Abstract: It relates to a method of operating a compression ignition engine comprising:— determining an instantaneous driver torque demand; selectively operating the engine in a first mode or a second mode dependent on the rate of change of driver torque demand; said first mode comprising an air lead mode whereby the intake air flow rate is controlled to achieve the instantaneous driver torque demand and an amount of fuel injected is controlled to obtain a target air/fuel ratio based upon said intake air flow rate; said second mode comprising a fuel lead mode wherein the amount of fuel injected is controlled to achieve the instantaneous torque demand.

Abstract: Apparatus and method for substantially reducing or eliminating pressure pulsations caused by the opening and closing of fuel injectors. A preferred embodiment provides a restriction orifice adjacent the inlet end of a fuel injector filter of a respective fuel injector.

Abstract: A solid-oxide fuel cell stack assembly comprising a plurality of sub-stacks, preferably two sub-stacks each containing one-half the total number of fuel cells. Cathode air and fuel gas are passed through the first sub-stack, wherein they are partially reacted and also heated. The exhaust cathode air and the exhaust fuel gas from the first sub-stack are directed to the respective inlets of the second sub-stack, becoming the supply cathode air and fuel gas therefor. A first heat exchanger in the flow paths between the sub-stacks and a second heat exchanger ahead of the sub-stacks can help to balance the performance of the two stacks. The result of dividing the number of cells into a plurality of sub-stacks, wherein the exhaust of one sub-stack becomes the supply for the next sub-stack, is that fuel efficiency and utilization are improved, thermal stresses are reduced, and electrical power generation is increased.

Abstract: A particulate (soot) sensor system has a diagnostic feature for verifying the integrity of the wiring leads. The sensor system includes a sensor and processing circuitry. The sensor has a substrate, first and second sensing electrodes on the substrate and a heater electrode. The heater electrode is electrically isolated from the first and second sensing electrodes, although there is a parasitic capacitance between them. The processing circuitry includes a heater driver, a measurement circuit connected to the sensing electrodes by wire leads, and a detector. The heater driver, in addition to energizing the heater, produces a stimulus signal that is applied to the heating electrode, which is then coupled via the parasitic capacitance to the sensing electrodes. The detector is coupled to the wiring leads and is configured to detect the stimulus signal when there is electrical conductivity over the leads to the sensing electrodes.

Abstract: An electrical interconnect for a fuel cell assembly comprising a peripheral frame formed of one or more materials having a coefficient of thermal expansion similar to that of adjacent elements to which the interconnect must be bonded and a central portion formed of a corrosion-resistant material for conducting electric current between adjacent fuel cells. Preferably, the central portion is attached to the peripheral frame via a brazed corrugated lap joint for relieving thermal expansion differences between the frame and the central portion. Preferably, the joint includes an interlayer of a ductile material, for example, a nickel, copper, silver or gold layer, which helps to relieve thermal stress between the frame and the central portion.

Abstract: In a solid-oxide fuel cell assembly comprising a plurality of components having electrically-conductive mating surfaces therebetween, the surfaces are sealed by gasket elements that include first and second silver braze alloy layers and a dielectric layer, formed preferably of yttrium-stabilized zirconia (YSZ), disposed between the alloy layers. The alloy is capable of bonding to many ceramics, including YSZ, and is readily brazed to the oxide layer formed on many metals at elevated temperatures. Because the braze alloy is electrically conductive, a dielectric layer must be included to break conductivity in bonding applications where electrical insulation is required. YSZ functions as a reliable insulator and will not crystallize or fracture as do prior art glass insulators. The assembly is useful as an auxiliary power unit in a vehicle.

Abstract: A method for forming a fuel cell assembly including the pre-final-assembly step of forming a plurality of fuel cell sub-assembly modules, each module including a predetermined number of individual fuel cell repeating units, for example, ten. Each module may be leak and performance tested and certified prior to inclusion in the final fuel cell stack, thus limiting potential rework to only an individual module and only before assembly of the final stack. Preferably, each module is assembled on an assembly fixture having alignment rods, using a combination of resilient gasketing and RTV to seal between the elements. The assembled module is then placed under compression while the silicone is cured.

Abstract: In one embodiment, the method of producing a ceramic assembly includes: disposing an electrode precursor on an electrolyte precursor having an electrolyte sintering shrinkage, disposing a stabilizer precursor having a stabilizer sintering shrinkage on the electrode precursor on a side opposite the electrolyte precursor to form a precursor assembly, and sintering the precursor assembly to form the ceramic assembly comprising a stabilizer layer, electrode, and electrolyte. The difference between the electrolyte sintering shrinkage and the stabilizer sintering shrinkage is less than or equal to ±1% and a surface of the ceramic assembly has less than or equal to about 5.0 degrees camber, as measured from the horizontal plane.

Abstract: A grounded wiper assembly for a fuel sensor includes a wiper housing for rotation relative to a variable resistor and a wiper with at least one contact operatively supported by the wiper housing for contacting the variable resistor as the wiper housing rotates. The grounded wiper assembly includes a float arm connected to the wiper housing and a float connected to the float arm such that the float moves the float arm and the wiper housing relative to the variable resistor as a level of fuel increases and decreases in the fuel tank. The grounded wiper assembly further includes a conductor interconnecting the float arm and the wiper to bleed off electrical charges attached to fuel to ground.

Abstract: A method for determining the optimum fuel injection timing angle in a CI engine provided with means disposed in one or more cylinders for measuring Indicated Mean Effective Pressure. The pressure level during the power stroke of a piston is a direct correlate of engine torque being generated, and the timing of fuel injection can increase or decrease the amount of torque. Thus, maximum torque can be obtained by optimizing the timing of fuel injection. An algorithm in the ECM varies the timing of fuel injection in a narrow range until a IMEP maximum is achieved, which timing is then retained and employed until the engine operating conditions change. Thus, the invention can optimize fuel economy by optimizing the torque obtained from each injection of fuel into the cylinders.

Abstract: In a solid-oxide fuel cell system, a fuel/air manifold conveys air and tail gas fuel from the anodes in a fuel cell stack assembly to a tail gas combustor, producing a heated combustor exhaust having the highest mass flow in the system. The exhaust is passed through a heat exchanger to warm incoming cathode reaction air, and the exhaust is partially cooled by the exchange. From the heat exchanger, the exhaust gas is passed through a tempering jacket space surrounding the fuel cells in the stack. During start-up of the system, the exhaust gas is hotter than the stack and so the warm-up period is shortened. During normal operation of the system, the exhaust gas is cooler than the operating temperature and therefore cooling of the stack is assisted by contact with the exhaust gas.

Abstract: A connector assembly for a planar sensing element of an exhaust gas sensor is shown, with a method for assembling. There is an opposed pair of ceramic clamshells which retain terminals, each terminal mates to corresponding contact pads of the planar sensing element. A spacer is positioned between clamshells and a seal. A retainer clip binds the ceramic clamshells. These components are contained within an upper shield, upon assembly. The spacer creates a hinge point between the clamshell devices, allowing insertion of the sensing element without abrasion or scraping of the contact pads against the terminals The retainer clip, with radially extending tabs, keeps the opposed pair of ceramic clamshells under compression upon the sensing element when assembled, due to an interference fit with the upper shield of the sensor.

Abstract: An active system for regenerating a NOx adsorber and a particulate filter, the system includes a fuel source, a reformer for generating hydrogen and carbon monoxide in fluid communication with the fuel source, a first valve, a second valve, and a third valve in fluid communication with the reformer, an oxidation catalyst, a NOx adsorber located downstream from the oxidation catalyst, a particulate filter located downstream from the NOx adsorber; and wherein the first valve, the second valve, and the third valve control fluid flow from the reformer to the oxidation catalyst, the NOx adsorber, and the particulate filter.

Abstract: A fuel rail assembly of an internal combustion engine includes an axially extending non-round fuel conduit and at least one axially extending stiffening feature integral with said conduit. Integration of the stiffening features in the conduit enables reduction or elimination of the objectionable frequency noise radiated by the fuel rail assembly. By aligning the stiffening features axially relative to the conduit, panels having a relatively small surface area are formed and, thus, the noise radiating surface area is significantly reduced. The axial orientation of the added stiffening features allows the length of the stiffening features to be relatively large, which increases the stiffening effects to provide increased resistance to flexing, thus, reducing the noise radiated by the fuel system of the internal combustion engine.

Abstract: A method for severing a solid-oxide fuel cell bi-layer element including a structural anode and an electrolyte layer, comprising the steps of orienting the bi-layer element such that the surface thereof is accessible to laser treatment; impinging a laser beam on the electrolyte surface; moving the impinged laser beam past the surface along a path in a plane corresponding to the desired severed edge to form a groove in the element extending partially through the element to a predetermined depth; and applying a bending moment across the groove to cause the element to break into first and second portions. The groove depth is preferably about 15% of the total thickness of the element.

Abstract: A bipolar plate for use in a stack of fuel cell modules includes a bipolar plate that has at least one surface containing a metal alloy oxidizable to form a metal oxide having a surface resistance no greater than about 0.007 ohm-cm2. The metal alloy is oxidized to form a layer of metal oxide having a thickness of about 10?8 cm to about 10?2 cm and a resistivity no greater than about 107 ohm-cm. In addition to their use in fuel cells, the alloys can be employed to form conductive surfaces of electrical contacts useful for various electrical devices.

Abstract: A metal alloy which when oxidized forms a highly conductive surface oxide layer. Alloy compositions such as, but not limited to, Ti—Nb, Ti—Ta, La—Sr—Cr, and La—Sr—Co are known to form oxide passivation layers which are highly conductive. Such alloys are useful in electrical contact apparatus. An electrical contact element formed of the alloy has a contact surface which when oxidized forms a highly conductive surface layer, thus maintaining electrical conductivity and continuity through the element. The oxide layer may be formed in situ after assembly of the electrical contact or may be provided in an oxidative step during manufacture. The electrical contact may be formed entirely of one or more of such alloys; or may be formed of an inexpensive substrate base metal, such as steel, having one or more of the alloys coated thereupon; or may be formed of a mixture of the base metal and the alloy.

Abstract: An internal combustion engine having valve deactivation capability for at least one cylinder, or for an entire bank of cylinders in a multiple-bank engine, is provided with a temperature probe in the exhaust stream of that cylinder or cylinder bank. The temperature probe is connected to an Engine Control Module programmed to determine the rate of temperature change during valve deactivation, to compare the determined value to an acceptable range of rates, and to signal, when the rate exceeds an acceptable range. When the valves of a cylinder are properly deactivated, the temperature in the exhaust pipe decreases slowly. However, when valve deactivation fails, the cylinders pump non-combusted air from the intake manifold into the exhaust manifold, resulting in a relatively rapid decrease in exhaust temperature. This abnormal rate of temperature decrease thus can be used as an indicator of failure of the VVA system.

Abstract: An apparatus and method for controlling charge motion in the air intake manifold includes a barrel-style valve rotatably mounted in the lower air intake manifold between the linearly arranged set of air inlets and the first and second sets of laterally offset air outlets which branch to the first and second cylinder banks, respectively. The barrel valve includes a plurality of openings and is rotatable between a fully open position wherein the plurality of openings are in alignment with the respective air inlets and outlets in the lower manifold allowing substantially unimpeded airflow therethrough, and fully closed position wherein the plurality of openings are substantially fully out of alignment with the respective air inlets and outlets substantially preventing air flow therethrough while allowing air flow through an air bypass formed adjacent to each air inlet and outlet pair.

Abstract: In an SOFC stack system, a reformer supplies reformate to the stack. An anode tail gas portion is recycled into the reformer. An inline flowmeter indicates an apparent recycle flow rate. A map of anode tail gas composition as a function of fuel utilization efficiency U, reformer oxygen/carbon ratio O:C, and recycle percentage R is generated on a laboratory test bed at various recycle rates and fuel utilization rates. Compositions are sent through a flowmeter and a Coriolus mass flowmeter provide a Coriolus flow and sensor voltage function across the various compositions and flow rates to create an average curve and an average (reference) voltage at a given flow. A scale factor Z is calculated and used to determine a scaled sensor voltage X for use in an average flow polynomial curve fit equation to calculate tail gas mass flow rate at any flow value indicated by the flow meter.