Fuel Injection Technology Trends

Transcription

1 Fuel Injection Technology Trends Edwin A. Rivera Delphi Powertrain Systems John E. Kirwan Delphi Powertrain Systems February 25, 2014

2 Green Legislation Fuels Innovation & Growth Global regulations are becoming more stringent Regulation Trends More Stringent standards di driving i innovation EPA 2025 proj.: 54.5 mpg NHTSA Fleet avg: 2021: mpg 2025: mpg GDi Engines Projected to be the fastest 120 growing market segment over 100 the next 10 years 80 Will become the dominant 60 internal combustion engine 40 Vehicles wide Light Duty V (Millions) Worldw 20 Fuel Cell & Electric Alternative Fuels PFI Gasoline Diesel GDi Gasoline Source: IHS Feb Diesel Hybrid GDi Hybrid PFI Hybrid 2

3 New Challenge for Gasoline Direct Injection Engines Particulate Emissions 25 Light Duty PM Chart from: g/mile) PM (m10 CA / US OBD Threshold 7.5 mg/mile difference Threshold = 1.75X Standard CA LEV / US Emission Standard LEV III 1 mg/mi Phase in 0.75 mg/mile difference Threshold = 1.75X standard 2.25 mg/mile difference Threshold = 1.75X Standard LEV III (& US Tier 3 Expected) 3 mg/mi Phase in Fuel injection technology performance relative to particulate emission standards LEVIII and EURO6c: Particulate Mass is currently lower than proposed limits Particulate Number will remain a challenge 3

4 GDi Fuel System High Level Functional Requirements ATOMIZATION 4

5 GDi Fuel System High Level Functional Requirements ATOMIZATION ATOMIZATION 5

6 GDi Fuel System - Metering Trend: Precise Fuel Mass Delivery 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 j differences and injector aging g effects Adjusts individual injector pulse width to balance fuel delivery Correction activated ICLC ON 4cyl. TGDi 1200rpm / 3x 2mg / 200bar 6

7 GDi Fuel System - Metering Trend: Precise Fuel Mass Delivery ATOMIZATION Improved coking resistance due to laser drilling Improved deposit resistance due to smoother surface in flow holes Sharp inlet for improved turbulence generation for lower deposit build-up up and more effective removal EDM Process Laser Drilling Flow Hole 7 Counterbore

8 GDi Fuel System High Level Functional Requirements ATOMIZATION ATOMIZING 8

9 GDi Fuel System - Targeting Trend: Precise Spray Targeting Fabrication of spray holes ATOMIZATION More consistent spray characteristics Reduced d variation in spray plume angle and plume targeting Leads to increased precision in spray penetration and cone angle Reduced deposit build-up improves performance over entire injector lifetime Patternation: Single injector Patternation: Center of plumes (280 injectors) Delphi: First to market with new non-thermal laser process 9 Delphi Production Exit Edge consistent and no spatter Thermal Laser process: Exit Edge Variation and Spatter

10 GDi Fuel System High Level Functional Requirements ATOMIZATION ATOMIZATION 10

11 GDi Fuel System - Atomizing Trend: Higher Fuel Pressure ATOMIZATION Delphi 400bar GDi fuel Motivation for increased fuel system available for MY2018 pressure: Thermodynamics Better combustion efficiency due to higher air utilization (improvements reported with fuel pressure up to 600 bar) Market info: Trade-off versus increased parasitic losses requires careful assessment Emissions Improved cold start HC emissions due to better mixing and less wall wetting Lower particulates - mass and number emissions planned SOPs 11

12 Homogeneous GDi Fuel System Trend: Non-Thermal Laser Spray Hole Manufacturing High precision material removal provides greater injector-to-injector targeting and metering consistency

13 Homogeneous GDi Fuel System Trend: Non-Thermal Laser Spray Hole Manufacturing High precision material removal provides greater injectorto-injector targeting and metering consistency Excellent surface quality and sharp edges reduce coking to improve consistency over injector lifetime Injector Spray Patternation Before Injector Coking Test EDM Laser Drilling

14 Homogeneous GDi Fuel System Trend: Non-Thermal Laser Spray Hole Manufacturing High precision material removal provides greater injectorto-injector targeting and metering consistency Excellent surface quality and sharp edges reduce coking to improve consistency over injector lifetime Injector Spray Patternation After Injector Coking Test Before Injector Coking Test EDM Laser Drilling

15 Homogeneous GDi Fuel System Trend: Non-Thermal Laser Spray Hole Manufacturing High precision material removal provides greater injectorto-injector targeting and metering consistency Excellent surface quality and sharp edges reduce coking to improve consistency over injector lifetime Non-conventional hole shape production capability increases spray generation flexibility Improved airentrainment Improved Air Entrainment

16 Advanced Combustion: Trend: Stratified Combustion Systems Future system scenario: stratified combustion in 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 Enhanced minimum fuel control: < 1mg/pulse with excellent atomization Side view Bottom view 16

17 GDi Fuel System High Level Functional Requirements ATOMIZATION ATOMIZING 17

18 GDi Fuel System - Timing Trend: Precise Timing with Multiple Injections ATOMIZATION Multiple injections can be effectively used to reduce particulate emissions Results: 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 Penetration ti control to minimize 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 start emissions and fuel consumption Single ge Cylinder Engine Total Particulate Number Low Load (NMEP < 2[bar]), 1200 [rpm] (#PN/ccm) cold engine 1E+0 1E+2 1E+4 1E+6 1E+8 TDC BDC TDC TDC BDC TDC 4.5E+6 (COV >25%) 4.4E+4 (COV >15%) 18

19 GDi Fuel System Summary ATOMIZING Further reduction of emissions and CO 2 is driving significant technology development for gasoline engines, subsystems and components GDi is a key enabler that t must meet stringent t requirements for: Precise metering Precise targeting Fine atomization Accurate timing Longer term: Stratified DI, alternative combustion systems and gaseous DI are potential candidates for further CO 2 reduction. 19

20 Recent Developments in Fuel Injector Technology for Alternative Fuels Compressed Natural Gas Port injection Direct injection E100 Heated Tip Injection 20

21 Delphi s Injector for Compressed Natural Gas Small Sized, Durable Port Fuel Injector Multec 3.5 CNG Functionality Port fuel injector for gaseous fuel Leverages CNG-fueled vehicle benefits: 25% CO 2 emissions reduction vs. gasoline from reduced fuel carbon content Reduced fuel cost vs. gasoline Near-zero particulate emissions Flow, g/s Flow Performance: M3.5-CNG Injector 8-Bar Nitrogen [SAE J1832, 10 ms PRP] Pulse Width, ms ion. % Deviati g/s %lin LL UL 21

22 For the Future: Delphi s Injector for Direct CNG Injection Natural Gas Availability and Attractiveness is increasing Global availability offers increased energy security and reduced fuel price Significantly reduced CO 2 (25%) due to fuel composition combined with lower ozone (smog) forming potential and reduced particulates Increased octane offers potential compression ratio increase for improved combustion efficiency CNG Direct Injection 400 Increases volumetric efficiency for improved 350 performance vs. PFI CNG vehicles 300 Enables aggressive scavenging strategies offering 250 additional improvements to low-end torque utilized for further downsizing 200 Torque [Nm] Manifold injection Direct injection 150 Manifold and DI tests conducted on same engine. (2.0-liter 4-cyl) Engine Speed [rpm] (IAV 7 th Gas Powered Vehicle Conference) 22

23 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 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 23

24 Thank you

25 Homogeneous GDi Fuel System Low Noise Injector Fuel Injector Decoupled armature mass design reduces impact energy during operation to reduce injector noise

26 Homogeneous GDi Fuel System Low Noise Injector Fuel Injector Decoupled armature mass design reduces impact energy during operation to reduce injector noise Decoupled armature