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Green Technologies Increase Fuel Economy, Reduce Emissions

Delphi helps manufacturers lessen environmental impact with products that improve fuel economy, lower emissions, and enable sustainability.

With an ever-growing emphasis on being "green," vehicle manufacturers around the world are relying on Delphi to help provide transportation technologies that are more eco-friendly. By expanding development capabilities, committing resources, and leveraging proven manufacturing techniques, Delphi is offering its customers sustainable, green innovations that will help protect the environment, while fully answering the needs of today's marketplace.

Green Never Goes Out of Style

Green is more than a trend at Delphi. Delphi is committed to putting real-world innovations on the road. The company is investing in technology that is helping vehicle manufacturers improve fuel economy and reduce emissions while offering high-performance products. Delphi is also helping make affordable hybrid and electric vehicles a reality.

"Development of economical, environmentally friendly vehicles is key to the auto industry's future," noted Denis Ulicny, Delphi director, hybrid electric vehicle business development. "With our experience and commitment, Delphi is positioned to help create a greener, more fuel-efficient future."

Delphi's "go power" is evident. In addition to strategically located technical centers and manufacturing sites in 32 countries around the globe, our "green" commitment is fueled by:

• Hybrid Development Center. In Champion, Ohio, USA, Delphi is developing hybrid-specific technologies for its customers' unique electrical/electronic (E/E) architecture requirements. With a team of designers and engineers and an accredited, full-service test facility, Delphi's Hybrid Development Center is generating new ideas and products for hybrid vehicles. Hybrid E/E architecture expertise is also front and center at Delphi's Technical Center in Wuppertal, Germany, and other sites around the globe.
• Power Electronics Development and Launch Center. From research and development to prototyping and test to product launch, Delphi's innovative power electronics designs are helping to reduce cost, resolve packaging challenges, and provide peak performance while offering the flexibility required for affordable hybrid and electric vehicles.
• Next Generation Research and Development. In 2007, Delphi was selected by the U.S. Department of Energy (DOE) to lead an industry-government team to develop the next-generation propulsion inverter for hybrid vehicles. With $3 million (U.S.) invested by the research and design team and $5 million contributed by the DOE, the project was designed to help reduce the cost and size of inverters for electric propulsion systems by 50 percent or more to provide the lower-cost technology needed to advance hybrid and electric vehicles in the marketplace.
  
  Delphi is continuing to apply for grants to support the expansion of our power electronics business. In August, 2009, the U. S. DOE announced the availability of $500 million (U.S.) in grants to United States-based manufacturers to produce electric drive components for vehicles, including electric motors, power electronics, and other drive train components. Delphi's application entitled "Low-Cost US Manufacturing of Power Electronics for Electric Drive Vehicles" was selected for negotiations leading to an award size of $89.3 million (U.S.) DOE funds. "This grant validates our expertise and helps accelerate our plans to provide products that make vehicles safer, greener, and more connected to consumer and environmental needs than ever before," said Jeff Owens, president, Delphi Electronics & Safety.

Green Means Hybrid Vehicles Today, Electric Vehicles Tomorrow

The automotive industry helps keep our world "going." Along with that role comes the responsibility of designing products with efficient use of fuel in mind. Government regulations, consumer demand, and environmental concerns have made conscientious use of fuel a number one priority both in the global vehicle market and at Delphi.

"It's a 'perfect storm' of factors that all lead to the same conclusion," said Dr. Andrew Brown, Jr., Delphi executive director and chief technologist. "The proliferation of hybrid and electric vehicle technology is forecasted to steadily increase in the short term, and then we expect to see a rapid progression to fully electric vehicles. From power electronics to electrical/electronic architecture to electric propulsion systems and thermal management, Delphi is developing and implementing real-world solutions that help our customers address environmental needs, peak performance and consumer demand."

Fuel Economy and Performance

With more than 70 years of automotive electronics experience, Delphi provides power electronics for hybrid and electric vehicles that are high-value and extremely reliable while offering peak performance. Since 2000, more than 100 Delphi patents have been issued for power electronics and advanced energy systems. This technological foundation helps Delphi offer customers the products they need to succeed in the fast-growing hybrid and electric vehicle market. Key products include inverters, battery management controllers, battery pack systems, and battery chargers.

Hybrid and electric vehicles present unique challenges when it comes to E/E architecture. They have rigorous power requirements and demand robust component performance and additional safety features due to the challenging environment in which they operate. Delphi is developing hybrid-specific E/E architecture technologies including harness protection systems, battery monitoring devices, and a new series of connection systems that incorporates the shielding, sealing, and high-voltage safety interconnects required for high-voltage/high-power applications.

Delphi gasoline and diesel engine management systems are capable of being seamlessly integrated with hybrid vehicle architectures. Delphi has developed software that caters specifically to integration of the internal combustion engine with the additional propulsion and regenerative braking of a hybrid electric vehicle. Products like Delphi's variable valve timing, variable valve lift, energy-efficient air conditioning including compressors, and electronic powertrain cooling play a powerful role in helping reduce fuel consumption.

To address the thermal challenges of traditional heating and cooling technologies, Delphi has developed a phase change material storage system that allows a hybrid vehicle to store excess thermal energy while the engine is running and then release it during "engine off" idle stops to maintain constant comfort in the vehicle.

Reducing Emissions

Innovative Delphi electronics are also enhancing — even replacing — mechanical systems to help improve performance and lower greenhouse gas emissions. "In the U.S., about one-third of carbon dioxide emissions come from transportation. That's more than the CO₂ emissions from factories, homes, and all other sources," said Dr. Brown. "At Delphi, we are working closely with manufacturers to produce hybrid and electric vehicles that will help reduce CO₂ emissions significantly. But even before those vehicles are commonplace, we are offering our customers products that can also improve emissions control for conventional vehicles." In addition to power electronics, these revolutionary products include Delphi's direct acting diesel common rail system, gasoline direct injection for spray stratified combustion, active scrubber technology, brushless fuel pumps, solid oxide fuel cell auxiliary power units, and alternative refrigerant HVAC technology.

Recyclability

As Delphi grows its green product lines, the company is quickly progressing development of technology that helps keep products out of landfills or incinerators at the end of their lives. "Recyclability has become an important part of our product development," noted Dr. Brown. "Take what seems like a simple thing — solder, for instance. By using lead-free solder in our products, we are reducing their environmental impact and helping to ensure product recyclability." Two examples of environmentally friendly Delphi products are ultra-thin wall halogen-free cable that can be recycled or incinerated unlike PVC or XLPE cable and the micro channel condenser that not only helps residential and commercial air conditioning manufacturers meet mandated energy efficiency ratings with less refrigerant but is also easily recycled.

Sustainability

Sustainability is a business mindset that focuses on the future. It goes beyond today's definition of being "green." Delphi is incorporating sustainability as a guiding principle and helping customers reduce their environmental footprint and help limit use of natural resources. "Having an understanding of environmental, economic, and social issues surrounding transportation is helping us to implement real-world solutions without compromising the needs of future generations," said Vishy Seetharaman, global marketing manager, Delphi Powertrain Systems. Corporate sustainability is executed through many activities designed to lessen environmental impact.

Delphi employees are using their experience to develop and produce green technologies that help reduce the company's carbon footprint. In 2008, Delphi reduced CO₂ emissions at its European operations by more than 6,000 metric tons. The CO₂ reduction program supports efforts to protect human health, natural resources and the environment. Beyond Europe, the company also seeks to proactively minimize the negative environmental impact of its manufacturing processes and of its products and technologies on a global basis.

Innovation for the Real World

In addition to developing new technology, innovating for the real world means anticipating tomorrow's needs and finding the right solutions today. "Delphi is committed to developing innovative technologies that help make the world a better place for us, for our children ... and for their children," said Dr. Brown. "Delphi is partnering with our customers to create green solutions that benefit everyone."

Watch for upcoming articles that highlight more of Delphi's green product expertise and its dedication to green technology today.