Delphi Automotive has announced it was awarded two Automotive News PACE (Premier Automotive Suppliers’ Contribution to Excellence) Awards.
Delphi took top honors in the manufacturing process category for the Multi-Port Folded Tube Condenser (MFTC) and in the product category for the L-Shape Crimp for 0.13 mm2 wire size. Additionally, Delphi was a finalist for the Premium Low Noise High Pressure GDi Fuel Pump in the product category and for the Wiring Harness Bend Fatigue Simulation Tool in the information technology category.
“PACE awards recognize the best of the best in the supply industry,” said Jeffrey Owens, Delphi chief technology officer. “This independent and expert recognition acknowledges all of the hard work we do to develop and produce technologically-advanced and market-relevant products.”
Presented annually to coincide with the SAE World Congress, the PACE awards recognize superior innovation, technological advancement and business performance by automotive suppliers. The judges are independent, distinguished and highly-experienced industry representatives focused on real-world benefits available from innovative technologies.
Multi-Port Folded Tube Condenser (MFTC)
In automotive air-conditioning, the condenser is designed to cool the system by transferring heat from the internal refrigerant — across metal surfaces — to the outside air. For condensers, more metal surface area means better performance. Conventional condensers use multi-channel extruded tubes to provide the surface area needed for effective heat transfer. Extruded tubes, however, are heavy and can require costly, complex manufacturing processes.
Delphi’s MFTC design uses parallel, tube-like channels for the heat transfer surfaces. These channels are formed by folding a metal strip back on itself several times. By replacing extruded tubes with folded tubes, condensers can be manufactured in significantly less time than it takes to produce a conventional condenser, eliminating costly production steps and saving valuable resources.
The improved design results in reduced refrigerant pressure drop and higher heat transfer capability in a lightweight, compact condenser. For consumers, this translates into better fuel economy and reduced noise and vibration while driving.
Delphi is a leader in miniaturization, including the development of small wiring (0.13 mm2 or 26 gauge) and terminals. In developing this technology, Delphi was challenged to effectively find a way to attach the terminals to the thin wiring. Delphi’s L-shaped Crimp addresses this challenge by offering two distinct crimp areas — one for optimized mechanical performance and one for optimized electrical contact. The mechanical area of the crimp provides low compaction rates for high pull-out forces, while the electrical area provides optimal electrical properties with high compaction.
The L-shaped Crimp’s patented design separates the mechanical and electrical functions of the crimp to allow for independent adjustment — an important feature for the automated assembly of wiring harnesses. Furthermore, Delphi’s L-shaped Crimp optimizes electrical contact by allowing the independent adjustment to optimal crimp height in each functional area.
Premium Low Noise High Pressure GDi Fuel Pump
Delphi’s new premium gasoline direct injection (GDi) pump is designed to mitigate a common complaint about the gasoline direct injection engine: noise. As GDi systems grow in popularity, drivers may notice the louder noise associated with engines operating at higher fuel pressures.
To help reduce GDi noise, the pump engineering team redesigned the pump’s moving components to hydraulically slow the impact of moving parts during operation.
Delphi also enhanced the engine management system’s control of the pump control valve to further reduce noise. Delphi engineers created an adaptive control algorithm that learns the minimum energy required to drive the spill valve and provide a custom drive signal for activation of each unique control valve ensuring low noise.
Wiring Harness Bend Fatigue Simulation Tool
Allowing vehicle designers and engineers to shorten the wiring harness design cycle, Delphi’s Wiring Harness Bend Fatigue Simulation Tools helps cut lead time and costs in the design and production of vehicle wiring harnesses.
Traditionally, harness durability could only be evaluated once the vehicle and wiring harness prototype had been designed and built. Cables in that newly designed prototype were physically tested for strength and durability, redesigned and rebuilt, and then tested again — a costly, time-consuming process. Using the new Delphi simulation tool during harness design shortens the process without compromising quality and cost. By applying unique algorithms to data on the physical properties of the cable, grommet, and insulation, engineers can model real-world wiring harness performance before the actual vehicle and harness are built.