Abstract: The present invention provides an internal combustion engine drive train actuating assembly which includes a dual overhead cam shaft arrangement wherein a pair of cam shafts is supported in the head section of the engine. One cam shaft is positioned to actuate the intake and exhaust valves. The other cam shaft is dedicated to actuating only the unit fuel injectors and is positioned relative to the injector actuating rocker levers to contact only these rocker levers during engine operation. The rocker lever-contacting lobes on the dedicated injector-actuating cam shaft are dimensionally wider than has heretofore been possible, which allows the high fuel injection pressures required to achieve optimum fuel economy and emissions while minimizing hertz stresses on the cam shaft.

Abstract: A cam roller pin for mounting a cam roller with a substantially uniform width to a rocker lever includes a substantially cylindrical pin body bounded by a pair of oppositely-disposed ends and having a length which extends from one end to the opposite end, the pin body defining an oblong trough therein which has a length that is at least 30 percent of the length of the pin body. The pin body has an outer surface which defines a passageway extending from the outer surface through the pin body and into one end of the oblong through. The passageway is configured with two portions having different entry locations into the pin body and the passageway provides a path for lubrication from the exterior of the cam roller pin to the oblong trough.

Abstract: An articulated piston for use in heavy duty diesel engines including a piston crown having an outer surface, a peripheral pending side wall and an inner surface having a pair of pin bosses extending downwardly from the inner surface with the inner surface and the pin bosses defining a hollow cooling cavity opening downwardly and extending about a circumference of the piston crown and a piston skirt with the piston skirt including a first longitudinal plane containing a pair of diametrically opposed bores for receiving a wrist pin for connection to the bosses of the crown and defining two semi-cylindrical thrust and non thrust surfaces of the skirt with a thickness of the non thrust surface being less than a thickness of the thrust surface and a second longitudinal plane, perpendicular to the first plane thereby dividing the piston skirt into four peripheral quarters.

Abstract: A high strength, lightweight camshaft for an internal combustion engine, comprising a shaft body having an axially oriented hollow interior extending a predetermined length from between a pair of spaced points, respectively, adjacent the ends of the shaft body. Plural camshaft journal bearings are spaced apart on the shaft body and include a pair of end camshaft journal bearings positioned adjacent the ends of the shaft body, respectively, with at least one inner camshaft journal bearing positioned intermediate the pair of end camshaft journal bearings. Each end camshaft journal bearing has a lubricant transfer means formed therein for receiving lubricant from an external supply and for transferring lubricant into the hollow interior of the camshaft.

Abstract: A high pressure fuel pump unit and assembly is provided which includes a pump barrel containing a bore, a pump plunger mounted in the bore for reciprocal movement between an advanced position and a retracted position, and a force transmitting device for transmitting axial loads to the plunger while minimizing side loads on the plunger. The force transmitting device includes an extension member extending into the inner radial extent of a bias spring and including a distal supporting end positioned in uncoupled abutment against a driven end of the pump plunger to form a decoupled force transmitting interface. The pump plunger and extension member are capable of relative lateral movement at the decoupled force transmitting interface which is positioned a spaced axial distance from the outer end of the pump barrel when the pump plunger is in the advanced position.

Abstract: A high pressure fuel line connection assembly for a fuel injector positioned in a cylinder head of an internal combustion engine is disclosed. The cylinder head includes at least two bores formed therein with the second bore intersecting the first bore at an angle with respect to an axial direction of the first bore. A fuel injector is received in the first bore for injecting fuel into a cylinder of the engine, a fuel line for directing fuel to the fuel injector, an intermediate elongated fuel line adapter are received in the second bore for fluidicly conducting fuel from the fuel line to the fuel injector. The elongated fuel line adapter includes a first end contacting the fuel injector in a region of the fuel injector for receiving fuel to be injected and a fuel line connection fitting for biasing an end of the fuel line against a second end of the adapter and the first end of the adapter against the fuel injector in order to sealingly engage the adapter with both the fuel line and the fuel injector.

Abstract: A system for controlling fuel flow in an internal combustion engine receives a command specifying a desired fuel flow rate from an electronic control module. The system generates a feedforward estimate of actuator current required to produce the desired flow rate. This estimate is combined with a fueling current offset value generated using a proportional-integral feedback controller. A differential pressure between the fuel rail and cylinder gas is converted, by surface interpolation based on a lookup table, to an estimate of actual fuel flow rate. The difference between this actual fuel flow rate and the desired flow rate is provided to the feedback controller as an error signal. The feedback controller preferably uses different gain values depending on an operating mode of the engine (speed control and torque control modes).

Abstract: An injection rate shaping nozzle assembly for a fuel injector is provided which includes a closed nozzle valve element and a rate shaping control device including an injection spill circuit for spilling a portion of the fuel to be injected to produce a predetermined time varying change in the flow rate of fuel injected into a combustion chamber. The spill circuit includes a spill passage integrally formed in the nozzle valve element. The rate shaping control may include a spill valve for controlling the spill flow through the spill circuit to create a low injection flow rate followed by a high injection flow rate. The spill passage may communicate with the injector nozzle cavity between injection events or alternatively may be blocked to prevent spill flow between injection events. The rate shaping control device may include a spill accelerating device in the form of a spill chamber formed in the nozzle valve element for creating a rapid increase in the spill flow rate.

Abstract: Manufacture of a liquid cooled cylinder head for an internal combustion engine is described which reduces incidence of casting fins that may block or impede coolant flow through the cylinder head. The head is cast without internal liquid coolant passages to interconnect the first and second cooling cavities. An opening is machined through an outer surface of the head to define a passage interconnecting the first and second cooling cavities to provide for communication of cooling liquid therebetween. The opening formed by machining through the outer surface of the head is closed. Throat area of the the passage may be selected to control coolant exchange between the first and second cooling cavities and additional passages may be machined in each head to provide additional coolant interchange or to vent air from the cooling cavities.

Abstract: A system and method for controlling an air-fuel ratio of an internal combustion engine using a ratio of cylinder pressures measured within at least one cylinder. The air-fuel ratio control system includes an electronic control module (ECM) which computes a measured cylinder pressure ratio of the cylinder pressure measured at a predetermined crank angle before top dead center and the cylinder pressure measured at a predetermined crank angle after top dead center. The measured cylinder pressure ratio is compared with an optimal cylinder pressure ratio. Based upon the results of this comparison, the ECM then determines an adjusted air-fuel ratio which would modify the measured pressure ratio to equal the optimal pressure ratio. This system controls the air-fuel ratio by measuring the quality of combustion without the need to measure the amount of air or fuel actually delivered to the engine.

Abstract: An injection rate shaping nozzle assembly for a fuel injector is provided which includes a closed nozzle valve element and a rate shaping control device including an injection spill circuit for spilling a portion of the fuel to be injected to produce a predetermined time varying change in the flow rate of fuel injected into a combustion chamber. The spill circuit includes a spill passage integrally formed in the nozzle valve element. The rate shaping control device may include a spill accelerating chamber in formed in the nozzle valve element for creating a rapid increase in the spill flow rate. A spill circuit purge device is provided to remove fuel from the spill circuit and accelerating chamber between each of the injection events thereby ensuring an unimpeded, effective spill fuel flow during the next spill event.

Abstract: A ring compressor is provided including a resilient compression band for encircling, and applying a compression force to, the ring, and a band actuation device connected to the compression band for moving the compression band between a decompressed position in which the band ends are spaced and a compressed position in which the band ends are positioned in end to end, nonoverlapping abutment preventing further compression of the ring. The band actuation device may include an outer band encircling the resilient compression band and a hand operated lever assembly. The outer band provides radial support to the ends of the compression band to guide the first and second ends radially into abutment. A ring end axial alignment device may also be provided for guiding the ends of the compression band into axially aligned abutment when in the compressed position.

Abstract: A turbocharger wastegate control system is responsive to electrical control signals to control the position of a wastegate valve positioned within an exhaust bypass conduit of the turbocharger. In one embodiment, the control system includes an air pressure control device having an inlet port receiving boost air pressure from an intake manifold connected to the turbocharger, an outlet port providing wastegate air pressure to a wastegate actuator and a vent to atmosphere. A number of air flow control switches are responsive to electrical control signals to control the levels of boost air pressure and vented air to thereby provide a plurality of discrete wastegate air pressure levels to the wastegate actuator. In another embodiment, the control system includes an electrically controllable wastegate actuator responsive to boost air pressure and electrical control signals to modulate the position of the wastegate actuator plunger.

Abstract: A load driver system for integrally controlling the flow of current through a number of inductive loads of an internal combustion engine, particularly the flow of current through a fuel injector solenoid and an engine brake solenoid during the operation of an engine cylinder, is provided. In one embodiment of the load driver system, a single multiplexed high side driver is connected to inputs of both solenoids, and separate low side drivers are connected to outputs of each of the solenoids. In an alternative embodiment, separate high side drivers are connected to inputs of each of the solenoids, and a single multiplexed low side driver is connected to the outputs of the solenoids.

Abstract: A fuel measurement and control system for a gaseous fuel engine having a solenoid actuated fuel flow control valve which is electronically actuated to control a desired metering duration when the control system is operating in a fuel flow control mode. The fuel measurement and control system further includes mode control valve for switching the control system between a fuel flow control mode and a positive fuel shutoff mode, wherein the fuel flow control valve is prevented from opening when the control system is operating in a positive fuel shutoff mode. The fuel flow control valve includes a pressure balance chamber to balance the biasing forces acting on the valve from the gaseous fuel, wherein gaseous fuel is introduced into the pressure balancing chamber to provide the balancing forces.

Abstract: An improved method and 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 injection control device for injecting small amounts of used lube oil into the engine's fuel system and an auxiliary flow control device for directing controlled quantities of fresh oil into the engine's lube oil 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 process 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.

Abstract: An engine control system is operable to provide an engine fueling rate equal to the larger of a first engine fueling rate at which the resulting engine torque is limited by a maximum input torque capacity of a presently engaged gear ratio of the transmission and a second engine fueling rate at which the resulting engine torque is limited by a nominal input torque capacity of the transmission. The foregoing technique can be enabled at all times, or alternatively only after determination that the vehicle is experiencing deceleration under heavy engine load conditions. The engine control system may be further operable to determine a third engine fueling rate at which the resulting engine output torque is limited by a maximum operating torque capacity of the transmission propeller shaft, as well as a fourth engine fueling rate at which the resulting engine output torque is limited by a maximum operating torque capacity of the drive axle connected thereto.

Abstract: A compression braking system is provided which permits an engine's exhaust valves to be operated by fuel pressure during a braking mode independently of the engine's mechanical actuating elements and associated control limitations. The present braking system includes a high pressure fuel supply including a high pressure fuel accumulating device for accumulating and temporarily storing high pressure fuel and an actuator device including an actuator piston operatively connected to the engine exhaust valve and a brake actuating valve for controlling fuel flow from the accumulating device to the actuator piston. The pressure of the fuel acting on the actuator causes movement of the exhaust valve. The system may include a pressure regulator for decreasing the accumulator fuel pressure to a more appropriate actuation fuel pressure to minimize high pressure joints and leakage. A improved sealing means may be provided for preventing leakage around the actuator piston.

Abstract: A system for controlling the temperature of recirculated exhaust gas supplied to an internal combustion engine is provided. In one embodiment, the system includes a heat exchanger having the recirculated exhaust gas flowing therethrough and further having coolant fluid flowing therethrough. A control valve is disposed within the flow path of the coolant fluid, and the valve position is modulated to vary the rate of coolant fluid flow through the heat exchanger, thereby controlling the temperature of the recirculated exhaust gas supplied by the heat exchanger. In another embodiment, the heat exchanger defines a number of exhaust gas flow passages therethrough and a number of gas flow control valves are disposed between the exhaust gas inlet of the heat exchanger and the number of exhaust gas flow passages.

Abstract: An improved coupling assembly is provided for transmitting rotary power from the working end of an internal combustion engine to a driven shaft. The crankshaft also has a free end connected to an accessory drive train. The coupling assembly comprises a low inertia flywheel having a mass so selected as to cause the node of the first crankshaft mode of torsional vibration to be located in the vicinity of the middle of the crankshaft, and a flexible coupling which interconnects the working end of the crankshaft with the driven shaft.