Abstract: A unitary cylinder head casting for an engine includes a plurality of valve guide bore casting portions, each valve guide bore casting portion defining a valve guide bore and a plurality of head bolt bore casting portions, each head bolt bore casting portion defining a head bolt bore. The cylinder head casting is constructed and arranged such that there is at least one head bolt bore corresponding to each valve guide bore. The cylinder head casting also defines an upper water jacket and a lower water jacket. In order to eliminate fillets in the area of the upper water jacket which represent likely locations for fatigue cracks to initiate, gusset ribs are included as part of the cylinder head casting. There is at least one gusset rib extending between at least one combination of one head bolt bore casting portion and its corresponding valve guide bore casting portion.

Abstract: A replaceable cylinder liner for an internal combustion engine. The position of the liner within the block is established by a midstop. An interference fit below the midstop seals the bottom end of a cooling passage that extends around the liner. The top end of the cooling passage is sealed by an o-ring, and when the engine is warmed up by an interference fit also. The top of the cooling passage is close to the top dead center position of the top piston ring, and reduces the temperature of the top piston ring.

Abstract: A pneumatic throttle system for maintaining sufficient exhaust pressure to maintain exhaust flow through an EGR system. The throttle system includes an apertured throttle plate positioned to selectively restrict the flow of exhaust gasses exiting the engine. Movement of the plate is controlled by a pneumatic piston assembly connected thereto. The piston assembly includes a piston movably mounted within a gas-tight chamber. The piston head functionally divides the chamber into two variable-volume portions. The first chamber portion is pneumatically connected to the intake manifold, while the second portion is pneumatically connected to the exhaust manifold. The gas pressure in one chamber portion relative the other determines the relative volume of each chamber portion according to P1V1=P2V2. The piston moves within the chamber to satisfy the above relationship.

Abstract: A system for programming a vehicle control computer with selectable features and/or trim values includes a first computer maintaining a web site containing vehicle control computer calibration information and a second computer operable to access the web site whereby the first computer is responsive to information provided by a user to generate a set of feature and/or trim values and to create a file of the set of feature and/or trim values along with a loading program therefore. In one embodiment, the file and loading program may be loaded onto a memory disk for subsequent transfer to a third computer configured for communicating with a vehicle control computer. In another embodiment, the file and loading program may be transferred directly to the third computer via a wired or wireless communications link. In still another embodiment, the third computer may access the web site and the file and loading program may accordingly be transferred directly to the third computer from the web site.

Abstract: A reprogrammable electronic step timing control system having a fuel pressure threshold that is discretely variable as a function of engine speed. The fuel pressure threshold is increased for engine speeds above rated speed by a predetermined amount. A programming key is provided in a wiring harness to allow fuel pressure and speed thresholds to be readily changed.

Abstract: The present invention relates to a system for controlling loading of an internal combustion engine based on a an adjusted load bias signal produced by an engine control computer. The engine control computer is responsive to engine speed and commanded fueling to produce a load bias signal, is responsive to engine speed, engine intake air pressure and the load bias signal to produce an acceleration-adjusted load bias value, and is responsive to engine speed, a reference engine speed and the load 10 bias signal to produce a deceleration-adjusted load bias value. The engine control computer is thereafter operable to compare the load bias value, the acceleration-adjusted load bias value and the deceleration-adjusted load bias value and produce the adjusted load bias signal as one of these three signals based on a comparison therebetween. The adjusted load bias signal is provided to an external load generator operable to control loading of the engine based thereon.

Abstract: An exhaust gas recirculation (EGR) enhancement system for a turbocharged internal combustion engine includes a throttle valve arranged in the exhaust duct of the engine, downstream of the EGR system. The throttle valve is controlled in response to engine load and engine speed to selectively provide back pressure upstream of the throttle valve to selectively drive an EGR exhaust flow through an EGR duct to the intake manifold. An embodiment of the EGR system includes a cooler that lowers the temperature of the EGR exhaust flow to provide better reductions in nitric oxide emissions. The turbine is equipped to allow excess pressure to be released through a wastegate duct arranged in fluid parallel with the exhaust turbine, thereby allowing for higher power and higher speeds.

Abstract: A system is disclosed for determining an effective throttle value of an internal combustion engine for controlling automatic transmission shift points. In one embodiment, the system is operable to determine an effective throttle value as a function of commanded fueling and engine speed under operating conditions wherein engine torque is requested by a system/component other than manual throttle control to thereby provide a throttle value indicative of what throttle position or percentage would be under present operating conditions if engine torque was being requested via manual throttle control. The present invention accordingly overcomes deficiencies in known automatic transmission shift point control systems by continuously computing an equivalent throttle percentage whenever fueling or requested torque values are not dominated by actual throttle (e.g. accelerator pedal) percentage.

Abstract: A system for controlling internal combustion engine performance in accordance with driver behavior includes a vehicle control computer operable to receive a plurality of vehicle operating parameter signals and control engine fueling based thereon. In accordance with an operational status, or an operational state determined over a predefined time interval, of one or more of the vehicle operating parameter signals, the system is operable to control available engine performance. Both the operational status and operational state of the various vehicle operating parameters are the result of the manner in which the driver operates the vehicle. The control system of the present invention is thus operable to reward/penalize driver performance by correspondingly adding/subtracting available engine performance in the form of available engine output power and/or available vehicle speed.

Abstract: A system and method for detecting abnormal operation of a turbocharger compressor reads data from a plurality of sensors and first conducts a series of rationality tests on the sensor data. The tests determine whether the data generated by certain ones of the sensors is accurate or compromised. If a particular sensor fails its corresponding rationality test, an error signal is generated. On the other hand, if all sensor data passes the rationality tests, the compressor performance data is compared to a compressor operation map, and more particularly to surge and choke regions defined by boundary lines on the map. If certain compressor performance data falls into either the surge or choke region, an appropriate abnormal performance signal is generated. In certain embodiments of the invention, the sensor rationality tests are based on a predetermined second order polynomial relationship between two compressor operating parameter, such as mass air flow, boost pressure, turbo speed, etc.

Abstract: A continuous liquid level measurement system is disclosed which is based upon a differential pressure measurement. The pressure of the liquid level to be measured is calibrated with a second pressure measurement of the pressure above the liquid in order to get a more accurate pressure measurement which is related in a predetermined manner to the level of the liquid. For instances in which the liquid to be measured is in a harsh environment, the invention provides for a means for mounting the sensitive pressure measurement devices remotely from the liquid.

Abstract: A lube oil and fuel blending system, pumping device and method are provided which effectively, inexpensively and controllably removes used lube oil from an engine and delivers the lube oil to the fuel system for consumption within the engine. The lube oil and fuel blending system includes a fuel pumping device or injector containing a bore and a plunger reciprocally mounted in the bore for movement through a retraction stroke and an advancement stroke, each having a predetermined stroke length. A fuel drain circuit communicates with the bore at a drain location spaced a predetermined seal length axially along the bore from an outer opening of the bore through which the plunger extends. The predetermined seal length is specifically designed less than the predetermined stroke length to cause lube oil on the outer portion of the plunger to be delivered by the plunger to the fuel drain circuit at the drain location.

Abstract: Apparatus and method for adjusting a gear in a gear train assembly. A first gear with a first rotational center and a second gear with a second rotational center are coupled to an engine. A third gear with a third rotational center is provided to form a first mesh with the first gear. The first mesh has a predetermined minimum backlash. The third gear also forms a second mesh with the second gear. The third gear includes an adjustable positioning mechanism which allows the rotational center of the third gear to be adjusted along a predetermined adjustment path that is substantially tangent to the first mesh. The adjustment mechanism of the third gear allows the minimum backlash of the first mesh to be maintained while the second mesh is adjusted to likewise achieve a generally minimized backlash.

Abstract: A fuel injector including a floating sleeve control chamber is provided which effectively minimizes friction and wear, and thus prevents stiction, of a nozzle valve element by avoiding the need to align two bore guiding surfaces for the element. The floating sleeve control chamber includes a floating sleeve positioned on a control piston formed integrally with a nozzle valve element and positioned in a cavity. The floating sleeve is sized with an outer extent or diameter sufficiently less than the size of a surrounding cavity wall so as to permit lateral movement of the floating sleeve and thus movement of the control chamber. Only the nozzle valve element guiding bore surfaces control the alignment of the nozzle valve element relative to its seat while the floating sleeve effectively forms and seals a floating control chamber. The floating sleeve may be formed from one or more sleeve sections.

Abstract: A rotary engine having a pair of nested rotors positioned with a housing to define a central combustion chamber and four subchambers having variable volumes. Rotors are mounted about a driveshaft extending through the housing. The rotary engine utilizes tunable gas compression and expansion in order to manage emissions without needing exhaust gas recirculation or a complicated and expensive fuel injection system. The rotary engine is relatively simple and inexpensive to manufacture, has no valve train, is vibrationless, has high power density, and has a wide speed range.

Abstract: A unit fuel injector is provided which includes a threadless injector body attaching device for attaching an upper body section of the fuel injector to a lower body section while avoiding imparting a transverse load to the upper body section thereby minimizing bore distortion, plunger wear and the likelihood of injector failure. The threadless injector body attaching device includes a groove formed in the lower end of the upper body section and one or more apertures extending through the lower body section for positioning adjacent the groove. Also, one or more pins are provided for insertion into a respective aperture and connection to the lower body section. The groove and opposing aperture or apertures are sized to create a slip fit to avoid a contact force between the pin or pins and the upper body section.

Abstract: A premixed charge compression ignition engine, and a control system, is provided which effectively initiates combustion by compression ignition and maintains stable combustion while achieving extremely low oxides of nitrogen emissions, good overall efficiency and acceptable combustion noise and cylinder pressures. The present engine and control system effectively controls the combustion history, that is, the time at which combustion occurs, the rate of combustion, the duration of combustion and/or the completeness of combustion, by controlling the operation of certain control variables providing temperature control, pressure control, control of the mixture's autoignition properties and equivalence ratio control. The combustion control system provides active feedback control of the combustion event and includes a sensor, e.g. pressure sensor, for detecting an engine operating condition indicative of the combustion history, e.g.

Abstract: A system for controlling the speed of an engine in a vocational application is implemented within a mobile cement mixer. The system permits operation of the engine at a high rpm PTO speed to drive the mixing drum at a recommended speed for optimal full mixing of aggregate within the drum. The system maintains the engine at this high rpm only for a predetermined time period necessary for full mixing. After expiration of the time period, the system directs the engine governor to drop the engine speed to low idle, thereby preventing overworking of the cement, reducing the abrasive effect of the aggregate on the interior of the mixing drum, and improving engine fuel economy. In one embodiment, the system permits operator entry of drum rotation speed and total drum revolutions, which are then used to calculate the time period value.

Abstract: A system for controlling vehicle braking operation includes a mechanism for determining desired service brake force, a mechanism for determining vehicle deceleration, an electronically actuatable engine compression brake unit, an electronically controllable turbocharger boost pressure adjustment device and a transmission including a number of automatically selectable gear ratios, wherein each of these components are coupled to a control computer. The control computer is operable to activate the engine compression brakes whenever service brake action is detected, and to modulate the downshift engine speed points of the transmission as a function of the desired brake force. The boost pressure adjustment device and the engine compression brake may optionally be controlled to maintain a vehicle deceleration rate below a deceleration rate threshold. Alternatively, the downshift engine speed points may be controlled to maintain the vehicle deceleration rate below the deceleration rate threshold.

Abstract: A premixed charge compression ignition engine, and a control system, is provided which effectively initiates combustion by compression ignition and maintains stable combustion while achieving extremely low oxides of nitrogen emissions, good overall efficiency and acceptable combustion noise and cylinder pressures. The present engine and control system effectively controls the combustion history, that is, the time at which combustion occurs, the rate of combustion, the duration of combustion and/or the completeness of combustion, by controlling the operation of certain control variables providing temperature control, pressure control, control of the mixture's autoignition properties and equivalence ratio control. The combustion control system provides active feedback control of the combustion event and includes a sensor, e.g. pressure sensor, for detecting an engine operating condition indicative of the combustion history, e.g.