Abstract: An integrated fuel injector and ignitor assembly is provided which includes an injector body, a fuel control valve and an ignition device. The components are packaged to create a compact assembly for positioning within an injector mounting bore and particularly in a mounting bore of an existing diesel engine. The assembly may include a fuel reservoir for accumulating fuel for injection so as to stabilize the injection pressure. Also, the ignition device may include an ignition coil mounted on the injector body and a replaceable ignitor electrode cartridge mounted on an opposite end of the injector body to permit simple, cost effective replacement of the electrodes/spark plug.

Abstract: A wear resistant, reduced stress at increased injection pressure fuel distributor assembly for distributing high pressure fuel to the fuel injectors of an internal combustion engine is provided. The assembly includes a fuel distributor rotor with a surface profile configuration that effectively and efficiently distributes high and low pressure fuel to the fuel injectors without internal fuel distribution channels. The rotor is preferably formed from a high thermal expansion, wear-resistant ceramic or coated metal material.

Abstract: A coated piston ring and method of manufacture for internal combustion engines and compressors. The piston ring having a outer peripheral surface that is coated with a thin substantially final finish spray wear resistant coating for contacting the cylinder wall. The material coating is deposited by high velocity oxygen fuel spray apparatus and a sharp bottom edge is lapped thereon for contacting the cylinder wall of the apparatus. The method of manufacturing comprising rotating a plurality of piston rings about a central axis while the high velocity oxygen fuel gun sprays molten coating material thereon. The molten coating material forming a mechanical interlock with the ring blank to produce a substantially final finish spray coating on the periphery of the piston rings.

Abstract: In accordance with preferred embodiments of the invention a timing adjustment device includes a cam follower that is engaged between an overhead cam and an injector rocker arm, and is mounted on a rotatable eccentric shaft. The geometry of the eccentric shaft and cam follower is designed so that, as timing is varied by rotation of the eccentric shaft, no change is produced in the vertical height of the rocker arm when the cam shaft is on the outer base circle and the injector is bottomed, in order to assure that the "mechanical crush" of the PT type injector is constant despite changes in timing. In a first application of the timing arrangement, it is used together with a simple injector, which does not utilize a multi-plunger arrangement to form a hydraulic link, to achieve lower parasitic losses.

Abstract: A hybrid gaseous fueling system having a low pressure supply and a high pressure supply is disclosed. This system provides the advantages of fueling with a low pressure charge during steady state operation and also provides a way to more rapidly smooth engine transients resulting from changes in engine operating characteristics such as speed or load by modulating high pressure fueling of the engine. Furthermore, air/fuel ratio control may be readily integrated into this system. In addition, start-up of the engine is performed using more fuel from the high pressure supply than the low pressure supply up to a predetermined level of engine operation. At that level and beyond, low pressure fueling is greater than high pressure fueling.

Abstract: A distortion reducing load ring disposed and connected between a fuel injector and a clamping device. The load ring functions as an intermediary for transmitting a static clamping load from the clamping device to the fuel injector body. The load ring includes a substantially cylindrical shaped main body having a bore extending therethrough between an upper portion and a lower portion. The upper portion of the main body being adapted for receiving a clamping load from the clamping device. The lower portion defining an annular ring for contacting the upper surface of the fuel injector body. A convex shaped portion connecting between the lower portion and the upper portion for increasing the resistance to bending of the load ring. The geometric relation of the load ring is utilized to transfer the static clamping load from the clamping device to a substantially central region of the fuel injector body.

Abstract: The present invention is directed to a system for detecting the tampering of the vehicle speed signal in a vehicle having electronic engine control. An algorithm that forms part of the present invention is operable to detect a tampering mode producing a constant transmission out-of-gear signal to the vehicle speed sensor input of the electronic controller, and tampering mode disallowing the electronic controller from acting upon a vehicle owner or manager-programmed top gear ratio, or maximum vehicle speed limit. In response to detecting a possible vehicle speed signal tampering condition, a vehicle speed signal tampering fault code is logged into a memory portion of the controller, a vehicle operator warning lamp is activated and the engine speed is electronically controlled to a vehicle owner/manager programmable maximum engine speed limit. The system is operable with a number of transmission embodiments including manual and automatic types intended for either on or on/off highway applications.

Abstract: A clamping load distributor disposed and connecting between a fuel injector body and a clamping device. The clamping load distributor functions as an intermediary to transmit the static clamping load from the clamping device to the fuel injector body. The clamping load distributor includes a cylindrically shaped main body having a bore extending therethrough between an upper surface and a lower surface. The upper surface of the main body being adapted for receiving the clamping load from a clamping device. The lower surface having at least one portion normally contacting the deck of the fuel injector body. The clamping device engages the upper surface of the clamping load distributor at a position axially aligned with a portion of the lower surface that normally does not contact the fuel injector body. The geometric relationship of the clamping load distributor functions to more uniformly distribute the static clamping load across the fuel injector body.

Abstract: A fluid level sensor system for a vehicle oil pan includes a fluid level sensor assembled to the oil pan which has a first LED/phototransistor sensor electrically arranged and responsive to a low oil level in the oil pan for generating a low level voltage signal. The fluid level sensor also includes a second LED/phototransistor sensor which is electrically arranged and responsive to a high oil level in the oil pan for generating a high level voltage signal. The low level voltage signal and the high level voltage signal from the fluid level sensor are electrically connected to an electronic control module (ECM) which receives and processes the two signals and activates a warning lamp with a flashing illumination to identify a low oil level condition and a constantly on illumination to identify a high oil level condition. The operation of the ECM is controlled by a flow logic algorithm.

Abstract: A spherical joint connecting rod. The connecting rod has a small end which terminates in a sphere or ball, and a big end which is adapted to sliding engage an engine crankshaft. The small end and big end of the connecting rod are coupled by a shank having a substantially elliptical cross-section. The shank has formed therethrough an internal oil passage which allows transmission of lubricating/cooling oil from the engine crankshaft to the spherical joint of the piston and to the piston cooling gallery.

Abstract: A molded cap is disclosed having a sealing ring groove just below the cap handle in order to seal crank case gases in an internal combustion engine. The cap includes two spiral grooves for engaging a respective protrusion formed on the inner annular surface of an oil fill snout which receives the cap. A recess is formed at the end of each spiral groove for receiving a respective protrusion to lock the cap into the oil fill snout. The oil fill snout has a draft angle to provide an outside vertical force component on the cap and sealing ring. The vertical force locks the protrusions into the respective recesses and provides a positive sealing force to the sealing ring when the cap is twisted into the snout and into the closed position. The two spiral grooves increase the resistance to back out and create symmetric force components. At the entrance of each groove, a lead-in angle is used to free the cap from the cover by continuing to turn the cap in a counter-clockwise motion.

Abstract: A method for automatically resuming vehicle speed control after a gear change of the vehicle's manual transmission. The method may be implemented as a subroutine in the vehicle's general control software. After disengagement of the clutch, the subroutine suspends the automatic speed control system and then periodically checks to determine if the driver has shifted gears within a predetermined time period. This determination is made by checking to see if the clutch has once again been engaged with the transmission in gear. If this occurs within the predetermined time period, then the control system automatically resumes the speed control of the engine. The determination of whether the transmission has been placed into another gear is made by an examination of calculated gear ratios, rather than by the addition of a hardware sensor.

Abstract: An electronic digital control system monitors and controls the operation of an engine fueling system. Signals activating injection for a plurality of cylinders are transmitted through a single line to a driving circuit for a single injector solenoid valve, while signals controlling accumulator fuel pumps are transmitted to pumping control solenoids. Injection signals are controlled to vary fuel delivery rate during an injection event. A back EMF sensing circuit measures valve opening delay and the control system compensates for valve delay. Variable cylinder-specific delays in the injection solenoid output signal pulses are programmed to compensate for a varying fuel line length to each injector nozzle. At startup, the control system pulses the pumping control solenoids to begin pressurizing the accumulator before engine angular position sensors provide an accurate indication of engine angular position to allow precise timed control of the pump.

Abstract: The improved needle controlled common rail fuel system of the present invention includes split common rails serving respective sets of injectors and a respective high pressure pump associated with each rail. The high pressure pumps reciprocate to cyclically create gradual periods of increasing pressure in the common rail during the advancement stroke of the plunger followed by respective periods of decreasing pressure during the plunger's retraction stroke. The fuel injectors include an injection control valve and a needle control device for creating an injection event during a pumping event by controlling the fuel flow to drain so as to control the fuel pressure forces acting on an injector needle valve element. A flow limiting device is provided to limit the fuel flow from a control volume to drain during an injection event thus reducing parasitic losses while maintaining quick valve closing. The system also includes an improved fuel injector design including an intensification plunger assembly.

Abstract: An electromagnetic fuel injection control valve positioned inside a fuel injector, i.e. a unit injector, for providing fast response and high pressure capability while minimizing the size and complexity of the injector. The control valve includes a valve housing having a supply inlet and fuel outlet, a center tube having a center passage and an annular valve seat, a control valve sleeve slidably mounted on the center tube and an actuator assembly having a coil spring, a stator and an armature. The control valve sleeve moves between an open position permitting fuel to flow between the supply inlet and the fuel outlet and a closed position which sealingly engages the annular valve seat for blocking the flow of fuel between the supply inlet and the fuel outlet. The coil spring biases the control valve sleeve in an open position and is positioned around the center tube. The stator is also axially positioned around the center tube and includes multiple poles.

Abstract: A rocker lever assembly including lubricant directing structure is provided for an internal combustion engine drive train. A lubricant deflecting shroud is secured to a joint-contacting end of a rocker lever above open lubricant channels to direct lubricant to an adjacent drive train joint and minimize airborne lubricant.

Abstract: Spherical joint connecting rod holder rings. The holder ring is formed in two halves which define a socket in which a spherical small end of the connecting rod is retained. The ring further includes a vertical wall which acts as an oil dam to retain oil in a piston cooling gallery. One or more drain holes are formed in the ring to drain oil from the cooling gallery back to the engine crankcase. Futhermore, one or more grooves are formed in the socket surface in order to channel oil into the socket for lubrication of the spherical small end.

Abstract: A cam follower lever assembly is provided which permits variable control of the timing of the beginning of operation of an engine component, i.e. fuel injector or engine valve. The cam follower lever includes a timing control lever and a force transmitting lever mounted for pivotal movement on a common pivot shaft. The timing control lever is also mounted for nonpivotal movement, relative to the pivot shaft, by a hydraulic actuation device permitting selective nonpivotal movement of the timing control lever relative to a cam's outer surface so as to selectively advance or retard the timing of, for example, fuel injection. The actuation device includes actuator cavities formed in the levers and a control valve arrangement. In one embodiment, a control valve is mounted in a cavity formed in the timing control lever.

Abstract: A piston cooling nozzle for an internal combustion engine includes a two-part construction comprising a mounting base and a main body. The mounting base includes a substantially flat end panel which is designed to attach directly to a plateau area on the engine block. The mounting base also includes a plug portion which is designed to seal closed an open end of the main body. The main body includes a through hole which is located in communication with an engine oil rifle. The main body represents a single piece component with an extension arm and cooling nozzle head. The extension arm includes a plurality of drilled passageways which are in communication with four flow jet apertures in the cooling nozzle head. The cooling nozzle head has a generally triangular shape and the four flow jet apertures are arranged so as to track the arc-like curvature of the corresponding piston cooling gallery.

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.