Delphi Technologies, which has its North American headquarters in Troy, has revealed its 500+ bar GDi system that can reduce particulate emissions by up to 50 percent compared to the 350-bar system. The system will help manufacturers meet global emissions standards.
The system does not need engine design modifications and reduces the number of exhaust gas particulates, including those smaller than 23 nanometers. Reducing engine-out emissions cuts tailpipe emissions and reduces the need for aftertreatment systems. Delphi entered production at the end of 2016 with its 350-bar GDi system, which reduces exhaust particles by 70 percent compared with industry-standard 200 bar systems.
“The industry has long recognized that increasing injection pressure to 500+ bar could substantially cut engine-out particulates while improving CO2 emissions and fuel economy,” says Walter Piock, chief engineer of gasoline systems at Delphi.
The challenge was to achieve such pressures without increasing the drive loads from the pump. Most engines power the GDi pump through the camshaft drive, so a conventional approach would require a redesign and strengthening of the camshaft mechanism.
“By designing an innovative new internal sealing system for our GFP3 500+ bar pump, in some applications, we have designed a downsized plunger diameter, which prevents increasing the loads in the drive mechanism,” says Piock.
To complete the new system, Delphi has developed all system components including Multec 16 injectors, pumps, forged rail, and an engine control system and software. The components require no or 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 onward.
The company also introduced the Westport High Pressure Direct Injection HPDI 2.0 system in a paper co-authored by Westport Fuel Systems. The system reduces tank-to-wheel CO2 emissions in heavy-duty commercial vehicles through the use of high-pressure natural gas.
The HPDI 2.0 system delivers a CO2 reduction of up to 20 percent. In the case of renewable natural gas, the system can achieve a reduction of almost 100 percent.
The system can be installed on current technology heavy-duty diesel engines and trucks with minimal change.
In April, new regulations took effect in the European Union mandating heavy truck OEMs to provide a 15-percent reduction in average CO2 emissions per truck by 2025 and a 30-percent reduction by 2030, both from a 2019 baseline.
Delphi is headquartered in London.