Delphi Presents State-of-the-Art Application of Latest GDi Technologies at Upcoming Aachen Colloquiums in Germany

At the Aachen Colloquium in Germany continuing through Wednesday, (Oct. 10-12), Delphi Automotive will present two technical papers on Gasoline Direct Injection (GDi) technologies.

One paper describes the ongoing development of an advanced combustion process called gasoline direct compression ignition (GDCI). This low-temperature combustion strategy offers high efficiency and low emissions, leading to substantial reduction of CO2 emissions from future gasoline-fueled powertrains.

A second paper, to be presented at the Aachen Colloquium in Germany and the first Aachen Colloquium China, to be held in Beijing (Nov. 1-2), was written by authors from Delphi and Hyundai & Kia. This paper discusses the application of Delphi's latest GDi system to Hyundai & Kia's new 3.8- litre, V-6 Lambda-II engine, which will be used in the upcoming 2012 BH model platform. Compared to its predecessor with port injection, the new engine produces 15 percent higher peak power and 11 percent more peak torque, together with more than a 5 percent improvement in fuel economy. Delphi provides the complete engine management system, including the fuel system, engine control module (ECM), and control software, and worked closely with Hyundai & Kia throughout the powertrain development program.

"This is a true collaboration that delivered outstanding results," explained Jim Zizelman, co-author of the paper and Delphi's engineering director, Gasoline Engine Management Systems and Powertrain Products. "By working with us as a single, integrated team from an early stage, Hyundai & Kia have delivered a premium engine."

"I appreciate Delphi's sincere cooperation and excellent contributions on the Hyundai /KIA GDi engine development project," said TS Han, engineering executive director, Powertrain Hyundai & KIA R&D. “We have been working jointly together for many years and I am very pleased to see this satisfactory result."

As GDi systems grow in popularity, new consumers may notice increased noise coming from the fuel system. The design of today's overhead cam engines means that the high pressure fuel pump sits on top of the engine — where it is easily heard by vehicle owners. Delphi's systems expertise has resulted in a value-added comprehensive solution that helps isolate and reduce fuel system noise and costs.

At the heart of Delphi's fuel system are Delphi's patented, PACE award-winning, Multec® 12 injector and Delphi's new premium low noise high pressure fuel pump. Delphi Multec GDi Multi-Hole Fuel Injectors offer precise fuel delivery over a wide flow range, with excellent atomization and spray flexibility. Decoupling of the armature and pintle reduces activation noise to provide "best-in-class" audible noise performance. Delphi's new premium low-noise, high- pressure fuel pump is a single piston pump with a compact design and flexible mounting and connection capabilities to facilitate packaging. Pump control algorithms complement hardware design to reduce production and transmission of pump noise. Comparison tests show noise levels for the pump, and for the system overall, to be substantially lower than competitor products, a key feature confirmed by customer feedback. "Delphi's products are setting a new standard for GDi technology. For the driver, this translates into better vehicle performance, improved fuel economy, and lower noise," Zizelman said.

Delphi also developed and supplies the stainless steel fuel rail, which is designed to dampen system pressure fluctuations while delivering good transient performance through optimizing the internal volume. Algorithms in the engine management system's control software vary the rail pressure in response to a number of inputs to minimize HC, CO, NOx and particulate emissions while maximizing torque and fuel economy. Increased software control also supports the variety of injection strategies possible with GDi technology. Injection during the compression stroke ensures fast, reliable cold starting, followed by split injection (where fuel is introduced during both the intake and the compression strokes), which reduces catalyst light-off time. Multiple intake injections can be applied to improve combustion stability under conditions of high load, particularly at low rpm.

"The success of the Hyundai & Kia Lambda-II engine shows what is possible by working in partnership with the vehicle manufacturer from the early stages of a project," Zizelman said. "It was also great that after a competitive evaluation, they specified the complete Delphi system, allowing optimization with designed-in synergies. The result is a vehicle with outstanding performance and driveability."

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