Delphi Automotive Systems is to supply what it claims is the world’s most advanced common rail diesel direct injection system for Ford’s new European market Focus TDCi, to be launched next May.

Delphi says Ford chose its Multec DCR 1400 system because of its outstanding technology and emissions performance.

“Ford will be one of the first vehicle manufacturers to use a high performance second generation common rail direct injection system,” said Delphi’s vice-president Jose-Maria Alapont.

“Our technology allows a substantial advance in performance, economy, emissions and comfort. It introduces levels of refinement that compete on equal terms with the best petrol engines.”

Delphi is claiming a number of unique technical innovations including the introduction of the first closed-loop control system for diesel engines.

Called Accelerometer Pilot Control (APC), it allows the engine management system to analyse the quality of the combustion. Information from the APC allows injection to be adjusted as conditions change, ensuring that the system is always calibrated correctly.

The major benefit of APC, combined with a new generation, fast-acting compact solenoid injector, is that it allows exceptionally precise control of pilot injection.

These tiny volumes of fuel, injected before the main injection pulse, smooth the start of combustion, eliminating the pressure spikes that produce the ‘clatter’ associated with previous generation diesels.

Delphi Multec DCR 1400

Existing technologies can provide a single pilot-injection event with a volume of around 1-2 cubic millimetres at low injection pressures, but typically suffer from reduced metering accuracy during their life on the car, at idle or higher pressure.

Engine designers need both low pressures for quiet idle and higher pressures because this allows cylinders to be fuelled more quickly and to have a better spray pattern, leading to improved torque and reduced smoke.

The Delphi system allows pilot volumes across the pressure range that remains stable between injectors throughout the engine life.

A second significant innovation is the introduction of an inlet-metering valve that controls the amount of fuel being pressurised. When the full pressure is not required, less energy is expended, leading to further fuel economy gains. The technique also allows a cost saving through the elimination of fuel cooling systems.

The use of fast actuation on the injector control valve also eliminates the need for a costly and inefficient rail pressure discharge valve.

Delphi is making its new diesel injection system in super-clean facilities in La Rochelle, France, and Barcelona, Spain.

Dominique Chauvin, European managing director of Delphi energy and chassis systems expects the injection system to maintain its outstanding refinement throughout its life.

“APC allows engines to recalibrate as their characteristics change, eliminating completely this problem,” he said.

Chauvin expects that in 2005 diesel will account for more than 40 percent of European new car sales compared with around 35 percent today.

To view related research, please follow the links below:-

Diesel Engines & Parts to 2003

Ford Strategic Review