GDI Systems
Gasoline Direct Injection technology (GDI) is rapidly increasing its market penetration, especially in Europe.
According to Magneti Marelli experience, the most efficient technological combination for small/medium cars is a GDI homogenous turbocharged engine.
In fact high fuel pressure, combined with fast and stable electromagnetic injectors and appropriate control algorithms in the Electronic Control Unit (ECU), allows good combustion in turbocharged engines with negligible soot formation.
The same level of torque and power can be achieved by significantly smaller engines producing an up to 13% reduction in CO2 emissions.
In fact high fuel pressure, combined with fast and stable electromagnetic injectors and appropriate control algorithms in the Electronic Control Unit (ECU), allows good combustion in turbocharged engines with negligible soot formation.
The same level of torque and power can be achieved by significantly smaller engines producing an up to 13% reduction in CO2 emissions.
Magneti Marelli GDI system consists of the Electronic Control Unit (ECU), with its own software, the GDI injectors, GDI intake manifold and the GDI pump.
All components are fully compatible with gasoline and ethanol blend at any % (E0….E100).
All components are fully compatible with gasoline and ethanol blend at any % (E0….E100).
Gdi electronic control unit
The ECU manages all the GDI system functionalities:
- Full torque management (Magneti Marelli is in production with Torque Based & Safety systems since 1999)
- Turbo management
- Homogeneous/Stratified management
- Swirl/Tumble Air Motion Actuator management
- Multiple injection management (high pressure pump and injector)
- Fuel Volatility Recognition Strategy & Fuel Composition (GDI ECu can use mixture of gasoline and ethanol in any percentage (from 0 to 100%))
- Valves opening management
- EGR management (with estimation of inert gas recirculation with lambda >1)
- NOx trap management
- NOx controller management
- Exhaust line and catalyst models management
The ECU hardware consists of new generation chip sets equipped with Freescale microprocessors, 32 bit ESYS generation.
One of the main characteristic of Magneti Marelli GDI software solution is a “robust” design based on:
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A layered software architecture which is easy to shift on more recent generation ECUs capable of greater performances
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A model based algorithms
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A certified SPICE 2 development process
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An AUTOSAR orientation
In addition, time to market is noticeably reduced due to possible pre-calibration on simulation environment.
Magneti Marelli GDI software can also be rapidly prototyped and supplied with computer aided software code generation which can be fully co-designed, following defined design rules, according to customer needs.
Gdi injectors
Magneti Marelli injectors can reach a pressure of 220 bar.
The advantages of the 220 bar multihole technology are various: first, it is characterized by a high flexibility in spray morphology, regarding both the numbers of holes and the spray cone direction.
It is also possible to perform a more homogenous particle spatial distribution.
Second, a minimal influence of back pressure on spray geometry has been detected, as well as a lower influence of air motion on spray geometry.
In addition multihole injection technology enables to obtain a better droplet size and speed at higher pressure (over 100 bar).
Our multihole and Swirl injectors are appreciated for spray formation and penetration in the combustion chamber.
They are specifically conceived for the coking reduction and they are also ethanol compatible.
They can be easily and rapidly customized.
Gdi pump
Magneti Marelli is developing a low cost single cylinder pump to follow the market request.
The main features are:
The main features are:
- Fuel pressure 200 bar
- Flow control with electromagnetic actuator on inlet valve
- Fuel flow up to 1 cc/cam revolution
- Integrated relief valve
- Integrated variable feed pressure damper
- Flow control valve with reduced dimensions and weight
- Body shape optimization for compactness and weight reduction
- Stainless steel, fully compatible with ethanol (up to E100)
Gdi intake manifold
Magneti Marelli GDI intake manifolds are designed using the most recent available technologies, with large employment of CAD-CAE tools and simulation SW.
We can choose together with our customers an optimal configuration of the plenum and runners and define innovative tumble systems, with flaps rotating inside the runners.
This permits to reach the target: better combustion control, lower pollution emission and high power from the engine.
This permits to reach the target: better combustion control, lower pollution emission and high power from the engine.
This system uses a special flaps shape that allows total disappearing of the flaps themselves when maximum power is required.
The position/orientation of the flaps is continuously detected and communicated to the engine control using a rotation sensor joined with the shaft that actuate the flaps.
The rotary sensor can be contact type or contact-less type, depending on the system and on the customer requirements.
The rotary sensor can be contact type or contact-less type, depending on the system and on the customer requirements.
The intake manifolds are produced with thermoplastic material PA6 or PA66, by shells joint using vibrations.
For components requiring special characteristics, like thermal and geometric stability or resistance to high level of stress, special plastic material or stainless steel is used, but only when strictly necessary, in order to reduce costs.
Each intake manifold is provided with up to date Drive By Wire Throttle Bodies also designed and manufactured by Magneti Marelli according to the latest automotive market specification, used to control the entering air mass flow.
Magneti Marelli intake manifolds designed for GDI systems are not provided with locations for injectors because they are directly connected with the engine head, supporting a better combustion of the air/fuel mixture.