Advanced powertrain and vehicle electrification technologies at Delphi
A vehicle on an average emits 154g of CO2 per km of travel as of today. By 2020, automakers will be required to meet the European Commission CO2 fleet-average target of 95g/km. This 2020 CO2 target is subject to review by January 2013 and could be even more stringent. In view of the changes that are in the offering, Delphi is developing and fine tuning technologies that would help it address the challenges of tomorrow. These include advanced diesel and gasoline engine management systems to products for hybrid and electrical vehicles.
At the forefront of development is the Gasoline engine management system with Spray Stratified Gasoline Direct Injection Multec 20 Injector and Multi Charge Ignition system. The new spray stratified gasoline direct injection (GDi) system from Delphi reduces CO2 emissions and delivers the performance needed for premium engines at a significantly lower cost than conventional piezo technology. With solenoid technology that delivers outstanding spray performance, Delphi's spray stratified GDi system improves fuel economy while reducing engine noise and harmful emissions. Due to the use of conventional solenoid-actuation, the Multec 20 Injector driver hardware is the same as for homogenous gasoline direct injection applications: therefore the electronic control unit (ECU) can also be used without modifications. This technology is helping manufacturers meet more stringent future CO2 standards by improving engine efficiency, is ethanol compatible and helps reduce engine noise. To further increase the operating range and improve fuel economy on stratified GDi engines, Delphi has developed a Multi-Charge Ignition System. The system features a single coil-per-cylinder control and fires the spark plug quickly and multiple times per combustion event to enable optimized combustion. The Multi-charge Ignition ensures therefore initiation of robust combustion and compensation of fuel spray variation. As a result, Delphi's MultiCharge Ignition provides an array of benefits for GDi, but the emission control may be the most valuable over the long run. Indeed, cold start is an area where emissions can really be lessened, and the multi charge takes advantage of this window to decrease emissions immediately.
An increasingly important strategy for efficiency improvement is to reduce the parasitic losses associated with engine ancillaries. Delphi's new fuel pump, due to become available by 2012, uses a next-generation brushless motor architecture and delivers reliable, uninterrupted fuel flow at system pressure. It also delivers high efficiency, improved durability, wide-ranging fuel compatibility (gasoline, diesel, alcohol mixes and even contaminated field fuels) and a 1-2g/km CO2 reduction compared to conventional fuel pumps. With Delphi's brushless fuel pumps, power consumption is reduced by approximately 36 percent (or more, depending on application). The reduction in power consumption contributes to an estimated fuel economy improvement of 0.2 mpg (0.12 l/100 km).
Development of economical, environmentally friendly vehicles is important to the auto industry's future. Building on more than 70 years of automotive electronics experience, Delphi is focused on reducing the cost of hybrid power electronics while, designing in market-leading functionality and reliability. We consider the rigorous electrical requirements of connection systems and wiring thermal management needs in our designs. Key power electronics products include battery pack systems, inverters and DC/DC (direct current to direct current) converters.
After the air compression process that occurs in a turbo- or super-charged engine, cooling the engine intake air with a coolant-to-air heat exchanger offers many benefits over conventional air-to-air charge air coolers. The flexibility of Delphi's Liquid Cooled Charge Air Cooler (LCCAC) designs allows the coolers to be incorporated into the ducting between the forced induction device and the engine or integrated into the intake manifold, minimizing the under-hood packaging impact and the air-pressure losses through the cooler. LCCAC's eliminate the large diameter elastomeric tubing used to route the charge air to the air-to-air charge cooler and the large diameter connectors that can lead to warranty problems. Engine response time during acceleration is improved because of the smaller volume of air between the induction device and engine and the high-transient thermal capacity of the liquid cooled system. This higher thermal capacity also helps to limit NOx peaks during transient driving conditions by maintaining cooler inlet air temperatures. For cold starts, coolant flow can be limited to increase engine warm-up rate and reduce the time for the catalytic converter to reach light-off temperatures. During partial load conditions, coolant flow can also be limited to reduce air density allowing a greater opening of the throttle valve, which helps to reduce engine-pumping losses. Additionally, Delphi's wide array of heat exchangers can be modified to fit any size engine allowing for greater automaker flexibility and packaging.
A vehicle on an average emits 154g of CO2 per km of travel as of today. By 2020, automakers will be required to meet the European Commission CO2 fleet-average target of 95g/km. This 2020 CO2 target is subject to review by January 2013 and could be even more stringent. In view of the changes that are in the offering, Delphi is developing and fine tuning technologies that would help it address the challenges of tomorrow. These include advanced diesel and gasoline engine management systems to products for hybrid and electrical vehicles. 
At the forefront of development is the Gasoline engine management system with Spray Stratified Gasoline Direct Injection Multec 20 Injector and Multi Charge Ignition system. The new spray stratified gasoline direct injection (GDi) system from Delphi reduces CO2 emissions and delivers the performance needed for premium engines at a significantly lower cost than conventional piezo technology. With solenoid technology that delivers outstanding spray performance, Delphi's spray stratified GDi system improves fuel economy while reducing engine noise and harmful emissions. Due to the use of conventional solenoid-actuation, the Multec 20 Injector driver hardware is the same as for homogenous gasoline direct injection applications: therefore the electronic control unit (ECU) can also be used without modifications. This technology is helping manufacturers meet more stringent future CO2 standards by improving engine efficiency, is ethanol compatible and helps reduce engine noise. To further increase the operating range and improve fuel economy on stratified GDi engines, Delphi has developed a Multi-Charge Ignition System. The system features a single coil-per-cylinder control and fires the spark plug quickly and multiple times per combustion event to enable optimized combustion. The Multi-charge Ignition ensures therefore initiation of robust combustion and compensation of fuel spray variation. As a result, Delphi's MultiCharge Ignition provides an array of benefits for GDi, but the emission control may be the most valuable over the long run. Indeed, cold start is an area where emissions can really be lessened, and the multi charge takes advantage of this window to decrease emissions immediately.
An increasingly important strategy for efficiency improvement is to reduce the parasitic losses associated with engine ancillaries. Delphi's new fuel pump, due to become available by 2012, uses a next-generation brushless motor architecture and delivers reliable, uninterrupted fuel flow at system pressure. It also delivers high efficiency, improved durability, wide-ranging fuel compatibility (gasoline, diesel, alcohol mixes and even contaminated field fuels) and a 1-2g/km CO2 reduction compared to conventional fuel pumps. With Delphi's brushless fuel pumps, power consumption is reduced by approximately 36 percent (or more, depending on application). The reduction in power consumption contributes to an estimated fuel economy improvement of 0.2 mpg (0.12 l/100 km). 
Development of economical, environmentally friendly vehicles is important to the auto industry's future. Building on more than 70 years of automotive electronics experience, Delphi is focused on reducing the cost of hybrid power electronics while, designing in market-leading functionality and reliability. We consider the rigorous electrical requirements of connection systems and wiring thermal management needs in our designs. Key power electronics products include battery pack systems, inverters and DC/DC (direct current to direct current) converters.
After the air compression process that occurs in a turbo- or super-charged engine, cooling the engine intake air with a coolant-to-air heat exchanger offers many benefits over conventional air-to-air charge air coolers. The flexibility of Delphi's Liquid Cooled Charge Air Cooler (LCCAC) designs allows the coolers to be incorporated into the ducting between the forced induction device and the engine or integrated into the intake manifold, minimizing the under-hood packaging impact and the air-pressure losses through the cooler. LCCAC's eliminate the large diameter elastomeric tubing used to route the charge air to the air-to-air charge cooler and the large diameter connectors that can lead to warranty problems. Engine response time during acceleration is improved because of the smaller volume of air between the induction device and engine and the high-transient thermal capacity of the liquid cooled system. This higher thermal capacity also helps to limit NOx peaks during transient driving conditions by maintaining cooler inlet air temperatures. For cold starts, coolant flow can be limited to increase engine warm-up rate and reduce the time for the catalytic converter to reach light-off temperatures. During partial load conditions, coolant flow can also be limited to reduce air density allowing a greater opening of the throttle valve, which helps to reduce engine-pumping losses. Additionally, Delphi's wide array of heat exchangers can be modified to fit any size engine allowing for greater automaker flexibility and packaging.