGETING

Fabrication of spray holes

More consistent spray characteristics

R
d
d variation
i ti iin spray plume
l
l and
d plume
l
Reduced
angle
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
(280 injectors)

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

Delphi Production Thermal Laser process:

Exit Edge consistent
and no spatter
9

Exit Edge Variation and

Spatter
Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System

High Level Functional Requirements

METERING

ATOMIZATION
TARGETING

TIMING

METERING

ATOMIZATION

TARGETING

10

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System - Atomizing

Trend: Higher Fuel Pressure
Motivation for increased fuel
pressure:

METERING

ATOMIZATION
TARGETING

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)
Trade-off versus increased parasitic
losses requires careful assessment

Emissions

11

Improved cold start HC emissions

due to better mixing and less wall
wetting

Lower particulates - mass and

number emissions

Fuel Injection Technology Trends Feb. 25, 2014

Market info:
planned SOPs

Homogeneous GDi Fuel System

Trend: Non-Thermal Laser Spray
p y Hole Manufacturing
g

High precision material removal provides greater

injector-to-injector targeting and metering consistency

Fuel Injection Technology Trends Feb. 25, 2014

Homogeneous GDi Fuel System

Trend: Non-Thermal Laser Spray
p y Hole Manufacturing
g

High precision material removal provides greater injectorto-injector targeting and metering consistency
E
Excellent
ll t surface
f
quality
lit and
d sharp
h
edges
d
reduce
d
coking
ki
to improve consistency over injector lifetime
Injector Spray Patternation
Before Injector
Coking Test

EDM

Laser Drilling

Fuel Injection Technology Trends Feb. 25, 2014

Homogeneous GDi Fuel System

Trend: Non-Thermal Laser Spray
p y Hole Manufacturing
g

High precision material removal provides greater injectorto-injector targeting and metering consistency
E
Excellent
ll t surface
f
quality
lit and
d sharp
h
edges
d
reduce
d
coking
ki
to improve consistency over injector lifetime
Injector Spray Patternation

After Injector
Coking Test

Before Injector
Coking Test

EDM

Laser Drilling

Fuel Injection Technology Trends Feb. 25, 2014

Homogeneous GDi Fuel System

Trend: Non-Thermal Laser Spray
p y Hole Manufacturing
g

High precision material removal provides greater injectorto-injector targeting and metering consistency
E
Excellent
ll t surface
f
quality
lit and
d sharp
h
edges
d
reduce
d
coking
ki
to improve consistency over injector lifetime
Non-conventional hole shape production capability
increases spray generation flexibility

Improved airentrainment

Improved Air Entrainment

Fuel Injection Technology Trends Feb. 25, 2014

Advanced Combustion:
Trend: Stratified Combustion Systems
Future system scenario: stratified combustion
in downsized,
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

Enables low particulate number due to low

penetration, rapid spray evaporation, and excellent
coking resistance

Side view

Enhanced minimum fuel control: < 1mg/pulse with

excellent atomization

Bottom view

16

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System

High Level Functional Requirements

ATOMIZATION

METERING

TARGETING

TIMING

METERING

ATOMIZING

TARGETING

17

Fuel Injection Technology Trends Feb. 25, 2014

TIMING

GDi Fuel System - Timing

Trend: Precise Timing with Multiple Injections

ATOMIZATION

METERING

TARGETING

Multiple injections can be effectively

used to reduce particulate emissions
Improved overall mixture chamber
homogeneity
Increased dilution tolerance via local
enrichment and higher turbulence at the
spark plug to support flame initiation and
early propagation

Low Load (NMEP < 2[bar]), 1200 [rpm]

cold engine

TDC

BDC

1E+0 1E+2 1E+4 1E+6 1E+8

TDC

4.5E+6
(COV >25%)

4.4E+4
TDC

BDC

P
Penetration
t ti control
t l to
t minimize
i i i
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
p
start emissions and fuel consumption

18

Total Particulate Number

(#PN/ccm)

Single
S g e Cy
Cylinder
de Engine
g e

Results:
R
lt

Fuel Injection Technology Trends Feb. 25, 2014

TDC

(COV >15%)

TIMING

GDi Fuel System

Summary

ATOMIZING

METERING

TARGETING

Further reduction of emissions and CO2 is driving significant technology

development for gasoline engines, subsystems and components
GDi iis a kkey enabler
bl th
thatt mustt meett stringent
ti
t requirements
i
t ffor:
Precise metering
Precise targeting
Fine atomization
Accurate timing

Longer term: Stratified DI

DI, alternative combustion systems and gaseous
DI are potential candidates for further CO2 reduction.

19

Fuel Injection Technology Trends Feb. 25, 2014

Recent Developments in Fuel Injector Technology

for Alternative Fuels
Compressed Natural Gas
Port injection
Direct injection

E100
Heated Tip Injection

20

Fuel Injection Technology Trends Feb. 25, 2014

Delphis Injector for Compressed Natural Gas

Small Sized, Durable Port Fuel Injector Multec 3.5 CNG
Functionality

Port fuel injector for gaseous fuel

Leverages
g CNG-fueled vehicle benefits:
25% CO2 emissions reduction vs.
gasoline from reduced fuel carbon
content
Reduced fuel cost vs.
vs gasoline
Near-zero particulate emissions
g/s
%lin
LL
UL

3.5
3.0
2.5
2.0
15
1.5
1.0
0.5
0.0

20
15
10
5
0
-5
-10
-15
-20
0

21

Fuel Injection Technology Trends Feb. 25, 2014

5
Pulse Width,
Width ms

10

Deviatiion. %

Flow, g
g/s

Flow Performance: M3.5-CNG Injector

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

For the Future:

Delphis Injector for Direct CNG Injection
Natural Gas Availability and Attractiveness is increasing

Global availability offers increased energy security and

reduced fuel price

Significantly reduced CO2 (25%) due to fuel

composition combined with lower ozone (smog)
forming potential and reduced particulates

Increased octane offers potential compression ratio

ed comb
stion efficiency
efficienc
increase for impro
improved
combustion

CNG Direct Injection

400

Increases volumetric efficiency for improved

performance vs. PFI CNG vehicles

Enables aggressive scavenging strategies offering

additional improvements to low-end torque utilized for
further downsizing

350
T o r q u e [N m ]

300
250

Manifold injection
Direct injection

200
150

Manifold and DI tests conducted on same

engine. (2.0-liter 4-cyl)

100
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Engine Speed [rpm]
(IAV 7th Gas Powered Vehicle Conference)

22

Fuel Injection Technology Trends Feb. 25, 2014

Multec PFI Heated Tip Injector

Electrically 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

23

Enables E100 cold starts without gasoline supplement

down to -5C

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, 2014

Thank you

Homogeneous GDi Fuel System

Low Noise Injector
j
Fuel Injector

Decoupled armature mass design reduces impact energy during

operation to reduce injector noise

Fuel Injection Technology Trends Feb. 25, 2014

Homogeneous GDi Fuel System

Low Noise Injector
j
Fuel Injector

Decoupled armature mass design reduces impact energy during

operation to reduce injector noise

D
Decoupled
l d armature
t
Fuel Injection Technology Trends Feb. 25, 2014