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Michael Hornby: Stanadyne’s gasoline fuel injection development and manufacturing expert

Michael Hornby: Stanadyne’s gasoline fuel injection development and manufacturing expert

Fuel Injection Expert and Innovator

Stanadyne continues to assemble top talent charged with developing internal combustion engine (ICE) solutions offering customers greater efficiency and lower emissions without sacrificing powertrain performance. One of these talented individuals is Mr. Michael Hornby. Michael joined the company in late 2020 as Global Chief Engineer in Fuel Systems and Components, and is based at the Jacksonville, North Carolina, operations within the new Gasoline Advanced Engineering Center of Excellence.

Michael has more than 35 years of experience creating, designing, and developing fuel systems and exhaust after-treatment products. He currently holds more than 100 automotive and fuel system patents. During his time in manufacturing management, he and his team won a Premier Automotive Suppliers’ Contribution to Excellence (PACE) Award for innovative gasoline fuel injection manufacturing technology. He also has authored several publications in automotive components and aftertreatment systems.

“There is a lot of innovation left to do and ground to break on the internal combustion engine,” said Hornby. “We are entering a golden age of ICE advanced engineering. Stanadyne is well positioned to provide technical solutions that will help support vehicle hybridization and emissions reduction activities across the mobility industry.”

Michael’s role as  Stanadyne’s fuel injection expert and innovator primarily focuses on the development of gasoline fuel injection components and systems. He oversees a growing product engineering group supporting current and future original equipment manufacturer (OEM) customer engine programs. One of his key project initiatives is the development of a 1,000 bar gasoline direct injection fuel injector and next generation high-pressure pump.

“As OEMs continue to pursue vehicle electrification, they are also looking at high-pressure fuel delivery systems to improve engine efficiency and performance, while continuing to reduce emissions,” said Hornby. “Our 1,000 bar pump and injector system will be able to deliver fuel into the cylinder as fine as an aerosol mist. This will allow the fuel to burn more cleanly, efficiently, and with more energy – perfect for engine downsizing.”

Michael spent 35 years with Continental Automotive Systems in Newport News, Virginia. During his tenure at Continental, he held positions of increasing responsibility within Product Engineering, Manufacturing Management, eventually becoming the Executive Director of Advanced Product Development.

“I spent a significant portion of my career working on gasoline fuel injectors for Continental, and Siemens VDO Automotive before that,” said Hornby. “I am excited and inspired to be able to apply my experience towards the continued advancement of fuel injection technology.”

Michael has an MBA in Technology Management and a bachelor’s degree in Mechanical Engineering from Old Dominion University in Norfolk, Virginia. He current serves on the Old Dominion University School of Engineering Advisory Board.

Stanadyne, a global fuel systems supplier based in Connecticut, was named a GM Overdrive Award winner during General Motors’ 27th annual Supplier of the Year awards ceremony held Thursday, May 16 in Warren, Michigan.

GM’s Overdrive Award, introduced in 2012, recognizes supply partners for extraordinary leadership in cultural change and commitment initiatives that drove exceptional business results for GM. Stanadyne was named one of four 2018 Overdrive Award winners.

“Everyone at Stanadyne is focused on providing the utmost quality and precision products to solve our customers’ fuel system challenges,” says Stanadyne CEO David Galuska. “However, in September 2018, Mother Nature presented a different type of test when Hurricane Florence tore into the East Coast, including Jacksonville, NC, where we manufacture gasoline direct injection pumps, and other fuel system components.”

“Well in advance of the storm, we implemented our emergency preparedness plan to prioritize the specific steps we were taking to first ensure the safety and wellbeing of our employees, and to protect GM engine builds. Despite the widespread devastation to roads and infrastructure in our area, Stanadyne employees went above and beyond to keep GM at the center of our recovery efforts. Thanks to our dedicated Jacksonville team, we were able to maintain supply without interruption, once again displaying our dedication to the experience of our customers.”

During the event, GM recognized 133 of its best suppliers from 15 countries that have consistently exceeded GM’s expectations, created outstanding value or introduced innovations to the company.

“We hold our suppliers to a high bar,” said Steve Kiefer, GM senior vice president, Global Purchasing and Supply Chain. “They went above and beyond to deliver the innovations and quality that will help us earn customers for life.”

Industry veterans, Jerry Sweetland and David Zimmerman to lead Stanadyne through next phase of global growth

Stanadyne has announced its management structure following the Windsor, Conn., fuel injection systems company’s acquisition of Pure Power Technologies Inc., earlier this month. Jerry Sweetland, President and CEO of Pure Power has been named President of diesel products, and David Zimmerman, Stanadyne’s Managing Director of the Americas, has been named President of gasoline products.

“Since Stanadyne acquired Pure Power earlier this month,” says David Galuska, Stanadyne Chief Executive Officer, “our collective goal has been to establish the best and brightest from both companies in positions where they can broaden our global market presence and accelerate growth.”

Pure Power, which manufactures fuel, air-management and after-treatment systems for light-, medium- and heavy-duty diesel engines, is based in Columbia, S.C., where Sweetland will continue to direct the operation through this transitional phase. He was one of six original employees in 1999 when Siemens and Navistar founded the company as a joint venture, and by 2016, Pure Power evolved into an independent operation with Sweetland at the helm. Sweetland, a 25-year industry veteran, has also held leadership positions at Detroit Diesel, Siemens Automotive and Continental Automotive.

“This is an exciting time for Stanadyne, and I am thrilled to be taking the lead on Stanadyne’s diesel products, says Jerry Sweetland. “Stanadyne has a long and innovative history in the diesel industry, and I look forward to bringing Pure Power’s diesel technology to the table for the next phase of our combined growth.”

Zimmerman, who joined Stanadyne in May 2018 after three decades in the auto industry, began his diverse career as a test engineer for Lear Corporation. He also led the development of Ford’s Windstar minivan seat system and was an engineer and sales manager for cam drive systems in powertrain at BorgWarner. Immediately prior to Stanadyne, Zimmerman was the Director of key account management at Continental Automotive, overseeing the commercial and technical relationships with Ford Motor Company.

“Having been with Stanadyne for the past year, it is an honor to be named President of gasoline products, says David Zimmerman. “The potential of our gasoline direct injection line is very strong, and I am ready to carry over the success we’ve had in the Americas under my tenure to the global stage.”

Defying Expectations, No Matter the Challenge

Case Study: Engineering a single pump GDI solution for V6 and V8 engines

When you need a solution quickly, you want a versatile partner who can solve the problem, based on the unique task at hand. For decades, Stanadyne has approached some of the world’s most complicated fuel system challenges with a flexible product strategy that delivers custom fuel pump solutions.

Having access to cutting-edge technology is essential to stay ahead of the curve in the automotive industry – but it isn’t the only necessity. At Stanadyne, we understand that every engine manufacturer has unique requirements for their GDI applications, and frequently, tough challenges to overcome. That’s why Stanadyne works closely with customers to tailor customized solutions that solve the toughest challenges with innovative solutions. This approach combined with decades of experience gives you an award-winning strategy.

SP1250 GDI Pump

Customer Challenge
It was this strategy that helped Stanadyne forge a successful partnership with a well-known, global OEM. In 2004, Stanadyne was approached by this OEM to help them to develop a unique single-pump solution for their V6 and V8 engines.

To meet the fuel delivery requirements for engines of this size, most GDI systems use two high-pressure pumps. But for this customer, there were unique requirements that made it difficult to install a two-pump system without cost and efficiency ramifications.

Stanadyne Solution
Stanadyne embraced the challenge, and by 2013 launched the first single pump solution for high-displacement, high-horsepower applications on trucks and SUVs. The SP1250 not only met the displacement requirements of the engine but was designed with several features that exceeded the customer’s expectations for performance, including a patented floating plunger sleeve mount, a beehive spring design and the first generation of our QuietTechTM metering valve technology.

Our patented floating plunger sleeve mount isolates mounting loads and the plunger bore, which allows for low clearances between the plunger and sleeve. The plunger and sleeve are match fit to a clearance of less than 8 micron, which enables industry-leading volumetric efficiency and pressure rise rates at cranking for fast engine start times.

Another feature that was designed for the pump is a dual, or beehive, spring. An outer spring to handle tappet loads and a smaller inner spring to handle plunger return. Separating these spring loads led to a more robust pump due to the minimized plunger side loading and improved tolerance to spring out-of-squareness.

The SP1250 was also among the quietest pumps on the market at the time of its development thanks to our QuietTech package of technology. From the inlet valve to the control valve, the internal hydraulics of this pump were optimized to address radiated and transmitted noise.

In conjunction with this pump development, Stanadyne also developed a larger single-pump solution for high-performance engines up to 650 HP. The SP1550-200 uses similar design concepts as the SP1250-200 I, but delivers even higher output for powerful sportscars. The SP1550 can supply up to 1550 mm3 of fuel per engine revolution, making it the highest output GDI pump on the market.

Since its launch in 2013, more than 5 million SP1250 and SP1550 pumps have been manufactured, and both have proven to be among the most dependable fuel injection pumps in the world.

Stanadyne continues to raise the bar for fuel injection technology by continuously developing new ideas for the future of GDI pumps. The next generation of the SP1250 pump, which is scheduled to begin production this month, is engineered to be even lighter, quieter and more efficient than ever.

Global Need for GDI Accelerates as Demand Grows for Greater Fuel Efficiency and Environmentally-Conscious Applications

Detroit, Mich. (April 10, 2018) – The global market for gasoline direct injection (GDI) fuel systems will reach $13 billion by 2026*, making it the fastest growing fuel system technology for the next decade.

Stanadyne, a fuel injection systems developer headquartered in Windsor, Connecticut with auto clients worldwide highlighted its recent GDI successes and design challenges during a white paper presentation at SAE International’s WCX World Congress Experience, April 10 in Detroit.

“New challenges in pump design continue to emerge as engines become smaller and more powerful in response to fuel economy and regulatory trends,” said Stanadyne President and Chief Technology Officer Dr. John Pinson during his presentation, Advances in Gasoline Direct Injection Fuel Pump Technologies.  “The demand for gasoline direct injection (GDI) systems is growing around the globe as manufacturers push for fuel efficiency, performance, and cost-effective regulatory compliance. GDI system design poses unique challenges to achieve these benefits with cost-effective, quiet and flexible product designs.”

Stanadyne produces customized and right-sized GDI pumps with flexible packaging for reduced mass and a broad operating pressure range. Stanadyne’s GDI pumps also feature QuietTech™, a patented control valve technology for quiet pump operation.

“GDI fuel systems are at the heart of the modern automotive engine,” says Dr. Pinson. “At the heart of our approach is providing breakthrough technology that is optimized for the application.”

Stanadyne has manufacturing facilities in the U.S. Italy, India, China and the UAE, with more than one million GDI pumps produced each year.

*From global market research company Statistics MRC



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