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