Abstract: The high efficiency gear pump includes a pump housing which defines an internal pump chamber. The pump chamber includes opposed first and second elongate gear receiving sections spaced on opposite sides of a central chamber section. The first and second gear receiving sections each have an arcuate peripheral wall which extends between a low pressure inlet port and a high pressure outlet port positioned on opposite sides of the central chamber section between the first and second gear receiving sections. Coaxially mounted on a drive shaft for rotation therewith are first and second pump drive gears having teeth which rotate in minimal spaced relationship with the arcuate peripheral wall of the first gear receiving section. The first and second pump drive gears are mounted for floating axial movement relative to each other and the drive shaft.

Abstract: An improved wastegated turbocharger including ejector nozzles such that the bypassed exhaust flow re-enters the main exhaust flow at a predetermined pitch angle and yaw angle so as to create a drop in turbine back pressure. The exhaust gas turbocharger includes a turbine housing having a turbine chamber, an exhaust housing portion, and an exhaust gas inlet to said turbine chamber wherein a turbine wheel is rotatably mounted in the turbine chamber and is rotatably responsive to exhaust gas flow from the exhaust gas inlet. In one embodiment, an outlet insert is provided which is rigidly attached to the exhaust housing portion and extends toward the turbine chamber thereby defining a bypass chamber and providing an exhaust gas outlet. A bypass flow passage which fluidly connects the exhaust gas inlet with the bypass chamber is also provided. The outlet insert includes a plurality of ejector nozzles for directing exhaust flow from the bypass chamber to the exhaust gas outlet.

Abstract: A road speed control system for a vehicle driven by an internal combustion engine includes a control computer operable to control engine fueling based on inputs from at least an accelerator pedal position sensor, a vehicle speed signal, and at least one control signal. According to one aspect of the invention, the control computer is responsive to a first control signal to decrease the maximum road speed limit value and to a second control signal to increase the maximum road speed value, to thereby provide a road speed limiting system operable under manual engine fueling conditions. According to another aspect of the invention, the control computer is responsive to at least one control signal to activate a maximum road speed limit override feature for temporarily increasing the maximum road speed limit value to, for example, facilitate passing attempts.

Abstract: A three-way fuel injection control valve assembly is provided which includes a pilot valve for controlling the movement of a drain valve member and a separate supply valve member to minimize valve response time and transition flow losses. The solenoid operated two-way pilot valve controls the flow of fuel from a control volume formed adjacent the ends of the drain valve member and the supply valve member to begin and end an injection event. A transition flow loss limiting feature is provided which causes the drain valve member to close prior to the opening of the supply valve member and subsequently causes the supply valve member to close prior to the opening of the drain valve member during a given injection event thereby minimizing transition flow losses.

Abstract: A system and method for diagnosing output power of an internal combustion engine includes means for diagnosing potential causes of low engine output power or torque and means for estimating actual engine output power or torque. In a preferred embodiment of the diagnosis of engine output power, low engine output power is first investigated for authenticity to verify whether a low engine output power condition exists. If one exists, a zero fueling engine cranking test is conducted to determine whether relative compression values for each of the cylinders are within specification, and any problems associated therewith are corrected by service personnel. If the low engine output power problem is not corrected in accordance with the engine cranking test, a snap-throttle cylinder balancing test is conducted to balance the relative power contribution from each cylinder.

Abstract: A system for protecting one or more drivetrain components from excessive inertial torque includes an automated clutch disposed between an internal combustion engine and a transmission coupled thereto, wherein the automated clutch is responsive to computer control. Under conditions wherein driveline acceleration exceeds an acceleration threshold, wherein the acceleration threshold preferably corresponds to the weakest of the drivetrain components, a control computer is operable to actuate the automated clutch to thereby electronically disengage the engine from the transmission, and accordingly protect the various drivetrain components from damage due to excessive engine inertial torque. In an alternate embodiment, a control computer is operable to compute or otherwise estimate engine inertial torque and actuate the automated clutch as just described if/when the engine inertial torque exceeds a torque threshold corresponding to an input torque capacity of one or more of the drivetrain components.

Abstract: A vehicle that has a drive train with an internal combustion engine, a transmission, and a number of ground engaging wheels. An operator-adjustable throttle control is monitored to provide a position signal corresponding to position of the throttle control. A sensor provides an observed speed signal corresponding to speed of the vehicle and a controller responds to the position signal and the observed speed signal to generate a target speed signal and an error signal. The target speed signal corresponds to a desired speed of the vehicle and is generated from a predetermined relationship between vehicle speed and throttle control position in accordance with the position signal. The error signal corresponds to a difference between the target speed signal and observed speed signal. The engine responds to the error signal to provide the desired vehicle speed for all operating speeds of the vehicle including a stopped or idle condition.

Abstract: A flow control valve having a controllable flow area which varies with the valve displacement. The flow control valve includes a poppet-type valve element mounted to reciprocate between a closed and open position in a valve cavity formed in a valve housing. The valve housing has an inlet and outlet passage to allow fluid to flow therethrough. A removable insert having a flow passage is positioned in the valve cavity adjacent the poppet-valve for controlling the flow rate of gaseous fluid from the inlet passage to the outlet passage while the poppet valve is in an open position. Movement of the poppet valve from a closed to an open position varies the effective cross-sectional flow area of the flow passage.

Abstract: An exhaust gas recirculation and control system is provided for an internal combustion engine, wherein a portion of engine exhaust gas flow is recirculated through an EGR duct to engine intake air. The recirculated exhaust gas is pumped through the EGR duct by an EGR compressor driven by a dedicated EGR drive that is independently controllable. Because the EGR drive is independently powered and controlled, the EGR flow rate capacity of the system is not dictated by, or limited, by factors such as engine exhaust flow rate. A controller modulates power delivery to the drive means in response to at least one operating condition parameter in order to achieve a desired EGR flow rate. In order to further optimize efficiency, the EGR compressor is preferably a discrete displacement pump which is controllably drivable in a pulse-capture mode, wherein each intake of the EGR compressor is timed synchronously with exhaust pulses in the exhaust manifold.

Abstract: A system for controlling output torque characteristics of an internal combustion engine includes a control computer operable to control the output power/torque of the engine that is coupled to a transmission through a torque converter. The system is operable to determine an engine speed range of interest and limit engine output power/torque to a predefined maximum value if the current engine speed is within the engine speed range of interest when the torque converter is operating in torque converter mode (i.e., not in lockup mode). The predefined maximum value of engine output power/torque is preferably a maximum horsepower value that may be a constant value or a function of engine speed within the engine speed range of interest. Alternatively, the predefined maximum value of engine output power/torque is a dynamic function of a torque ratio of the torque converter and a predefined turbine torque limit.

Abstract: A method and apparatus is disclosed for recursively estimating vehicle mass and/or aerodynamic coefficient of a moving vehicle. The vehicle speed and push force data are collected and a segment of qualified data is then selected from the collected data. Newton's second law is integrated to express vehicle mass and/or aerodynamic coefficient in terms of vehicle push force and vehicle speed. This expression is then used in a recursive analysis of the qualified data segment to determine an estimated vehicle mass and/or aerodynamic coefficient.

Abstract: The improved solenoid actuator assembly of the present invention includes a solenoid stator assembly positioned in an actuator housing and a flux dissipation reducing feature which minimizes flux leakage into the housing thereby maximizing the attractive force and minimizing the response time. The flux dissipation reducing feature includes a slot formed in the housing adjacent each outer face of the solenoid stator pole pieces thereby avoiding a metallic housing wall into which leakage may occur. The slots also permit the cross sectional area of the pole pieces to be maximized thereby increasing the available attractive force. The solenoid stator assembly requires only a single housing which functions to directly support the laminate stack assembly without an intermediate housing while also functioning as an injector body component subject to the compressive assembly load of the injector and including high pressure fuel passages.

Abstract: A wear and scuff-resistant plunger for use in high pressure fuel system components in internal combustion engines is provided. The plunger, which is formed of a high thermal expansion, high hardness ceramic with a thermal expansion coefficient preferably greater than 6.times.10.sup.-6 /.degree. C. and a hardness preferably greater than 800 Kg/mM.sup.2, maintains a desired optimum minimal diametral clearance while avoiding excessive fuel leakage and efficient plunger function without scuffing or sticking under the high axial, side and pressure loads and variable quality fuels encountered in the fuel system operating environment. Preferred high thermal expansion, high hardness ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A fuel injector for use in a diesel engine which is equipped with an engine brake governed by a hydraulic circuit includes an injector body with a hollow interior, a plunger located within the injector body, a moveable coupling positioned within the injector body, a nozzle for the dispensing of fuel, and a variable rate return spring which is positioned between the injector body and the moveable coupling. The variable return spring is designed with a variable pitch between adjacent coils such that the pitch between coils near the end(s) of the spring is reduced over that near the center of the spring. The use of the variable rate spring is intended to address the problem of premature fatigue failures caused by the return spring oscillating at or above its natural frequency. The oscillations are induced due to the exhaust valve opening and closing events and are transmitted directly through the engine brake hydraulic circuit to the injectors by way of the injector push tube.

Abstract: A tappet socket assembly for a rocker lever assembly or other lever assembly includes a retainer, a tappet socket, and a ball bearing. The rocker lever is adapted to be rocked about a pivot axis and includes a cylindrical opening or bore which partially receives the ball bearing. The retainer includes a cage provided by a plurality of legs and a cylindrical side wall insert. The side wall is secured within the cylindrical bore and press fitted therein by the ball bearing. The ball bearing exerts radially outward force on the retainer to secure the ball bearing and retainer to the rocker lever. The tappet socket includes a spherical concave recess that closely receives the ball bearing to provide a ball and socket joint and a flat engaging face for transferring the force of the rocker lever to a valve crosshead. The tappet socket is retained in the cage between the legs.

Abstract: A system for controlling operation of an internal combustion engine includes a control computer responsive to a number of engine/vehicle operating conditions to control engine operation to thereby control engine speed and engine or vehicle acceleration. In one embodiment, the control computer is configured to determine an engine or vehicle acceleration limit value based on current engine or vehicle speed, and an engine speed limit value based on current engine load, and to control engine fueling and/or speed to thereby limit engine speed to the engine speed limit value and/or engine/vehicle acceleration to the engine/vehicle acceleration limit value.

Abstract: An apparatus for sensing engine speed and engine angular position. A tone wheel with a plurality of reference indicators and a position indicator is mounted to a camshaft gear. The reference and position indicators rotate past a Hall effect sensor which generates a sensor signal suitable for use by a controller for determination of engine speed and engine angular position.

Abstract: A road speed control system for a vehicle driven by an internal combustion engine includes a control computer operable to control engine fueling based on inputs from at least an accelerator pedal position sensor, a vehicle speed signal, and at least one control signal. According to one aspect of the invention, the control computer is responsive to a first control signal to decrease the maximum road speed limit value and to a second control signal to increase the maximum road speed value, to thereby provide a road speed limiting system operable under manual engine fueling conditions. According to another aspect of the invention, the control computer is responsive to at least one control signal to activate a maximum road speed limit override feature for temporarily increasing the maximum road speed limit value to, for example, facilitate passing attempts.

Abstract: A system for controlling ignition energy of an internal combustion engine includes an ignition coil having a primary coil and a secondary coil coupled to first and second electrodes of an ignition plug defining a spark gap therebetween, wherein the primary coil is operable to induce a spark voltage across the secondary coil and across the spark gap. The secondary coil is responsive to the spark voltage to produce a discharge current across the spark gap of the ignition plug. In accordance with one aspect of the invention, means are provided for controllably shunting the primary coil to thereby control the duration of discharge current across the spark gap of the ignition plug. In accordance with another aspect of the present invention, means are further provided for drawing discharge current away from the ignition plug to thereby limit the magnitude of the discharge current within some time period after the transfer of energy from the primary coil to the secondary coil begins.

Abstract: An intermetallic bond between a ferrous metal and a non-ferrous metal wherein an intermetallic bond layer that is substantially free of graphic inclusions joins the two. The graphite is effectively eliminated from the bond layer by either removing it from the ferrous metal or by sealing it off from the bond layer. Graphite removal may be accomplished in a variety of ways, including electrochemical cleaning and laser surface treatment. Alternatively, the graphite may be prevented from incursing into the bond region by sealing it off with a layer of metal, such as a chromium plating, that prevents it from penetrating through the bond layer and into the non-ferrous metal.