Delphi Automotive has just started production of its ground-breaking common rail technologies for heavy-duty diesel fuel injection equipment (FIE) that will meet the requirements of Euro VI and other demanding global emissions standards. As production begins on these first applications, Delphi continues to work on the next generation of ultra-high-pressure systems for 2020 and beyond. The new systems provide a choice of three architectures, allowing vehicle manufacturers to select the best solution for their engines: conventional remote pump common rail (F2R) and two common rail systems with distributed pumps; F2E for overhead cam-driven pumps; and F2P for pumps driven by a cam in the block.
Working at up to 2,700 bar, they combine the proven high-pressure capability of Delphi’s popular EUI/EUP systems with the fast, high-pressure fuel delivery over the entire range of speed, timing and load that can be achieved with common rail.
For engine designers upgrading the existing EUI or EUP power units, the two distributed pump systems offer an ideal progression with minimal changes to engine architecture.
“Between now and mid-2013, we will be entering production with each of these three systems for customers launching ranges of new and revised engines from 9 to 16 liters. Delphi secured three contracts for these systems for a lifetime value expected to exceed 3.7 billion euros,” said Mr. David Friday, Managing Director, Delphi Diesel Systems (Heavy-Duty). “To achieve this while retaining Delphi’s outstanding record for consistent high quality, we have made significant investments in our facilities around the world, including our sites in Stonehouse and Sudbury in the U.K.”
Latest technology for developing markets
A low-cost common rail fuel injection system for heavy duty diesel applications is also being developed in order to cater to the requirements of emerging markets.
The new system uses the latest technology to deliver improved fuel economy and allows upgrades to meet future emissions standards. It comprises a high-pressure pump, rail assembly, electronic controller and state-of-the-art injectors.
Suitable for engines with a displacement of 9 to 16 liters, the system provides a maximum rail pressure of 1,800 bar, allowing compliance with China 4/5 emissions standards.
“Key challenges are cost, local manufacturability, an affordable upgrade to future emissions standards, diverse fuel qualities, robustness and fuel economy, which is a fundamental driver of vehicle choice,” said Mr. David Draper, Engineering Director, Delphi Diesel Systems (Heavy-Duty). “Rather than start with a low-cost, older system and work forward, the team started with Delphi’s portfolio of advanced fuel injection technologies, carefully selecting appropriate components and then optimizing them for the unique requirements of the new application”, he added.