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In 2002 Orbital completed an extensive development and application
program of its OCP DI4s (gasoline direct injection) technology.
This was a program involving a full range of engineering aspects
from cylinder head concept to running vehicle demonstrator. The
program was engineered and managed by Orbital for the European division
of a major worldwide automotive OEM.
Objectives:
- design a new 2-valve, 4 cylinder variant
of an existing production engine
- feature the close integration of Orbital's
direct fuel injection technology
- demonstrate capability to achieve production
sign-off
- manufacture several engine hardware sets
- engine dynamometer and vehicle calibration
Milestones:
- over 15% less fuel consumption
- Euro IV emissions capability
- Rapid project turnaround through discriminating
use of SCRE and multicylinder development engines
Experience gained:
- Clean sheet cylinder head design
- Valvetrain analysis using VALDYN
- WOT camshaft optimisation using WAVE
- In-cylinder modeling and spray interaction
using Star-CD
- Localisation of complex cylinder manufacturing
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