Abstract: Additive manufacturing's reliance on embedded computing renders it vulnerable to tampering through cyber-attacks. Sensor instrumentation of additive manufacturing devices allows for rigorous process and security monitoring, but also results in a massive volume of noisy data for each run. As such, in-situ, near-real-time anomaly detection is challenging. A probabilistic-model-based approach addresses this challenge.

Abstract: A solenoid actuator includes a stator assembly with a stator core of formed powder metal received in a stator housing. A ferromagnetic protective sleeve is in contact with and covers a majority of an inner end face and a cylindrical wall of the stator core, while a flux ring is in contact with and covers an outer end face of the stator core. An armature assembly includes an armature attached to a stem that is movable in an air gap relative to the ferromagnetic protective sleeve. A spring is operably positioned in the ferromagnetic protective sleeve but electrically isolated from the stator housing. The stator core is encapsulated to protect against erosion and fragmentation. A magnetic flux line around a solenoid coil passes through the stator core, the ferromagnetic protective sleeve, the armature, the flux ring and back to the stator core.

Abstract: A solenoid actuator includes a stator assembly with a stator core of formed powder metal received in a stator housing. A ferromagnetic protective sleeve is in contact with and covers a majority of an inner end face and a cylindrical wall of the stator core, while a flux ring is in contact with and covers an outer end face of the stator core. An armature assembly includes an armature attached to a stem that is movable in an air gap relative to the ferromagnetic protective sleeve. A spring is operably positioned in the ferromagnetic protective sleeve but electrically isolated from the stator housing. The stator core is encapsulated to protect against erosion and fragmentation. A magnetic flux line around a solenoid coil passes through the stator core, the ferromagnetic protective sleeve, the armature, the flux ring and back to the stator core.

Abstract: A pressure relief valve includes a valve body having a valve seat fluidly positioned between an inlet and an outlet. A valve member is movable among a first position, a second position, and a third position. The valve member is in contact with the valve seat and fluidly blocks the inlet from the outlet at the first position. At the second position of the valve member, the inlet is fluidly connected to the outlet via a small flow area. The inlet is fluidly connected to the outlet via a large flow area when the valve member is at the third position. An electrical actuator is attached to the valve body and is operably coupled to move the valve member when energized. The valve member includes an opening hydraulic surface exposed to fluid pressure in the inlet when at the first position. A spring is operably positioned to bias the valve member toward the second position when the valve member is at the third position.

Abstract: An internal combustion engine, such as a direct injection compression ignition diesel engine, includes an engine housing having a plurality of cylinders and a plurality of fuel injectors associated one with each of the cylinders. The fuel injectors each include a first fuel inlet and a second fuel inlet, and an actuator subassembly which is configured to actuate a control valve assembly positioned within the fuel injector. The engine further includes a fuel system having a fuel supply circuit, and a cooling system for the actuator subassembly having a cooling circuit with a segment in common with a segment of the fuel system. The cooling system is configured to pass cooling fuel across a heat exchange interface of the actuator subassembly to exchange heat therewith. The actuator subassembly may include a piezoelectric actuator and a preloading spring, which are each fluidly sealed within a casing of the actuator subassembly.

Abstract: A check valve for use with a pump is disclosed. The check valve may have a body at least partially defining a central bore with an open end and a closed end, and a spring guide separate from the body and disposed within the closed end of the central bore. The check valve may also have a spring located within the central bore and having a first end operatively engaged with the spring guide, and a valve element operatively engaged with a second end of the spring and being movable by a pressure differential to compress the spring. The spring guide may be moveable relative to the body.

Abstract: A pressure relief valve includes a valve body having a valve seat fluidly positioned between an inlet and an outlet. A valve member is movable among a first position, a second position, and a third position. The valve member is in contact with the valve seat and fluidly blocks the inlet from the outlet at the first position. At the second position of the valve member, the inlet is fluidly connected to the outlet via a small flow area. The inlet is fluidly connected to the outlet via a large flow area when the valve member is at the third position. An electrical actuator is attached to the valve body and is operably coupled to move the valve member when energized. The valve member includes an opening hydraulic surface exposed to fluid pressure in the inlet when at the first position. A spring is operably positioned to bias the valve member toward the second position when the valve member is at the third position.

Abstract: An internal combustion engine, such as a direct injection compression ignition diesel engine, includes an engine housing having a plurality of cylinders and a plurality of fuel injectors associated one with each of the cylinders. The fuel injectors each include a first fuel inlet and a second fuel inlet, and an actuator subassembly which is configured to actuate a control valve assembly positioned within the fuel injector. The engine further includes a fuel system having a fuel supply circuit, and a cooling system for the actuator subassembly having a cooling circuit with a segment in common with a segment of the fuel system. The cooling system is configured to pass cooling fuel across a heat exchange interface of the actuator subassembly to exchange heat therewith. The actuator subassembly may include a piezoelectric actuator and a preloading spring, which are each fluidly sealed within a casing of the actuator subassembly.

Abstract: A check valve for use with a pump is disclosed. The check valve may have a body at least partially defining a central bore with an open end and a closed end, and a spring guide separate from the body and disposed within the closed end of the central bore. The check valve may also have a spring located within the central bore and having a first end operatively engaged with the spring guide, and a valve element operatively engaged with a second end of the spring and being movable by a pressure differential to compress the spring. The spring guide may be moveable relative to the body.

Abstract: A universal vehicle electric power distribution module employs reconfigurable inputs and outputs enabling use of the same hardware across vehicle lines. The module is scalable for ease of expansion and is capable of handling both low current and high current load management on the same module.

Abstract: A thin film coating for a low allow steel or tool steel components in a fuel injector (14), such as a fuel injector needle valve (86) is disclosed. A thin film coating (96) consists of a metal carbon material layer less than 2.0 microns thick applied to a low alloy steel substrate (95) or tool steel substrate (95) used in fuel injector components, such as the fuel injector needle valve (86) or a portion thereof. Optionally, a thin bond layer (98) of chromium is deposited between the steel substrate (95) and the primary metal carbon material coating (96). The thin film coating (96) minimizes abrasive and adhesive wear associated with the needle valve (86) and cooperating nozzle surfaces (62,63) of the fuel injector (14).

Abstract: A thin film coating for a low allow steel or tool steel components in a fuel injector (14), such as a fuel injector needle valve (86) is disclosed. A thin film coating (96) consists of a metal carbon material layer less than 2.0 microns thick applied to a low alloy steel substrate (95) or tool steel substrate (95) used in fuel injector components, such as the fuel injector needle valve (86) or a portion thereof. Optionally, a thin bond layer (98) of chromium is deposited between the steel substrate (95) and the primary metal carbon material coating (96). The thin film coating (96) minimizes abrasive and adhesive wear associated with the needle valve (86) and cooperating nozzle surfaces (62,63) of the fuel injector (14).

Abstract: A universal vehicle electric power distribution module employs reconfigurable inputs and outputs enabling use of the same hardware across vehicle lines. The module is scalable for ease of expansion and is capable of handling both low current and high current load management on the same module.

Abstract: A thin film coating for a low alloy steel or tool steel components in a fuel injector (14), such as a fuel injector needle valve (86) is disclosed. A thin film coating (96) consists of a metal carbon material layer less than 2.0 microns thick applied to a low alloy steel substrate (95) or tool steel substrate (95) used in fuel injector components, such as the fuel injector needle valve (86) or a portion thereof. Optionally, a thin bond layer (98) of chromium is deposited between the steel substrate (95) and the primary metal carbon material coating (96). The thin film coating (96) minimizes abrasive and adhesive wear associated with the needle valve (86) and cooperating nozzle surfaces (62, 63) of the fuel injector (14).

Abstract: A reverse flow valve member is positioned within an injector body of a fuel injector and is movable between a closed position and an open position. When the reverse flow valve member is in its closed position, an upper portion of a nozzle supply passage is blocked from fluid communication with a lower portion of the nozzle supply passage. A compressed spring biases the reverse flow valve member to its closed position. When the reverse flow valve member is in its open position, the fuel pressurization chamber is fluidly connected to the lower portion of the nozzle supply passage. The present invention limits gas ingestion due to tip leakage, and allows an injector with trapped gas to prime itself.

Abstract: A reverse flow valve member is positioned within an injector body of a fuel injector and is movable between a closed position and an open position. When the reverse flow valve member is in its closed position, an upper portion of a nozzle supply passage is blocked from fluid communication with a lower portion of the nozzle supply passage. A compressed spring biases the reverse flow valve member to its closed position. When the reverse flow valve member is in its open position, the fuel pressurization chamber is fluidly connected to the lower portion of the nozzle supply passage. The present invention limits gas ingestion due to tip leakage, and allows an injector with trapped gas to prime itself.

Abstract: An improved apparatus for withstanding the high temperatures in the exhaust assembly of an internal combustion engine. A quilted insulating element is extended about a liner of a manifold or port liner. The liner in this invention is preferably ceramic. After assembling the insulating element about the liner, a metallic ring is installed for support during casting. A metallic housing, preferably cast iron, can then be cast around the liner, insulating element, and metallic ring.

Abstract: An improvement in a thermally insulating component for an engine part, made by sintering from ceramic materials, comprises, the thermally insulating component having a composition, consisting of a mixture of zirconium oxide in the range of about 5% to about 25% by volume and mullite in the range of about 75% to about 95% by volume. Further, the mixture of zirconium oxide and mullite is obtained by chemically mixing the zirconium oxide and mullite in their molecular states, rather than mechanically mixing them. Another feature of this invention includes, forming said thermally insulating component by slip casting and pressureless sintering the mixture of zirconium oxide and mullite at a temperature no greater than 1700.degree. C. This improvement in a thermally insulating component for an engine part, made from a mullite-zirconia ceramic composite, embodying the present invention, is particularly useful in making flame decks for cylinder heads, and insulating coverings for pistons and exhaust ports.

Abstract: A process and composition are disclosed for slip casting a ceramic powder in a porous mold. In this invention, a ceramic powder is blended with a polymeric cellulose ether. A slurry of ceramic powder-cellulose ether is formed. A porous mold is coated with a hydrophilic colloid of ammonium alginate to form a treated mold. The slurry is then poured in the treated mold and a slip is formed. This invention is particularly useful for forming crack-free slips made from difficult to cast ceramic powders.

Abstract: An improvement in a thermally insulating component for an engine part, made by sintering from ceramic materials, comprises, the thermally insulating component having a composition, consisting of a mixture of zirconium oxide in the range of about 5% to about 25% by volume and mullite in the range of about 75% to about 95% by volume. Further, the mixture of zirconium oxide and mullite is obtained by chemically mixing the zirconium oxide and mullite in their molecular states, rather than mechanically mixing them. Another feature of this invention includes, forming said thermally insulating component by slip casting and pressureless sintering the mixture of zirconium oxide and mullite at a temperature no greater than 1700.degree. C. This improvement in a thermally insulating component for an engine part, made from a mullite-zirconia ceramic composite, embodying the present invention, is particularly useful in making flame decks for cylinder heads, and insulating coverings for pistons and exhaust ports.