Delphi's new Common Rail system brings latest heavy-duty technology

A low-cost common rail fuel injection system for heavy duty diesel applications is being developed by Delphi Automotive (NYSE: DLPH). Optimized for 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.

"Vehicle and engine manufacturers in China and other developing markets face tough challenges that are unique to their region,” explained Richard Green, Delphi Diesel Systems (Heavy-Duty) China business director. “When we looked at the best solution from their perspective, it became clear that only a system with a design path through to the latest high-pressure systems would provide the right combination of attributes now and into the future.”

The new system 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 David Draper, Delphi Diesel Systems (Heavy- Duty) engineering director. “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.”

Cost-optimized system with outstanding results

The fuel pump, for example, uses a modular design that eliminates unnecessary capability for the market, resulting in potential cost savings. This strategy also simplifies manufacturing andallows each module to be upgraded as technical requirements change. The lower rail pressure, which creates less fatigue, has allowed cost-optimization of the materials and the manufacturing process. The pressure control valve and electronic control unit also are simplified, as is the electronic control unit, which provides diagnostics and other functionality appropriate to the system performance.

To help ensure class-leading fuel economy, Delphi has specified a proven, high-performance fuel injector that provides the robustness essential for markets with varying fuel quality and other known issues. As well as being highly-durable, these injectors provide the capabilities necessary for efficient combustion, improving fuel consumption and reducing the need for costly aftertreatment.

Delphi supports its customers in China via a global network of diesel R&D, manufacturing and applications support facilities that together employ more than 1,500 engineers. “We believe that a rigorous approach to design and manufacturing has delivered a robust, affordable system with performance that will help our customers provide extremely competitive next-generation vehicles for developing markets,” Green said. “Because it is based on our latest architectures, Delphi customers will have an affordable development path to future emissions standards in their domestic markets and worldwide.”

Delphi Powertrain supplies complete diesel fuel injection systems for light-, medium- and heavy-duty applications in all world markets. Their latest state-of-the-art technology, providing a choice of innovative architectures for Euro VI compliance, is about to enter production for European customers. Delphi also supplies gasoline fuel injection and engine management electronics and is at the cutting-edge of developments in power electronics for electric and hybrid vehicles.