Delphi at the Paris motor show

Please note that what follows is a mildly edited version of Delphi’s press-release.

Delphi Automotive is supplying technologies to a significant number of new vehicles introduced at this year’s Paris Motor Show: diesel injection systems, active safety technology and connection systems.

Delphi’s multimode Electronically Scanning Radar (ESR) provides wide coverage at mid-range and high-resolution long-range coverage to enable multiple safety system features, including ‘intelligent’ cruise control, forward collision warning and automated braking. Wide, mid-range coverage not only allows vehicles cutting in from adjacent lanes to be detected but also identifies vehicles and pedestrians across the width of the vehicle. Long-range coverage provides accurate range and speed data with powerful object discrimination. This technology is featured on the new Ford Mondeo and Volvo V60. The Volvo system fuses radar and camera data to warn drivers of a potential collision with a vehicle or pedestrian and automatically brakes if the driver fails to respond to warnings.

Delphi electronically scanning radar.

The Volkswagen Polo Blue Motion is among the new vehicles currently fitted with Delphi’s Multec modular common rail diesel injection system. Using balanced valve solenoid injector design, this system claims injection performance similar to competitive servo-piezo technologies. Its control strategies enable the system to deliver precise fuel quantities over the life of the vehicle. This system helped the new Volkswagen Polo BlueMotion, voted 2010 World Car of the Year, achieve record low CO2 emissions and fuel consumption — 3,3l/100km and 87g/km.

Delphi’s other technologies include heating, ventilation and air conditioning systems. At the Paris show, Ferrari’s California features fuel-efficient air conditioning technology that helps reduce fuel consumption while maintaining maximum passenger comfort. The system, engineered by Delphi and Ferrari, features an electronically controlled compact variable displacement compressor that reduces the torque absorbed by the system by up to 35 per cent. when using the full automatic HVAC module.

The Ferrari California is also equipped with Delphi’s halogen-free ultra-thin-wall cable. A recyclable and environmentally-friendly product, this advanced cable offers pinch resistance nearly double that of traditional cable and outstanding abrasion resistance. This cabling offers the prospect of significant mass-reduction.

Staying connected continues to grow as a priority for drivers and passengers. Delphi’s connectivity navigation radio’s (CNR) open architecture offers OEMs flexibility and vehicle differentiation. Offering the ability easily to adjust media centre capability to meet the unique needs of individual vehicle models, the flexible media centre design is based on Delphi’s scalable hardware platform and was recently unveiled on the Audi A1. The scalable design also helps to differentiate vehicles.

As system complexity in vehicles increases, so does electrical complexity. Delphi is supplying numerous vehicles with complete wiring assemblies — for example, the Porsche Cayenne, Renault Wind, Volkswagen Touareg, Volvo S60 and V60. Delphi has developed the first smart fuse box that includes a dedicated ECU for enhanced battery management. Thanks to the development of a new high power bi-stable relay that meets harsh automotive environments, the smart fuse box provides significant energy management functionalities that reduce battery sise, weight and total function cost, while protecting the vehicle against short circuits. Optional features, such as an integrated battery monitoring system, can also be offered. It is featured on several new PSA Peugeot Citroën models including the Peugeot 3008 Hybrid4.

Delphi hybrid and electric vehicle technologies include power electronics, electrical/electronic architecture and thermal management.

Delphi’s laser-based head-up display is fitted to the all-electric F-City car in Paris. Although mirror-based head-up displays are readily available, the Delphi system uses laser- and micro-structure-based technologies to generate a virtual image: that is, it is focused at infinity, where the driver’s eyes are focused when he is driving. Delphi claims that its laser HUD is both small and cheap, offering the potential to make head-up displays more widely available.

Other vehicles at the Paris Motor Show with Delphi technologies include:

  • Audi A7 sportback: ultrasonic alarm, LED light controls, connectivity navigation radio, interior harness;
  • BMW Mini E: reception system, interior lighting, switches, ultrasonic anti theft sensor, roof module, engine wiring;
  • Citroën C4: alarm sounder, alarm ultra sonic module, integrated centre panel, various switches, underhood body controller, transponder antenna, rear body controller, diesel electronic throttle body, diesel common rail, EGR valvetrain, cam phaser, ignition coil, oxygen sensor;
  • Citroën DS4: alarm sounder, alarm ultrasonic module, integrated centre panel, various switches, underhood body controller, transponder antenna, rear body controller, condenser, radiator and charge air cooler;
  • Ferrari California: halogen-free ultra-thin-wall cable, connection systems, dual-zone heating, ventilation and air conditioning (HVAC) module with Stop-and-Start function, condenser with integrated receiver drier, latest generation of compact variable compressor, control head and software; and additional system components (including lines and hoses, filters and all pressure and temperature sensors);
  • Ford Focus: interior motion sensing, battery backed sound, adaptive cruise control and electronically scanning radar (ESR sensor), connection systems, wiring harnesses;
  • Ford Mondeo: adaptive cruise control, body computer module, electronically scanning radar (ESR sensor), wiring harnesses, connection systems;
  • Mercedes CLS: DAB Tuner, satellite digital audio reception system, passive occupant detection system, ultrasonic alarm, TV receiver, integrated antenna, ignition PTC, EGR valve;
  • Opel Astra Sports-Tourer: integrated centre panel, ultrasonic alarm, power sounder module, fuel tank wiring harness, CRFM (condenser, radiator and fan module), compressor;
  • Peugeot 3008 HYbrid4: electronic key fob, alarm system, pre fuse block, cruise control, switches, seat heating, selespeed (speed selection control under the steering wheel), CAN gateway, network gateway, body computer module, wiring harnesses, smart electronic fuse control;
  • Peugeot 508: body computer module, switches, condenser, radiator, charge air cooler;
  • Renault Laguna Phase 2: head lamp levelling module and dimmer, switches, connection systems, cam phaser;
  • Volvo V60: adaptive cruise control, forward collision warning, collision mitigation system, passive occupant detection system, electronically scanning radar (ESR sensor), lane departure warning, head-up display, complete wiring, connection systems, electrical centres, body computer module, immobiliser;
  • Volkswagen Passat: radio receiver, ultrasonic alarm, transponder, compressor, charge air cooler (diesel engines).

Electronically scanning radar

Delphi boasts that it is bringing its electronically scanning radar (ESR) to market at a price that will help make radar-based safety and convenience systems more affordable in the automotive market.

The Company’s multimode ESR combines a wide field of view at mid-range with long-range coverage to provide two measurement modes simultaneously. While earlier forward-looking radar systems used multiple beam radars with mechanical scanning or several fixed, overlapping beams to achieve the view required for systems like adaptive cruise control, Delphi’s multimode ESR provides wide coverage at mid range and high-resolution long-range coverage using a single radar. Wide mid-range coverage not only allows vehicles cutting in from adjacent lanes to be detected but also identifies vehicles and pedestrians across the width of the vehicle. Long-range coverage provides accurate range and speed data with powerful object discrimination that can identify up to 64 targets in the vehicle’s path.

Delphi’s ESR offers functionality including adaptive cruise control, forward collision warning, brake support and headway alert — this feature provides distance information and alerts the driver when a preset time-gap to the vehicle ahead is broken.

Small-gauge cable advantages

Smaller is usually better for new vehicle applications. Advances in manufacturing technology such as automated assembly processes continue to enable the trend toward miniaturisation to reduce the size and weight of products. The use of small-gauge wiring in state-of-the-art manufacturing processes will be required by factories of the future.

Products and processes are intrinsically connected. For most product innovations to become reality and to deliver tangible benefits, unique process advances often need to be developed as well. This is the case with smaller gauge cable for vehicle electrical and electronic systems. Not only is it important to be able reliably to manufacture and handle the smaller cables, but it is also necessary to achieve consistency and reliability in their incorporation into the wiring harness assembly.

Delphi light cabling.

Unfortunately, the harsh environment and physical abuse that automotive primary wiring must withstand has previously limited the introduction of wires smaller than 0.35mm² (‘22 gauge’) into vehicle wire harnessing. But Delphi has now developed ways to slim its high-performance cables. Small-gauge wiring — 0.13mm² or 26 gauge — is now part of Delphi’s cabling range. These thin cables are created with advanced materials in both the cable core and the insulation.

These light cables’ high strength is achieved through proprietary copper-alloy construction, allowing the decreased gauge size without sacrificing mechanical performance. The thin cables offer physical properties comparable to current 0.35mm² cable constructions, though only half the size.

Halogen-free thin-wall and ultra-thin-wall 0.13mm² cables are for use in interior and exterior vehicle applications on low-current circuits. They contain no restricted chemicals, such as halogens, heavy metals or phthalates. The insulation on the ultra-thin-wall HF cable is half as thick as conventional coatings: 0.2mm. When compared with PVC thin-wall cables, the HF thin-wall cables offer up to 25 per cent. reduction in diameter and 45 per cent. reduction in area.

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