1. Orbital Australia Pty. Ltd. Lightweight Heavy Fuel Engine Technology
Orbital Confidential

2. Overview Orbital FlexDI –Air Assisted Direct Injection.
Heavy fuel technology
Synerject – Fuel system supply (USA)

3. Orbital Corporation
Orbital provides innovation, design, product development and operational improvement services to the world’s producers, suppliers, regulators and end users of engines and engine management systems.
Headquartered in Perth, Australia
Annual Revenue ~US$12 million
Employees ~100

5. FlexDI – Air Assisted Direct Injection

6. Orbital Air-Assist Direct Fuel Injection
Fuel metering injector
720 o
BTDC
360
180
FUEL METERING
EVENT
DIRECT INJECTION
INJECTION SEQUENCING
IGNITION
Fuel to air regulator
Fuel-air interface
Direct (air) Injector

8. Orbital DI System Schematic

10. Consumer Products in the Market
Over 500,000 Orbital DI engines in the market

12. Heavy Fuel Technology

13. Air-assist Direct Injection Spray Characteristic
Spray shape not effected by fuel type
Similar droplet sizes for all types of fuel
DIESEL FUEL
GASOLINE FUEL
10 mg/shot
6.8 micron SMD
5.7 micron SMD

14. UAV Benefits of Air-Assisted DI
Benefits of Air-Assisted Direct Injected Engines for UAV’s:
Reliable cold start
Smooth transient operation.
Multi-fuel capability (gas, JP5/8, diesel)
Lower weight & vibration than diesel.
Lower cost & consumption than turbine
Engine monitoring via advanced EMS.

15. Military Applications Utilizing Orbital DI Technology (Currently in the public domain)

16. Technology Used by US Navy
Mercury 3.0L V6 2-Stroke Outboard with Orbital’s air-assisted direct injection. JP5/JP8 operation and EPA emission compliant. Available on GSA since

17. Technology under evaluation by UK MoD
EP Barrus has designed, developed and delivered a multi fuel 50hp outboard trial engine under license for the UK MoD, capable of running on gasoline, JP5, JP8 and diesel. Has also been evaluated by US Navy and US Marines.

18. Teledyne Brown Engineering S1204 Hirth-Orbital 500cc 2-stroke Boxer (44hp) – JP8 Fuel

19. Polaris MV800/MVRS Military ATV/UTV 760cc 4-Stroke with Orbital DI – JP8 Fuel Available since

20. ESW Lightweight 17kW APU

21. Fuel System Supply – USA Joint Venture

22. Synerject Overview
42:58 Joint Venture with Siemens-VDO established in 1997
Supplies and manufactures Engine Management Systems (EMS) and electronic fuel injection systems for global non-automotive market
Access to Siemens-VDO (Continental) automotive components and know how for non-automotive applications
Largest independent supplier in the world for non-automotive applications

23. Synerject North America
Synerject LLC
201 Enterprise Drive
Newport News, Virginia, USA 23603
Telephone: +1 (757)
Fax: (757)
Current Facility Opened August 2000
Synerject Company Headquarters
60,000 square feet
70 employees
Engine Management Systems applications for North America
Chassis Dynamometer
Modules & Component Product Engineering
Production of EMS Modules and Components
Engineering Center
Certified ISO 9001: 2000
Synerject Newport News

24. Synerject – Delevan, WI
Synerject took over Bombardier Recreational Product’s ETEC Fuel System production facility in 2006.
Produces ETEC fuel systems for Evinrude Outboards
40,000 square feet
65 employees
Synerject Newport News

25. Synerject – Products and Markets
2 Stroke
Direct Injection
Port Injection
4 Stroke
Port Injection
Direct Injection

26. Production Assembly and Engineering Test

27. Contact Info
Bob Schmidt
US Technical Sales Rep for Orbital
PH:
FAX:
Website:
Skype: schmidtproducts

28. Innovative Engine Technology for a Safer World …