Automotive Supplier Shares Vision on Technologies That Are Shaping the Future
PARIS September 9, 2009; In advance of the 2009 edition of the IAA International Motor Show in Frankfurt (Germany), Delphi Corporation , a leading global automotive supplier highlights 'green' technologies that will equip the car of the future. To help address global fuel conservation efforts and increasing concerns about global warming, car makers are accelerating the introduction of technologies that reduce fuel consumption and cut emissions of all pollutants. By leveraging its rich heritage and extensive technical knowledge, Delphi provides robust solutions to complex challenges, helping car makers develop vehicles that offer enhanced performance and reduced emissions. For further information on any of the technologies mentioned below, interviews with Delphi subject matter experts can be scheduled upon request.
Power Electronics
Delphi designed and manufactured the major
electronic and electrical components of the first modern electric vehicle
in the early '90s. The company remains committed to developing innovative
hybrid electric vehicle technologies that will increase fuel economy,
reduce emissions and help make hybrid vehicles an appealing choice for
consumers. Delphi inverters, DC/DC converters, controllers, energy storage
systems and stop/start systems are helping to make HEVs a more popular
choice by providing peak performance, resolving packaging challenges and
lowering cost. Delphi innovation will soon include integrated Power
Electronics and Lithium-ion (Li-ion) energy storage systems to be offered
to vehicle manufacturers.
Delphi power electronics are currently on the road in the Ford Fusion, Ford Escape, GM Tahoe and Cadillac Escalade. With the growth in hybrid vehicle popularity, these products will appear on more vehicles globally.
Integrated Inverter, DC/DC Converter, Controller System
Today's
hybrid and electric vehicles require an inverter to manage power
requirements for propulsion, a controller to intelligently control multiple
functions, and a DC/DC Converter to manage voltage between the battery pack
and the vehicle accessory systems. The integration of these products into a
single unit coupled with Delphi's patented power silicon ICs will result in
the same high performance and high reliability as the individual components
while lowering cost and reducing mass.
Expected on the roads : Delphi's integrated power electronics systems are expected on the road as early as 2010.
Lithium-ion Energy Storage Systems
Delphi's hybrid energy storage
systems are designed to meet specific customer requirements for energy and
performance. The systems monitor and control high-voltage contactors within
the bussed electrical center to maintain occupant safety, as well as
calculate battery state-of-charge (SOC) and available power to the
vehicle's energy system controller. These systems also maintain the health
of the battery cells by monitoring and managing voltage, current and
temperature while improving their performance and life. Currently,
nickel-metal hydride (NiMH) battery packs pervade the market, but Li-ion
batteries will soon displace them as they reach cost parity. Li-ion
batteries have higher energy density, weigh less and can be
charged/discharged more often without the degradation seen in other
rechargeables. They also have a lower self-discharge rate so they retain
their charge longer.
NiMH energy storage systems are currently available on the Ford Fusion and Ford Escape. Li-ion systems will be introduced in the market as early as 2010.
Revolutionary Direct Acting Diesel Fuel Injection System
The
Direct Acting Common Rail (CR) from Delphi represents a radical
break-through in diesel injection technology as, for the first time, the
injector needle is directly activated by the piezo stack, removing the
hydraulic circuit and its associated lag and energy consumption. This
change enables vehicle manufacturers to comply with future emission
legislations while providing more power and uncompromised fuel economy.
This technology is currently available and was launched as a world premiere on the Mercedes C-Class in 2008.
Spray-Stratified Gasoline Direct Injection with Multec 20 injector
The new spray-stratified gasoline direct injection (GDi) system from Delphi
reduces CO2 emissions at significantly lower costs than traditional
systems. With solenoid technology that delivers outstanding spray
performance, Delphi's spray stratified GDi system improves fuel economy
while reducing engine noise and harmful emissions. Spray stratified GDi,
also known as "lean" burn GDi, uses less fuel by creating a stratified
charge with a stoichiometric air-fuel ratio near the spark plug with no
fuel outside the mixture plume in the remainder of the chamber. The Multec
20 injector delivers the performance needed for premium engines at a
significantly lower cost than conventional piezo technology. This
technology is helping manufacturers meet more stringent future CO2
standards by improving engine efficiency and is ethanol compatible while
helping reduce engine noise.
Expected on the roads: In development for production in 2012.
Multec Homogeneous GDi Fuel Injector with its multi-hole spray generator enables optimum charge distribution for more efficient combustion. The system delivers more precise fuel injection for a "cleaner" engine and it's an enabler for boosting and downsizing -- a key strategy for reducing fuel consumption and helping OEMs meet future standards.
Expected on the roads: Homogeneous GDi is in development for production in 2010.
High efficiency fuel pumps are designed to require a lower electrical load which can help reduce CO2 emissions. Delphi's new brushless fuel pump technology features a unique pump motor architecture with lower internal resistance to help reduce CO2 emissions even more.
Delphi's high efficiency fuel pumps are currently in production, with brushless technology in development for production in 2012.
Automotive ammonia sensor -- New technology allows closed loop control of Selective Catalytic Reduction (SCR) systems, reducing NOx. and helping diesel owners save money. Delphi has developed the world's first automotive ammonia sensor. By directly measuring tailpipe ammonia, the sensor allows the injection of urea (an ammonia rich compound required by the SCR system) to be optimized and ammonia emissions reduced.
Control of urea injection is expected to become a rapidly increasing priority as SCR levels increase to meet new emissions regulations in both light and heavy duty diesel markets.
Solid Oxide Fuel Cell Auxiliary Power Unit is a high-efficiency electrochemical generator that provides up to 5 kW of reliable, environmentally friendly electrical power for a wide range of transportation and stationary uses. This ultra-clean -- near zero emissions -- power generation source operates independent of the main engine. In addition to its high fuel-efficiency, it also offers fuel flexibility and low noise.
Expected on the roads : This SOFC Power Unit is in development for production in 2012.
Advanced electrical/electronic architecture -- Delphi is currently working on electrical/electronic architecture technology to reduce bundle sizes, lower mass, and make use of advanced automation processes to enable smaller gage cables. Advanced products such as aluminum cable, Ultra-Thin-Wall Halogen-Free Cable, high conductivity alloys and miniaturized components such as waferized connectors all help automakers deliver more functionality without requiring more space. By reducing mass, many of these advancements also help reduce CO2 emissions and improve fuel economy and will continue to do so long into the future.
Expected on the roads : Many of the technologies are available today. Advanced electrical/electronic architecture systems are expected on future vehicles in the coming years. Aluminium cable is expected to be introduced early in the next decade. Ultra-Thin-Wall Halogen Free Cable is already on the roads.
Electrical/electronic architecture for hybrid vehicles -- Hybrid vehicles have rigorous power requirements and demand robust component performance in a challenging environment. Understanding the needs and requirements of these systems allows Delphi to propose the right combination of standard components and customized architectures for each hybrid application. A number of complex factors in the electrical system must be addressed and engineered for reliability and peak performance to keep drivers safe in high-power environments.
As vehicles of the future begin to rely more on hybrid solutions, Delphi is prepared to support automakers with the proliferation of this technology.
Halogen-free ultra-thin-wall cable
A new, highly-durable
automotive cable with significantly lighter and thinner insulation than
traditional cable, the Halogen-Free Cable, a recyclable and
environmentally-friendly product, is free of dangerous halogens and offers
excellent pinch resistance, nearly double that of traditional cable, and
outstanding abrasion resistance. The use of this advanced cable also leads
to size and weight reductions in the cable that, in turn, results in lower
fuel consumption and reduced CO2 emissions.
Expected on the roads : After making its debut on the 2007 Toyota Tundra, Delphi Halogen-Free Ultra-Thin-Wall Cable is now being produced for multiple vehicles from three major automakers. It is an environmentally responsible alternative to conventional cable such as polyvinyl chloride (PVC) and cross-linked polyethylene (XLPE).
Battery Monitoring Device
As automakers and drivers heighten their
focus on fuel economy and concern for the environment, Delphi expects to
experience a growing demand for its Battery Monitoring Device, an electric
innovation that calculates the battery state of health (SOH) and state of
charge (SOC) and alerts drivers to the need to replace or charge the
battery. The device helps ensure optimal battery performance, making more
electronic features possible while ensuring sufficient power for starting
the engine. When integrated into a vehicle as part of active energy
management system, the Delphi Battery Monitoring Device can also help
improve fuel efficiency and extend battery life.
Expected on the roads : 2011
Use of phase change materials (PCMs) to cool or warm hybrid cars
Phase change materials (PCMs) are ideal for use in hybrid vehicles or
vehicles with start-stop capability. Delphi has developed a unique solution
that integrates PCM into current heat-exchanger technology, using existing
packaging space. This "Thermal Storage" system with PCM enables a hybrid
vehicle to store excess thermal energy while the engine is running and then
releases this energy during engine off idle stops to maintain comfort in
the car. Use of PCMs allow hybrid vehicles to turn the engine off while the
vehicle is stopped, greatly improving fuel economy, without sacrificing
occupant comfort. Similar technology is used in warehouses where PCM
material is charged in the evening (when the electric rate is low) and then
used to cool the interior of a building during the day (when the electric
rate is high). Thermal Storage systems with PCM allow hybrid vehicles to be
more efficient and keep vehicle comfort more consistent.
Expected on the roads: PCM thermal storage may be available starting in 2012.
Internal Heat Exchanger
Delphi's counter-flow, tube-in-tube heat
exchanger transfers the refrigerant from the evaporator outlet back over
the refrigerant headed to the evaporator. The refrigerant then returns to
the compressor. The system efficiency is increased by providing supercooled
liquid to the evaporator. Concurrently, the compressor's efficiency is
increased by the consistent supply of superheated refrigerant and by
maintaining the evaporator close to saturation. This is important to the
car of the future as it enables the increased capacity required for the new
alternative refrigerant -- R-1234yf -- along with the simultaneously
increased energy efficiency.
Expected on the road : Delphi's Internal heat exchanger technology will help improve energy efficiency starting in 2011.
Liquid Cooled Charge Air Cooler (LCCAC)
Delphi is developing a
LCCAC portfolio to add to its industry-leading Air-To-Air Charge Air Cooler
portfolio. 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 LCCAC's 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 lightoff 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.
Expected on the roads: Delphi's innovative LCCAC is expected on the roads in 2011.
Innovation for the Real World
Delphi brings the power of innovation to a wide range of products and services that add value for car makers and car drivers alike. From vehicle components and systems to medical devices and beyond, Delphi delivers real-world innovations that help make products smarter, safer, more powerful, and much more valuable.
For more information about Delphi Corp., visit www.delphi.com.