Abstract: Hydraulic valve actuation systems and methods to provide multiple lifts for engine valves using fixed or hard stops at each lift. The fixed or hard stops provide a very repeatable selection of engine valve lifts dependent on engine operating conditions. For full valve lift, unidirectional hydraulic dashpots are used to decelerate the engine valve, both as it approaches the full lift fixed stop, and as the engine valve approaches the valve seat from the engine valve full lift position. Various embodiments and methods of operation are disclosed.

Abstract: High efficiency, high pressure fixed displacement pump systems and methods of control. A typical application is for engine driven high pressure pumps for powering loads such as fuel injectors and/or hydraulic engine valve actuators. The pump systems include a control valve controllably coupling the pump output back to the pump input to stop the pumping when the desired pressure of the output is reached. Reinitiating pumping an increment in crankshaft angle before a load event based in the increment in pressure needed to reach the desired pressure at the crankshaft angle of the load event provides a simple control algorithm assuring accurate repeatability in the pressure at the beginning of a load event. Pumping throughout the load event minimizes the decrease in pressure during the load event. Providing underlap in the control valve minimizes pressure peaks and maximizes efficiently when starting and stopping the pumping action. Various embodiments are disclosed.

Abstract: Herein disclosed is a combustion cell adapted for an internal combustion engine, comprising i) a hydraulic engine valve actuation portion capable of providing a selection of two different and stable engine valve lift (i.e., open) positions per engine valve or per coupled engine valves and ii) a fuel injection portion capable of providing a selection of comprising i) a hydraulic engine valve actuation portion capable of providing two stable engine valve lift positions and ii) a fuel injection portion capable of providing a selection of one, two or three injection pressure levels for injection fuel. The combustion cell provides more flexibility in control of incoming intake air, outgoing exhaust gas, and/or incoming injection fuel relative to an engine combustion chamber so as to better match engine operating conditions that may change over time.

Abstract: Fuel injectors and methods of fuel injection allowing direct control of the flow of fuel at an intensified pressure to the needle. A valve, typically a spool valve, is placed in the fuel passage between the intensifier actuation piston and the needle, and controlled by a control valve which may be independent of the control valve controlling the coupling of actuation fluid and a vent to the intensifier actuation piston. This allows achievement of intensification before initiating injection, and control of multiple injections in a single injection event while maintaining fuel intensification throughout the duration of the injection event. Various embodiments are disclosed, including embodiments having multiple intensifiers, having control of pressure over the needle, having two stage control valve systems for control of intensifier actuation fluid, and combining control of one of the intensifiers and the valve controlling flow of intensified fuel to the needle for injection.

Abstract: Multi-stage intensifiers for injectors of pressurized fluid (e.g., fuel) allowing selection of intensified injection fluid pressure and thus fluid injection flow rate by selectively applying actuating fluid supply pressure to one or more of the multi-stage intensifiers. In a disclosed embodiment, two coaxial unequal sized intensifier pistons are used, with a control valve controlling selective pressurization of either the relatively smaller intensifier piston, or pressurization of both the relatively smaller intensifier piston and the relatively larger intensifier piston to control the intensified injection fluid pressure and flow rate of injection. Other embodiments, including ones using multi-stage intensifiers mechanically coupled together, controlled by different types of control valves and having more than two stages are also disclosed.

Abstract: Hydraulic engine valve actuation methods for internal combustion engines having improved energy efficiency. In hydraulic engine valve operating systems using spring returns for valve closure, the spring force is a minimum when the valve is closed and a maximum at the maximum lift. The present invention takes advantage of this difference by using a valve opening hydraulic force which is greater than the spring force when the valve is closed and less than the spring force when the valve is open at its maximum lift. The valve actuator is controlled to allow the valve, when opening, to overshoot the equilibrium condition. During the overshoot, the hydraulic actuator backfills with actuating fluid at it normal actuating pressure. When the valve velocity decays to zero or near zero, the flow of hydraulic fluid to (and from) the valve actuator may be cut off, capturing the valve substantially at the overshoot position.

Abstract: Digital fluid pumps having first and second electromagnetic actuators formed in part by a piston to alternately drive the piston in opposite directions for pumping purposes. The piston motion is intentionally limited so that the electromagnetic actuators may operate with a high flux density to provide an output pressure higher than that obtained with conventional solenoid actuated pumps. The electromagnetic actuator coils are electrically pulsed for each pumping cycle as required to maintain the desired fluid flow and output pressure, with the piston being magnetically latchable at one or both extreme positions between pulses. Alternate embodiments and control methods and systems are disclosed.

Abstract: Hydraulic engine valve actuation systems and methods for internal combustion engines. The systems utilize a proportional valve to regulate the flow of a working fluid to and from a hydraulic actuator controlling the engine valve position. The position of the proportional valve is controlled by one or more high speed valves to control various engine valve parameters, including engine valve takeoff and landing velocities. Returning all valves to a known starting position between engine valve events avoids accumulation of errors in proportional valve positioning. Embodiments using spool valves for the high speed valves and the proportional valve, and spring return and hydraulic return for the engine valve, are disclosed. A specially shaped spool in the proportional valve provides enhanced control over the engine valve operation. Various further alternate embodiments are disclosed.

Abstract: Fluid valves suitable for manufacture as a miniature poppet valve assembly. The valves include an upper pole piece, a lower pole piece and an armature, all formed of magnetic material. The upper and lower pole pieces are permanently joined such as by a press fit to entrap an electromagnetic actuator coil and form the magnetic circuit for a moveable armature assembled therein. A valve seat member is molded to, presses, snaps or barbs onto the lower pole piece entrapping the armature and armature return spring to complete the assembly. Use of intended permanent assemblies and use of the parts of the magnetic circuit as the valve outer housing or case allows realization of valves in relatively smaller sizes and capable of relatively higher speeds and frequencies of operation than could be practically provided using valves of other designs or using other assembly techniques.

Abstract: A valve assembly includes a valve housing, an engine valve having a valve stem, an armature, and two solenoids. The valve housing has a first end and an opposing second end. The valve stem is located within the valve housing. The engine valve is moveable between an open position and a closed position. The armature is coupled to the valve stem. The armature is moveable between a first and second positions. The first solenoid is adjacent the first end of the valve housing and is operable to move the armature to the first position and the engine valve to the closed position in response to a first digital pulse. The second solenoid is adjacent the second end of the valve housing and is operable to move the armature to the second position and the engine valve to the open position in response to a second digital pulse.

Abstract: A valve assembly adapted for an internal combustion engine, including a valve housing having a pressure chamber. A piston seperates the pressure chamber into a first subchamber and a second subchamber. A first port is coupled the first subchamber and a second port is coupled to the second subchamber. A valve is coupled to the piston and moveable between an open position and a closed position. The valve is moved from the closed position to the open position by supplying a high pressure working fluid to the first port and coupling the second port to a drain. The valve is moved from the open position to the closed position by supplying the high pressure working fluid to the second port and coupling the first port to the drain.

Abstract: A three position digitally latched actuator actuated fluid control valve. The control valve includes a housing which has a cylinder port, a supply port and a return port. The control valve also contains an internal valve that moves between a first position, a second position and a neutral position. In the first position the internal valve provides fluid communication between the cylinder port and the supply port. In the second position the valve provides fluid communication between the cylinder port and the return port. In the neutral position the valve prevents fluid communication between the ports. The control valve has a first actuator and a second actuator that are actuated by digital pulses to move the internal valve between the first, second and neutral positions.

Abstract: A control module which controls camless hydraulically driven intake and exhaust valves and an hydraulically driven fuel injector of an internal combustion engine. The module contains a valve assembly to control the intake valve, a valve assembly to control the exhaust valve and a valve assembly to control the fuel injector. The valve assemblies preferably each contain a pair of solenoid actuated two-way spool valves. The solenoids are actuated by digital pulses provided by an electronic assembly within the module. The solenoid actuated spool valves control the flow of a hydraulic fluid to and from the fuel injector and the intake and exhaust valves. The hydraulic fluid opens and closes the intake and exhaust valves. The hydraulic fluid also actuates the fuel injector to eject a fuel into a combustion chamber of the engine. The electronic assembly of each module can be connected to a main microprocessor which provides commands to each assembly.

Abstract: A fluid control module that can control the flow of fluid between a rail line, a drain line, a first cylinder line and a second cylinder line. The control module includes a plurality of fluid-driven valves that can couple the cylinder lines to the rail and drain lines. Each fluid-driven valve is controlled by a control valve. The module may be actuated into one of a plurality of different states.

Abstract: An internal combustion engine that contains a controller which controls different components such as a fuel injector, an exhaust valve and a by-pass valve of a pump with digital control signals. The engine may have an hydraulically driven fuel injector which ejects a volume of fuel into an internal combustion chamber. The flow of air into the internal combustion chamber and the flow of exhaust gas out of the chamber may be controlled by camless hydraulically driven intake and exhaust valves. The hydraulic actuation of the fuel injector and valves are controlled by solenoid actuated latching fluid control valves. The operation of the injector and the valves is controlled by a controller which provides digital signals to actuate and latch the solenoid control valves. The digital signals consume minimal power and actuate the valves at relatively high speeds. The engine further contains a pump that pumps the hydraulic fluid to the control valves.

Abstract: A pump which can operate in a number of different modes, wherein each mode corresponds to a different output of the pump. The pump may have a plurality of pump chambers located within a pump housing. The pump chambers may be arranged in fluid communication with an inlet port and an outlet port. Each pump chamber may have a pumping device which draws in fluid from the inlet port during an intake stroke and pushes fluid through the outlet port during a discharge stroke. The pump may also have a plurality of electronically controlled valve assemblies which control the output of the pump. Each valve assembly can be selectively switched to a by-pass state for by-passing the fluid flowing from the pump chamber back to the inlet port during the discharge stroke of a pumping device. The pump may operate in a number of different modes which each have a distinct output. Each mode may be defined by which valves are chosen to be switched to their by-pass state.

Abstract: A valve module that can be assembled to an internal combustion engine chamber. The valve module may have a first intake valve, a second intake valve, a third intake valve, a first exhaust valve and a second exhaust valve. The valves may be driven to an open position by hydraulically driven first pins. The exhaust valves may further have hydraulically driven second pins. The additional pins may increase the hydraulic forces which allow the exhaust valves to be opened even when there is a large pressure in the combustion chamber. The first pins of the exhaust valves may be controlled by a microprocessor controlled first control valve. The second pins may be controlled by a microprocessor controlled second control valve. The separate control valves and additional hydraulic force of the second pins may allow the microprocessor to open the exhaust valves at any point during a cycle of a combustion engine.

Abstract: A hydraulic valve control system that includes a plurality of digitally actuated magnetically-latchable four-way valves that directly or indirectly control the position of a hydraulic actuator. The digitally actuated magnetically-latchable four-way valves are controlled by a controller that can control the valves in accordance with a servo routine. The servo routine may include the computation of a plurality of cost functions and the selection of an action that corresponds to the lowest cost.

Abstract: A three position digitally latched actuator actuated fluid control valve. The control valve includes a housing which has a cylinder port, a supply port and a return port. The control valve also contains an internal valve that moves between a first position, a second position and a neutral position. In the first position the internal valve provides fluid communication between the cylinder port and the supply port. In the second position the valve provides fluid communication between the cylinder port and the return port. In the neutral position the valve prevents fluid communication between the ports. The control valve has a first actuator and a second actuator that are actuated by digital pulses to move the internal valve between the first, second and neutral positions.

Abstract: A fuel injector that contains no springs and is controlled by a valve assembly that has more than two modes of operation. The fuel injector includes a housing which has a supply port, a drain port and a cylinder passage that is in fluid communication with an intensifier. The intensifier moves between a first position and a second position within a fuel chamber. The fuel chamber is coupled to a fuel port. Movement of the intensifier into the second position pressurizes the fuel within the fuel chamber. The pressurized fuel opens a needle valve so that fuel is ejected through an aperture of the housing. The cylinder passage is coupled to a first fluid control valve and a second fluid control valve. Each control valve can be actuated between a closed position and an open position.