Meet Michael Hornby – Stanadyne’s Fuel Injection Expert and Innovator

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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.

David Zimmerman Joins Stanadyne as Managing Director of the Americas, Brings Versatile Skillset in Automotive Components Engineering and Sales

Windsor, Conn. (May 30, 2018) – Stanadyne, a global fuel injection systems company based in Windsor, Connecticut, today announced the hiring of David Zimmerman as its Managing Director of the Americas. A 30-year veteran in the automotive industry, Zimmerman will apply his sales management and operational expertise to expand Stanadyne’s business throughout North and South America.

Dave Zimmerman, Managing Director of the Americas

Prior to Stanadyne, Zimmerman was Global Sales Director at Continental Automotive, where he represented six business units with manufacturing touchpoints on six continents. Zimmerman focused on developing new powertrain markets to meet rapidly evolving emission and electrification demands while increasing existing business, resulting in approximately $2B in incremental sales.

Zimmerman will structure Stanadyne’s business in the Americas and develop growth strategies in Stanadyne’s original equipment (OE) and aftermarket sales markets. Additionally, Zimmerman will continue to drive operational excellence across Stanadyne’s America’s organization positioning the business for top and bottom line growth.

“Stanadyne fuel system products are gaining increased traction around the globe. Expanding our reach to new markets is a key strategy to ensure continued competitiveness,” says David Galuska, Stanadyne Chief Executive Officer. “David has a proven track record of success in growing automotive business and sales accounts globally, and I look forward to seeing him expand our reach in the Americas.”

Beginning his career at Lear Corporation as a test engineer, Zimmerman oversaw development of the Ford Motor Company Windstar minivan seat system, until broadening his horizons as resident engineer at BorgWarner. It was here he shifted into a sales role, ultimately becoming a lead account manager for fuel systems and powertrain.

Throughout his career, Zimmerman has led an expansion of powertrain products into new and existing markets, ensuring compliance with emission regulations while staying attuned to the voice of the customer, to deliver high-performance products for a superior driving experience.

“Stanadyne is an innovative company that is transforming industry expectations of the capabilities of fuel injection equipment,” says Zimmerman. “I look forward breaking into new markets and building business in the Americas. Stanadyne is on the move and I am excited to be a part of their future.”

Zimmerman holds a degree in mechanical engineering from Western Michigan University.

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

Being Quiet is the Best Way to Be Heard: Minimizing Fuel System Noise

Drivers expect a lot out of their vehicles, and one of these expectations is what you hear – or rather what you don’t hear – while in the driver’s seat. To give vehicle owners the best driving experience possible, Stanadyne has set out to build the quietest high-pressure GDI pumps on the market. With the rise of gasoline direct injection (GDI) in the past decade, automotive fuel systems are operating at higher pressures than ever before – and with higher pressure comes the risk of more noticeable noise from the fuel system.

IMPORTANCE OF NOISE
There are several factors that contribute to audible noise from the engine. However, noise is subjective. Some drivers prefer the roar of a performance engine while others favor the silence of a luxury sedan. In either case, unwanted sounds from the engine interfere with those expectations. That’s why we are constantly working to make sure noise from the fuel system is the last thing a driver hears from the engine.

ACOUSTICAL ANALYSIS
The noise that a driver hears is a composite of all the different sources of sound that the vehicle makes. Complicating matters, noises that engine components make can emanate through the engine and vehicle structures to radiate in unexpected ways. At Stanadyne, we understand how important these interactions are, so we optimize the noise signature of all our GDI pumps on-engine in a unique sound isolation chamber. Our engineers use the data from this ultra-advanced facility at our Connecticut headquarters, along with powerful hydraulic and acoustic analysis tools, to optimize our pumps to produce the best possible overall noise signature on the actual engine on which it will run. It’s the only way to get the job done right.

QUIETTECH™
With help from state-of-the-art facilities, our patented QuietTech™ technology, and customer feedback, we are constantly refining our strategies to reduce hydraulic and mechanical noise. Our latest QuietTech™ components maximize the efficiency of the pump to minimize the volume of fuel flow, reduce the velocity and mass of moving parts, incorporate hybrid materials and material coatings and seal surface finishing techniques. These efforts result in GDI pumps that run as quietly as possible in each engine application.

We are pushing the boundaries of what’s possible in noise reduction through QuietTech™ and advanced analysis techniques. As engine technology continues to progress, demanding better fuel efficiency and lower emissions, new challenges in pump design will emerge. We keep GDI technology moving forward by building solutions that exceed expectations for our customers. These efforts go toward our commitment to fueling innovation.

Stanadyne Engineers Are Driving the Future of Fuel Systems

Engineers are what make Stanadyne thrive. They are the engine of our innovation, building solutions for customer needs and market demands. Stanadyne would not be the company it is today without the invaluable contributions of our engineering team, not only in the United States but at our centers of engineering excellence around the world.

In light of National Engineers Week, Feb. 18-24, Stanadyne is proud to celebrate our company’s innovators – the engineers who work each day to create fuel systems that enable engines to be cleaner and more efficient, solving challenges for the customers and communities we’re privileged to serve.

National Engineers Week is a reminder of the positive impact engineers have in our lives every day. Since 1951, the annual event has spotlighted the important contributions engineers have made to our society. It also now encourages young students to pursue careers in science, technology, engineering and math (STEM).

Stanadyne is dedicated to developing and recruiting the next generation of engineers that will join our workforce. We work with colleges and universities to offer students unique opportunities to engage in product development, analysis led design, metrology, and other innovative programs.

As the automotive and diesel industries continue to transform in a time of widespread emissions improvements, technological innovation, and greater consumer expectations, our engineers must continuously evolve to address the needs of the markets we serve. And we know they’re up for the challenge.

Thank you to our engineers in the United States and around the world for your imagination in elevating our engineering. The inventive and creative solutions you create for the toughest challenges facing fuel systems are at the heart of what we do every day.

New Systems Enable Cost-Effective Pathway to Achieve Upcoming Emissions Compliance for Small Engines in India

NEW DELHI (Feb. 15, 2018) – Stanadyne, a global fuel injection systems developer headquartered in Windsor, Connecticut, debuted two new fuel systems at the Feb. 8-11 Auto Expo components show in New Delhi that offer a differentiated approach to meet India’s forthcoming small engine emissions regulations.

Stanadyne’s Gasoline Pumping Injector (GPI) and Solenoid Controlled Unit Pump (SCUP) have been developed as cost-effective replacements for mechanical systems in two- and three-wheeler applications and enable manufacturers to achieve India’s emissions norms.

The GPI is an integrated pump and injector designed to replace mechanical carburetors commonly used on small gasoline engines today. The SCUP is an electronically controlled unit pump that offers precise timing and fuel delivery control and is an alternative to diesel common rail technology.

“This (GPI and SCUP) technology fits in the footprint of today’s mechanical systems; offering a direct advantage over other options in the market that require manufacturers to make major design changes to their engines,” said Jayabalan S, Stanadyne Senior General Manager of Application Engineering. “With manufacturers working to meet 2019/2020 emissions requirements of small diesel and gasoline engines, we’re supplying low-cost solutions that require fewer engine modifications compared to more complex systems like port fuel injection and diesel common rail.”

Stanadyne’s Sanjay Chadda, Managing Director (left) and Dr. John Pinson, President & CTO (right) revealed two new products – the Gasoline Pumping Injector (GPI) and Solenoid Controlled Unit Pump (SCUP) at the 2018 Auto Expo Components Show in New Delhi February 8th – 11th. Designed to meet BS-VI norms through electronic fuel injection systems, the products offer cost-effective alternatives to traditional mechanical systems.

Also showcased at the Auto Expo were Stanadyne’s other diesel and gasoline fuel systems – Gasoline Direct Injection (GDI) pumps and Diesel Common Rail (DCR) systems – which marked their inaugural exhibition in India, though Stanadyne has been manufacturing products in the country for nearly 10 years.

Stanadyne, which developed the world’s first 200 bar GDI pump for the automotive market in 2006, today designs GDI technology primarily for 3-cylinder and above passenger-vehicle engines.

The company’s DCR technology is developed for the harshest operating conditions and low-lubricity fuels. The high-pressure pumps are available in two or four plunger configurations and sized for engines up to 16L.

“With manufacturing facilities strategically placed across the globe, Stanadyne is committed to enabling the next generation of clean and fuel-efficient engines,” said Stanadyne President, Chief Technology Officer Dr. John Pinson. “Solving the unique regional challenges faced by our customers with tailor-made products is part of our company philosophy. The technology in our GPI and SCUP products exemplifies this business blueprint.”

GM Honors Stanadyne as Supplier of the Year.