Delphi Technologies Develops System to Reduce Particulates by up to 50 Percent

DeIphi Technologies has revealed that it has developed a system that has the capability to reduce particulates by up to 50 percent. This was revealed in a paper that the company presented at the 2019 Vienna Motor Symposium. The new 500+ bar GDi system 50 percent more effective when compared to the state-of-the-art 350 bar system and needs no expensive engine design modifications.

Most vehicle manufacturers are constantly engaged in a drive to reduce the number of exhaust gas particulates, including those smaller than 23 nm in order to meet increasingly stringent future global emissions standards.

In the event that engine-out emissions can be reduces, it would cut tailpipe emissions in the crucial period before catalyst light-off and this would minimize the need for costly aftertreatment systems. It would reduce emissions in regulated testing including RDE (Real Driving Emissions). Delphi Technologies had commenced production of its industry first 350 bar GDi system in late 2016. At that time, this system reduced exhaust particulates by up to 70 percent when compared with industry-standard 200 bar systems.

Walter Piock, chief engineer, Gasoline Systems, Delphi Technologies explained that the industry has long recognized that increasing injection pressure to 500+ bar could significantly reduce engine-out particulates while at the same time improving fuel economy and CO2 emissions.

It has however not been an easy task to achieve such pressures without increasing the drive loads from the pump. Most engines power the GDI pump through the camshaft drive, and using a conventional approach would mean an expensive revamp and strengthening of the camshaft mechanism.

Piock revealed that by designing an innovative new internal sealing system for the company’s GFP3 500+ bar pump, in some applications, Delphi came up with a downsized plunger diameter which can prevent the increase of the loads in the drive mechanism.

By using the new Delphi Technologies system, engine designers can benefit from 500+ bar injection pressures without making expensive changes to most current camshaft drive systems.

In view of the growing demand for better air quality in urban areas and the drive to attain lower greenhouse gas emissions, the fuel injection system can play a key role in meeting future legislative targets. The new 500+ bar system can help vehicle manufacturers to meet both challenges.

According to Piock, “Our 350 bar GDi system reduces exhaust particulates by up to 70 percent compared with industry-standard 200 bar systems and we are going one step further with our new 500+ bar GDi system which further reduces these emissions by up to 50 percent compared to the 350 bar system”.

Delphi Technologies has developed all system components like Multec 16 injectors, pumps, forged rail engine control system and software which are compatible with the new 500+ bar system. These components, which can further enhance the system’s durability and reliability, also call for no or only minor physical changes to existing engines because they match existing packaging constraints and interfaces. The 500+ bar system could be used in production from 2022 onwards.