Abstract: A solenoid operated pin-within-a-sleeve three-way valve for high pressure fuel systems is provided which is capable of effectively minimizing the side loads imparted to the movable pin and sleeve elements while effectively controlling the timing and quantity of fuel injection. The three-way valve assembly includes a floating pin telescopingly received within the cavity of the movable valve member. A side load reducing device is provided for minimizing side loading on the floating pin and the movable valve member which includes a tappet reciprocally mounted in the valve housing adjacent one end of the floating pin, a biasing spring for causing the tappet to follow the pin and for causing the pin to follow the movable valve member to keep the second valve seat closed as the movable valve member is advanced toward the first position from the second position.

Abstract: A vehicle/engine speed data collection and preprocessing method and apparatus comprises obtaining speed signal data, typically from a speed sensor; computing a linear equation of the speed signal data; adding artificial data to the speed signal data in accordance with the linear equation; filtering the speed signal data having the artificial data added thereto; and removing the filtered artificial data from the filtered data. The technique minimizes the transient effects of filtering, particularly at the data boundaries.

Abstract: A gas mass flow sensor for sensing the flow of a gas to an internal combustion engine including a main flow passage having an inlet and an outlet for directing a gas flow to the internal combustion engine with the inlet communicating with a source of the gas and an outlet communicating with the internal combustion engine. A secondary flow passage for isolating a portion of the gas flow from the main flow passage is provided with the secondary flow passage including an inlet surrounding the main flow passage and a flow sensing section. Positioned within the flow sensing section of the secondary flow passage is a gas mass flow sensor for sensing the mass flow of gas through the secondary passage which is indicative of the mass flow through the main flow passage.

Abstract: A gas/air mixer for injecting gas into the intake air stream of an internal cumbustion engine using a combination of radial holes and radial tubes located around the perimeter of an air flow passage. The gas/air mixer includes an intake air passage which has a combination of radial holes and radial tubes arranged so that the gas is injected into the air stream. The gas passage contains gas which is at a higher pressure than the intake air. The gas flows around an annulus which distributes the gas to all the radial holes and radial tubes. The size of the intake air passage, the number and size of the radial holes, and the number, size and length of the radial tubes can be varied in any combination to achieve adequate gas/air mixing for the particular engine application. This combination can even include a device that contains all radial holes or all radial tubes. The distance that the gas is injected into the air stream is small at the radial holes and larger at the radial tubes.

Abstract: Improved fatigue strength properties are achieved in an induction hardened microalloy steel useful for demanding service environments. The microalloy steel has low carbon and sulfur contents, comprising in % by weight, 0.15% to 0.45% C, 0.50% to 1.60% Mn, up to 0.20% V, 0.0001% to 0.01% S, balance Fe. The material is fabricated to a selected configuration, such as an engine crankshaft, for example. Selected surfaces of the fabricated article are hardened by induction heating. The article can be used directly after induction hardening or it may be tempered at low to moderate temperatures of from about 100.degree. C. (200.degree. F.) to 290.degree. C. (550.degree. F.) to achieve a desired surface hardness and compressive residual stress level. The controlled alloy chemistry and low tempering temperature provide a substantial increase in bending fatigue strength over conventional higher carbon grade steels.

Abstract: Engine (60) has manifold (62) and includes an air pathway (20) and a fuel line (30) coupled to the manifold (62) for supplying a fuel charge. Fuel line (30) has a controllable valve (40) for regulating fuel flow and a first sensor (38) providing a fuel signal corresponding to mass flow rate of fuel through the fuel line. A second sensor (65) provides a speed signal corresponding to rotational speed of the engine. A third sensor (63) provides a temperature signal corresponding to temperature within the manifold. A fourth sensor (64) provides a pressure signal corresponding to pressure within the manifold. A fifth sensor (76) provides an exhaust signal corresponding to air/fuel ratio for combusted air and fuel in the exhaust pathway. A controller (80) responsive to the controllable valve (40) and sensors (38), (63), (64), (65), and (76) determines an air signal corresponding to the mass flow rate of air through the air pathway (20) as a function of the speed signal, temperature signal, and pressure signal.

Abstract: An improved plunger and barrel assembly is provided which includes a plunger reciprocally mounted in a cavity formed in the barrel and a leakage flow reduction device positioned in the cavity for reducing fluid leakage flow around the plunger thus increasing system efficiency. The leakage flow reduction device includes a sealing sleeve removably mounted in the cavity between the plunger and the barrel, which includes a bore for slidably receiving the plunger to form an annular clearance gap between the plunger and the bore. The sealing sleeve is designed to resiliently flex in response to fluid pressure forces to reduce the annular clearance gap so as to minimize fluid leakage through the annular clearance gap. The sealing sleeve is formed as a separate piece from the barrel to permit simple, low cost replacement. The sealing sleeve is preferably applied to a fuel pump having a pump plunger for pressurizing fuel in a high pressure chamber.

Abstract: An improved sensor and sensor assembly is provided which permits the easy removal of the sensor from its mounting bore even in the presence of corrosive residue in the mounting bore. The sensor assembly includes an elongated sensor body having an annular tapered portion with a frusto-conical shape for positioning in a mounting bore having a complementary taper. As the sensor is removed from the mounting bore, the annular gap between the sensor and inner wall of the mounting bore will gradually increase at any point along the sensor body thereby increasingly separating any corrosive residue accumulated on the opposing surfaces. In addition, a seal assembly is provided which effectively vents gas pressure from the annular gap between the sensor and the mounting bore without damaging the seal and while ensuring the seal returns to its fully sealed position thereby preventing contaminants from entering the bore throughout engine operation.

Abstract: A fuel injector assembly is provided which operates to effectively creating a low injection flow rate followed by a high injection flow rate during all engine operating conditions, including idle and low engine speed conditions, to produce a high quality fuel spray with proper atomization and thus improved fuel air mixing resulting in improved emissions abatement and fuel economy. The assembly includes two biased valve elements designed to sequentially open and close to initially open a limited number of orifices followed by the opening of a remainder of the orifices thereby effectively varying the available cross sectional flow area from the nozzle cavity into the combustion chamber of the engine during the injection event. The nozzle valve elements may be spring biased or fluid pressure biased and include biasing surfaces sized to cause the sequential opening and closing of the elements.

Abstract: A wear and scuff-resistant timing plunger for a timing assembly in a unit fuel injector for an internal combustion engine is provided. The timing plunger is formed of a high thermal expansion ceramic with a thermal expansion coefficient greater than 6.times.10.sup.-6 /.degree. C. and a hardness greater than 800 Kg/mm.sup.2, which maintains a desired diametral clearance and efficient plunger function without scuffing or sticking under the axial, tangential and pressure loads encountered in the fuel injector operating environment. Preferred high thermal expansion ceramics are zirconia, alumina-zirconia and alumina.

Abstract: An improved cam operated, open nozzle, unit injector is disclosed including an injector body formed by a barrel, spring housing, and nozzle and containing a central bore for receiving a variable length plunger assembly mounted for reciprocal movement within the injector body wherein the variable length plunger is formed by an outer plunger and inner plunger combined with a timing plunger, mounted between the inner and outer plungers to form a collapsible timing chamber into which a variable quantity of fuel may be metered and expelled on a cycle by cycle basis to provide a variable effective length to the plunger assembly to cause controlled variation in injection timing based on variation in the timing fluid supplied to the injector and wherein the timing plunger is provided with a radial flange for engaging a stop formed in the injector barrel to hold the timing plunger in a predetermined precise location during metering of timing fluid into the collapsible timing chamber and to render the injector timing i

Abstract: Fuel injection rate shaping is integrated into the pressure intensification stage of a hydraulically actuated fuel injector having a pressure intensifier. In a first embodiment, the pressure intensification plunger is formed of two parts creating a damping chamber therebetween from which fluid is forced out through orifices in a lower one of the plunger parts during an initial phase of displacement of the upper part. Thus, injection will be performed initially at a lower pressure and rate, which increases once the plunger parts make contact. In a second embodiment, a throttled flow is set via a restrictor housing that telescopingly receives the upper plunger part, so that a lower injection rate occurs while fluid is bled off through a restricted flow path between the restrictor housing and the upper plunger part, and a higher injection rate is produced once a port in the upper plunger clears the restrictor housing.

Abstract: A constant horsepower throttle progression control system and method. In order to improve driveability of a vehicle compared to prior art engine controllers, the present invention operates an engine so as to either produce a constant (or nearly constant) output horsepower at all engine speeds for any throttle position, or so as to produce an output horsepower equal to a predetermined percentage of the range between full rated power and motoring horsepower at all engine speeds for any throttle position. The predetermined percentage may or may not be equal to the percentage of full throttle represented by the throttle position, and may or may not be linearly related thereto.

Abstract: An improved fuel injector for providing precise control over injection timing, quantity and rate shape is provided which includes a piezoelectric actuator for compressing actuating fluid in an actuating fluid circuit which includes a fluid chamber positioned adjacent a needle valve element and fluidically separate from a fuel supply circuit for supplying high pressure fuel for injection. Actuating fluid pressure in the chamber acts on the needle valve element to initiate injection. A fuel pressure balancing device is provided for balancing the fuel pressure forces acting on the needle valve element while the element is in both the closed and open positions thereby permitting the piezoelectric actuator to more precisely and predictably control the rate of movement, and the extent of movement, of the needle valve element.

Abstract: An effervescent fuel injector, particularly one suitable for diesel and direct injection engine applications, which is capable of injecting, particularly intermittently, an atomized fuel spray with droplets of a size in the range of 5-6 micron SMD without requiring high pressures is achieved in a preferred embodiment effervescent fuel injector of the valve covered orifice (VCO) type having primary and secondary nozzle valves which remain closed when the control valve is not actuated, but which open one or two sets of nozzle orifices depending on fuel volume requirements. A three-way, on-off control valve is used to trigger commencement of the supply of gas via a control valve simultaneously with opening of at least some of the nozzle orifices. Gas and fuel are mixed in a mixing chamber located upstream of the nozzle valves in a manner creating a gas-fuel aeration, and as the aeration is sprayed from the nozzle orifices, the gas expands rapidly breaking the fuel into fine droplets.

Abstract: In an internal combustion engine, a barring adapter member is mounted on an auxiliary engine component, such as an air compressor shaft which is geared to the engine crankshaft. The barring adapter member is configured to receive a barring tool, permitting manual rotation of the air compressor shaft for desirably positioning engine crankshaft-driven components during engine repair or adjustment. In an arrangement according to the invention, the air compressor gear is enclosed by a gear casing, but the adapter is accessible through an aperture closeable by a removable cap. The barring adapter member facilitates barring the engine from a convenient position and is particularly advantageous in an engine designed to eliminate most externally-exposed rotational shaft seals and associated external pulleys conventionally used as barring locations.

Abstract: A separable gasket for use in sealing the interface between a gear housing and an engine block as well as the interface between an air compressor and the gear housing includes a first gasket portion constructed and arranged for sealing the interface between the gear housing and the engine block and a second gasket portion constructed and arranged for sealing the interface between the air compressor and the gear housing. A third gasket portion in the form of a perforated score line is positioned between the first gasket portion and the second gasket portion. In the event the air compressor requires servicing, the present invention enables the second gasket portion to be manually flexed and ultimately separated from the first gasket portion so that a replacement gasket can be assembled when the air compressor is reassembled to the gear housing.

Abstract: An improved system for automatically continuously replacing an engine's used lubricating oil with fresh lubricating oil throughout operation based on engine operating conditions is disclosed. The present system includes an intermittent injection control device for intermittently injecting small amounts of used lube oil into the engine's fuel system. An electronic controller is provided to vary the amount of used lube oil injected into the oil system based on the severity of engine operation. The system periodically determines an engine operating severity value, i.e. fuel consumption value, for an interval of engine operation and calculates a base line quantity of oil for injection based on the current fuel consumption of the engine during the current interval. The system may also include an auxiliary flow control device for directing controlled quantities of fresh oil into the engine's lube oil system for maintaining the engine's oil sump at a proper level.

Abstract: A system for processing output signals associated with multiple vehicle condition sensors includes a first sensor producing a pair of output signals indicative of a first vehicle condition and a second sensor producing an output signal indicative of a second vehicle condition. One of the first sensor output signals and the second sensor output signal are received by an interface circuit which produces an output signal that is a function of its two input signals. A vehicle control computer receives the output of the interface circuit and the other of the first sensor output signals and processes these signals to provide diagnostic information related to each of the two sensors. The diagnostic information may include fault codes associated with individual ones, or a combination, of the two sensors which are stored in memory, and may further include energizing signals for energizing warning means associated with each of the two sensors.

Abstract: A control system for controlling automatic shifting of a manual/automatic transmission is disclosed including a cruise control system and an auto-shift mode for controlling automatic upshift and downshift operations between the top two gears of a heavy duty truck transmission. Certain failures of equipment or incorrect driving habits of operators are corrected for with algorithms which prevent undesirable operating conditions which compromise the acceptability of an electronically controlled heavy duty truck transmission equipped vehicle. The mechanism by which auto-shift operation of the transmission is requested is also compared with parameters such as vehicle speed and engine speed in order to determine whether gears should be engaged or disengaged, the gears being those subject to auto-shift control of the system controller.