Common sense: Delphi launches new third-generation diesel common rail system

Automotive Industries,  Nov, 2002  by Peter Mullins

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Launched at the recent Paris Motor Show, the next-generation of Delphi's common rail diesel fuel injection system, the Multec DCR 1600 succeeds the present Multec DCR 1400 currently being used in a number of European cars. The new system provides increased injection pressure-from 1400 to 1600 bar-and increased accuracy of control for very small volumes of fuel. It also introduces the option of up to five injection events during the combustion cycle.

While fitted with a simple oxidation catalyst, Multec DCR 1400 complies with Euro 3 emissions regulations. The new Multec DCR 1600 complies with Euro 4 when fitted with existing oxidation catalysts on small/medium cars with high power density potential. On larger vehicles weighing more than 3,300 lbs., after-treatment systems like particulate filters and NOx traps are being investigated.

"This new injector allows Delphi to provide customers with two advanced technology options to bring value to the vehicle and ultimately to the end consumer," notes Jose Maria Alapont, president Delphi Europe, Middle East and Africa and vice president Delphi Corporation. "This is an important milestone towards meeting Euro 4 and future Euro 5 requirements for lower emissions."

The technology used in both 1400 and 1600 systems is similar. It is based on solenoid injectors with balanced valve and feedback control strategies.

"Combined with the location of the solenoid close to the needle, this provides extremely fast actuation and precise metering, even in high-pressure applications of up to 1,600 bar," explains Dominique Chauvin, manager director Delphi Energy and Chassis Systems Europe. "The fast, ultra-compact solenoid requires less energy than other systems currently in production and operates at battery voltage. This allows for a simpler and more cost-effective electronic design."

Using a combustion feedback system called accelerometer pilot control (APC) the Multec 1600 common rail is further refined to control both pilot and main injection. This closed-loop control allows the engine management system to reduce engine noise and emission levels very effectively. Consistent engine performance is maintained throughout the life of the vehicle. Information from the APC enables each injector to be driven individually with the result that pilot and main injection are always matched to the ideal calibration.

Delphi points out that it has been a leader in another common rail system innovation--an inlet metering valve that controls the amount of fuel being pressurized. This development effectively obviates the need for a high-pressure discharge valve mounted on the rail as well as reducing the need for expensive fuel coolers.

According to Delphi executives, common rail technology for passenger cars is on a fast growth curve. The company has supplied over one million systems to date and sees this business expanding to more than 2.5 million systems a year by 2006. Delphi is clear that higher-pressure systems--possibly up to 1800 and 2000 bar--will be needed to cope with the more stringent emissions standards predicted for the future. The company is also forecasting the introduction of an accumulator piezo diesel injector in the future.

"Demand for precision diesel systems is growing at a strong rate as customers experience the odorless, smokeless performance of contemporary, clean diesel vehicles," observes Guy C. Hachey, president, Delphi Energy and Chassis Systems. "Delphi is positioned to meet customer and consumer needs with a strong engineering team along with innovative solutions."

Delphi Europe says it has achieved record growth during 2001 and the first half of 2002 will be equally good. During 2001, the company's European operations received new orders with a lifetime contract value of $6.2 billion. The figure to date for 2002 is $3.0 billion. Delphi Europe expects that sales for 2002 will amount to over $5 billion, up 37 percent since the company obtained independence from GM in 1999.

RELATED ARTICLE: Delphi Secures $2.5 Billion Contract With Renault

Delphi Corp. has secured a major contract with an estimated lifetime value of $2.5 billion to supply Multec DCR 1400 common rail diesel injection systems to Renault.

Commenting on the contract, Jose Maria Alapont head of Delphi Europe, said: "We are delighted to have developed the second-generation diesel common rail system with Renault and to sign this very important contract The jointly-developed advanced diesel common rail technology provides better performance, noise reduction, greater refinement and lower fuel consumption and emissions--all key factors differentiating diesel vehicles in an increasingly competitive market."

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