Abstract: An improved rotary fuel distributor is provided which effectively dynamically centers the rotor during operation while actively cooling the rotor and refilling fuel passages to minimize cavitation. A pressure balancing system is provided which includes pressure area defining grooves formed adjacent a rotor outlet port to control the pressure gradient in the clearance between the rotor and the distributor housing thereby effectively providing a more predictable force component which can be controlled to more effectively balance the rotor in conjunction with two balancing ports positioned on the opposite side of the rotor from the outlet port. A refill and cooling system is provided to continuously and actively cool the rotor with cool, low pressure fuel throughout rotation thereby displacing the hot fuel with cool fuel and effectively preventing thermal seizure of the rotor.

Abstract: The present invention gathers and processes engine speed and position information gathered during cranking, without fuel injection or combustion, in order to derive a set of parameters that are shown to correlate very well with the presence of cylinder compression leakage. Using engine speed and position information from, for example, camshaft gear targets, crankshaft tonewheels, or the flywheel itself, etc., a parameter designated as "metric distance" between adjacent firing cylinder speed fluctuation pulses is determined. For engines with well-balanced cylinder compression, the values of the metric distances measured between all cylinders should be close to each other within a certain threshold. If a cylinder exhibits leakage, the metric distance of the cylinder from its adjacent firing cylinders will significantly exceed the threshold, thereby detecting a leaking cylinder. The method of the present invention also provides a relative estimation of the percentage compression loss from the leaking cylinder.

Abstract: A solenoid actuated valve assembly is provided which achieves accurate control of valve movement while maximizing valve seat life. Specifically, the solenoid actuated flow control valve assembly includes a valve plunger, a solenoid actuator including a coil and an armature, and an armature overtravel feature for permitting continued movement of the armature relative to the valve plunger from an engaged position into a disengaged position when the valve plunger reaches a closed position. The armature overtravel feature includes an overtravel biasing spring for returning the armature from the disengaged position to the engaged position prior to subsequent energization of the actuator coil. As a result, the overtravel feature minimizes the mass impacting the valve seat thereby extending valve seat life while, importantly, avoiding lost motion in the armature during the next actuation cycle thereby minimizing valve response time.

Abstract: A fuel system includes a pair of electronically controllable high pressure fuel pumps operable to supply high pressure fuel from a lower pressure fuel source to a high pressure fuel accumulator having a pressure sensor associated therewith. The fuel collection chamber feeds an electronically controllable valve operable to dispense the high pressure fuel to a fuel distribution unit supplying fuel to a number of fuel injectors. A control computer is provided for controlling the high pressure fuel pump and valve in response to requested fueling, engine speed and fuel pressure provided by the pressure sensor. The accumulator pressure signal is processed in accordance with the present invention for diagnosing erratic pressure sensor failures. The control computer is operable to compute error pressure values based on differences between peak accumulator pressure values and a target pressure value, and compute pressure error variance values based on subsets of the pressure error values.

Abstract: A control valve comprising a valve housing including a valve cavity, an inlet means formed in the valve housing for directing fluid into the valve cavity, and an outlet means formed in the valve housing for directing fluid out of the valve cavity. The control valve further includes a valve element mounted for reciprocal movement in the valve cavity between open and closed positions and biased toward the closed position by fluid pressure forces. A valve seat is associated with the valve element which engages the valve seat when in the closed position and permits flow between the valve seat and the valve element when in the open position. A flow force inducing means is positioned adjacent the valve element for redirecting fluid from the inlet means through a predetermined flow path arranged relative to the valve element to cause fluid flow to impact the valve element and create flow induced forces of sufficient magnitude necessary to advantageously counteract the fluid pressure forces.

Abstract: A method for controlling a vehicle engine coolant fan. Because operation of the engine coolant fan creates a power drain upon the engine, it is undesirable to operate the coolant fan when the engine is fueled. Conversely, a power drain upon the engine is desirable when an attempt is being made to slow the vehicle. Consequently, the present invention requests activation of the coolant fan whenever a power drain upon the engine is desirable. Not only is this desirable in order to slow the vehicle, but it also lowers the coolant temperature, thereby reducing the chance that the coolant fan will have to be operated in the future when such operation is undesirable.

Abstract: A cover assembly for closing off the opening in a panel so as to establish a sealed interface around the opening includes a cover member with a four corners arrangement of clearance holes for attachment of the cover to the panel which also includes a matching pattern of clearance holes. The cover assembly includes a gasket member which is constructed with a carrier and a cooperating edge seal. The carrier includes a substantially planar surface which faces the cover member and extending outwardly from this facing surface are two series of pin-like projections. The cover member is cooperatively arranged with two substantially straight and elongated channels which are constructed and arranged to receive the outwardly extending projections. The two channels act as abutment surfaces for the projections so as to restrict outward or lateral movement of the gasket relative to the cover and panel.

Abstract: A system for controlling air flow to an engine cooling system includes a control computer responsive to a number of engine and/or engine accessory operating conditions, and to various engine operational states to control operation of an engine cooling device. The engine operational states are each a function of at least engine fueling commands and include a "free energy" state corresponding to zero fueling, an "absorbing additional torque" state corresponding to zero fueling and activation of either service brakes or engine brakes, and a "needs additional torque" state corresponding to a rapid positive change in fueling, recent gear shifting to the lower gears of the transmission with fueling above a predefined level or a high rate of change in fueling rate. All other engine operational states are defined as a don't care state.

Abstract: An improved cylinder liner, and method for making the liner, is provided which includes a top section and a bottom section connected by a friction weld. The top section is formed from a material having a higher resistance to wear and/or a higher resistance to thermal distortion while the bottom section is formed of a less expensive material thereby minimizing costs while achieving a durable liner. A liner durability and cost optimizing arrangement is provided which limits the predetermined axial extent of the top section to an area corresponding to the greatest amount of mechanical and thermal loading thereby limiting material costs, maintaining structural integrity and maximizing durability. The method of the present invention creates an effective seamless connection between the top and bottom sections while permitting materials of different resistance properties to be utilized to maximize durability and minimize costs.

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: A system for controlling operation of an internal combustion engine includes a control computer responsive to a number of engine/vehicle operating conditions to control engine operation to thereby control engine speed and engine or vehicle acceleration. In one embodiment, the control computer is configured to determine an engine or vehicle acceleration limit value based on current engine or vehicle speed, and an engine speed limit value based on current engine load, and to control engine fueling and/or speed to thereby limit engine speed to the engine speed limit value and/or engine/vehicle acceleration to the engine/vehicle acceleration limit value.

Abstract: A system and method for air compressor control wherein the air compressor is loaded only when engine activities require it to be loaded or when free engine power is available to operate the compressor. An air compressor system is an engine-driven, piston-type compressor which operates in a loaded and an unloaded mode and provides air to a vehicle's air powered devices, such as service brakes, air suspension, windshield wipers, etc. The operating mode of the compressor is controlled by a pressure activated air governor which applies an air signal when pressure in a reservoir reaches a set level that activates a cap valve on an unloader stopping the air compressor. When the air pressure in the reservoir drops below a lower set pressure or when energy is "free," such as during downhill operations, the air governor exhausts the air signal allowing the air compressor to resume operation.

Abstract: A combustion seal for sealing high pressure combustion gas within at least one cylinder of an internal combustion engine including a cylinder block, a cylinder head having a groove formed in its bottom face, a cylinder liner having a complementary groove formed in its top face, and a O-ring formed from a ductile material and positioned between and contacting each edge of the groove formed in the cylinder head and the complementary groove formed in the cylinder liner, wherein the O-ring is compressed when the cylinder head is secured on the cylinder such that the O-ring has multiple radial restraint points of contact with the edges. When securing the cylinder head onto the cylinder block, the O-ring is positioned between the grooves in the cylinder head and cylinder liner before a compressive force is applied.

Abstract: A controlled energy ignition system for an internal combustion engine includes an ignition coil having a primary coil and a secondary coil coupled to first and second electrodes of an ignition plug defining a spark gap therebetween, wherein the primary coil is responsive to activation of a control signal to produce a spark voltage across the secondary coil and across the spark gap. The secondary coil is responsive to the spark voltage to produce a discharge current across the spark gap of the ignition plug. In accordance with one aspect of the invention, means are provided to draw discharge current away from the ignition plug to thereby limit the discharge current to below a threshold current value within some predefined time period after activation of the control signal.

Abstract: An improved unit fuel injector is provided which effectively and precisely controls the timing of fuel injection by avoiding outside influences acting on a timing plunger. The unit fuel injector includes a timing plunger positioned between upper and lower plungers, a timing chamber positioned between the timing plunger and upper plunger and a spring chamber positioned between the timing plunger and a metering chamber for containing one or more springs for biasing the plungers. A spring chamber drain valve device is provided for directing fuel in the spring chamber to a low pressure drain while isolating the spring chamber from the low pressure drain system thereby preventing pressure variations in the drain system from entering the spring chamber and acting on the timing plunger. In addition, a scavenge circuit is provided to direct a scavenging flow of fuel and combustion gas from the injector directly to the low pressure drain without communication with the spring chamber.

Abstract: A method for accurately and economically shaping a zirconia workpiece with a relatively inexpensive silicon carbide grinding wheel is provided. The grinding wheel used in the method preferably utilizes 220 mesh silicon carbide particles bound in a low porosity vitreous matrix. The grinding wheel is then rotated at a sufficient speed to implement a grinding operation, and is engaged against the zirconia workpiece at a diametral feed rate of at least 0.04 mm/sec. The method advantageously removes material from the zirconia workpiece at a high rate of speed with minimal wheel wear, and results in accurate cuts and smooth surface finishes, and also eliminates the need for dressing the wheel prior to the grinding operation.

Abstract: The present invention relates to a method and apparatus for control of current rise time during multiple fuel injection events. The invention utilizes a single boost voltage supply circuit, in which the boost capacitor is designed to store slightly more than twice the total energy required to pull-in a single fuel injector solenoid during the prescribed time. A reference waveform simulating the desired current rise time is compared to the actual boost voltage produced by the circuit. The boost voltage is modulated (switched on and off) in order to maintain the boost voltage within a predetermined window around the reference waveform. This modulation will compensate for any droop in boost voltage at the time of actuation, and will also compensate for two solenoids being actuated at the exact same time.

Abstract: A swirl tip injector nozzle housing is provided for a fuel injector which includes a fuel atomization enhancing feature for creating effective fuel atomization and breakup during discharge from the injector. The fuel atomization enhancing feature includes a plurality of curvilinear spray holes having an angle of curvature equal to approximately 90 degrees. Fuel flowing from the inlet of each spray hole to the outlet is induced, by the 90 degree angle of curvature, to flow through a tangential flow path or swirl within the spray hole causing rapid spreading and breakup of the fuel jet spray upon exiting the outlet of the spray hole. The fuel atomization enhancing feature may also include positioning each spray hole so as to extend orthogonally from the interior surface of the fuel cavity to create optimal entry of the fuel into the tangential flow path.

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: Manufacturing/design imperfections and component failures in the fuel system/engine can lead to non-uniform torque production among the cylinders. Non-uniform cylinder torques can be observed as small engine speed fluctuations about the average engine speed at any given operating point. Severe imbalance conditions can be heard, felt, and seen by human operators. The present invention uses the fluctuations in engine speed to detect an unbalanced engine and attempts to correct the unbalance by applying trims to the fueling commands for each individual cylinder. The present invention is based on the calculation of a 6-point Fourier Transform (FFT) of engine speed data over one complete engine cycle. This FFT is calculated continuously to provide imbalance detection. An unbalanced engine results in non-zero magnitudes of the FFT components that correspond to the 0.5, 1.0, and 1.5 engine orders.