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This paper focuses on the development process of safety critical systems, particularly with regard to the application of norms and standards so as to meet the expectation on safety and to facilitate compliance with regulations relevant to automotive development. The considered norm is the IEC 61508, which is a generic norm for the functional safety of E/E/PE safety related systems and established software tools are used in order to guarantee the traceability within the development process. International regulations like the Federal Motor Vehicle Safety Standard (FMVSS) and the Economic Community Europe (ECE) are also considered.

Vehicle manufactures are significantly increasing the production of Direct Injection Gasoline (DIG) engines to help meet the requirements of governmental regulations and the demands of consumers. While DIG powertrains offer multiple advantages over conventional gasoline engines they can be susceptible to fuel related deposit formation, specifically within the fuel injector nozzle. Fuel injector deposits have been linked to a number of negative effects that can impact the normal operation of the engine. A DIG deposit test has been developed to evaluate Deposit Control Additives (DCA) and their effect on injector deposits. Multiple metrics for evaluating fuel injector deposits were investigated to determine a suitable method for quantifying deposit formation. Interrogation of the vehicle On-Board Diagnostic (OBD) system was identified as the optimal method for quantifying deposit formation throughout the duration of the test.

For a better understanding of how soot is generated due to fuel films, a constant volume vessel was used together with four visualization techniques due to their high spatial (2D) and time resolution: Schlieren, natural luminosity, diffused back illumination and OH* chemiluminescence. The analysis was performed keeping the injection pressure at 30 bar and changing the plate temperature on which the spray impacts: 80, 120, 160 and 200 °C. The fuel is a mixture of iso-octane, hexane, toluene and 1-methylnaphthalene, which presents similar properties to commercial gasoline. Valuable insights were gained from the results that infer the real nature of the radiation observed during combustion events in gasoline direct injection (GDI) engines due to the presence of a fuel films which are conventionally described as “pool fires”. The results show that the highest quantity of soot is generated between plate temperatures of 80 and 120 °C.