Abstract: Fuel injectors with boosted needle control providing controlled and rapid needle closure. Boost and drive pistons are provided for hydraulic actuation to controllably close the needle, with the boost piston reaching a mechanical stop before the needle reaches the closed position, with the drive piston alone providing adequate hydraulic force to hold the needle closed. In a preferred embodiment, fuel from the intensifier is coupled to the top of the boost and drive pistons to close the needle, and controllably coupled to the bottom of the boost and drive pistons to allow pressure in the needle chamber to open the needle. Apparatus for control of fuel pressure to the bottom of the boost and drive pistons is disclosed.

Abstract: Low emission high performance engines, multiple cylinder engines and operating methods based on compression ignition of a combustion chamber charge already containing at least some fuel and air. Air is injected into the combustion chamber after top dead center is reached to maintain combustion until all fuel is consumed. Various modes of operation are disclosed.

Abstract: Methods and apparatus to selectively use engine valves as both intake and exhaust valves and to selectively operate the engine as a 2 cycle or as a 4 cycle engine. In a disclosed embodiment, the intake valves and the exhaust valves, are manifolded together through a small manifold, with the manifold being connectable to the intake manifold or the exhaust manifold through two-way valves. In preferably a camless engine, the engine valves may be controlled to operate the intake valves as intake valves only or to operate as both intake valves and exhaust valves, and to operate the exhaust valves as exhaust valves only or to operate the exhaust valves as both intake valves and exhaust valves. Exemplary embodiments are disclosed.

Abstract: Digital regulators using a plurality of latching solenoid actuators, each having a spring return, the springs being configured to provide a force on the valve member of a regulator, when the solenoid actuators are unlatched, in a binary progression. The solenoid actuators are selectively latched by an latching current pulse and retained in the latched condition by residual magnetism in a zero air gap magnetic circuit. Various embodiments are disclosed, including embodiments having the solenoid actuators side by side and in a stacked relationship, solenoid actuators having springs providing a spring force in a binary progression, solenoid actuators having equal springs and distributed in a binary progression from a hinge axis, and solenoid actuators not distributed in a binary progression from a hinge axis and not distributed in a binary progression from the hinge axis. Embodiments are also disclosed having the capability of interpolating between binary settings of the digital regulator.

Abstract: Pressure balanced spool poppet valves with printed actuator coils minimize valve leakage and facilitate efficient manufacturing and reliable operation. The spool poppet valves may be configured like a conventional spool valve, but further include a poppet valve at one end of the spool to proved much better sealing when the poppet valve is closed. Various features are disclosed, including pressure balancing for high pressure operation. The printed actuator coils for the spool poppet valves are formed by the interconnection of conductive coils on each of multiple layers of a multiple layer printed circuit board, which circuit board may have a hole there through for accommodation of mechanical and/or magnet requirements, and may include similar printed actuator coils for one or more additional spool poppet valves as well as electronic devices associated with the operation thereof.

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: Fluid sensing shut-off devices with timer and methods of operation to shut off fluid flow if a primary shutoff valve sticks in the on condition. An embodiment is disclosed using a microphone to sense fluid flow, with a microprocessor periodically awakening from a sleep mode to power the sensor and determine if there is flow. If there is flow, the microprocessor times flow, and if flow is not shut off within a predetermined length of time, the microprocessor shuts off the valve. The valve itself normally held in a magnetically latched, valve open state, but may be unlatched by a current pulse to close the valve. Various embodiments and applications are disclosed.

Abstract: Digital fuel injector, injection and hydraulic valve actuation module and engine and high pressure pump methods and apparatus primarily for diesel engines. The digital fuel injectors have a plurality of intensifier actuation pistons allowing a selection of up to seven intensified fuel pressures. The disclosed engine operating methods include using at least one cylinder for a compression cylinder for providing compressed intake air to at least one combustion cylinder. A pressure sensor in each combustion cylinder may be used to indicate temperature in the combustion cylinder to limit combustion temperatures to below temperatures at which substantial NOX is generated. A re-burn cycle may be used to complete the burning of hydrocarbons, providing a very low emission engine. A compression cylinder may be provided with a pump actuated by the piston in the compression cylinder. Various aspects and embellishments of the invention 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: Hydraulic valve actuation systems and methods to provide variable lift for one or more engine air valves by way of a variable position hard stop. Various embodiments are disclosed, including embodiments controlling lift by providing a choice of two different fixed stops, three different fixed stops, stops continuously variable throughout a range of lifts, and a fixed stop and stops continuously variable throughout a range of lifts. The valves controlled by a variable position hard stop may be a single engine intake or exhaust valve, or multiple valves of any number, and of either intake or exhaust valves or both, or of one intake or one exhaust valve for one or more cylinders in engines having more than one intake or exhaust valve per cylinder. Dashpot deceleration of engine valve velocity on opening to the hard stop and on engine valve closure is disclosed, as are other aspects and embodiments of the invention.

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.