Abstract: An internal combustion engine system is disclosed which includes an engine crankshaft with a plurality of crankshaft webs. A reference ring is mounted to one of the crankshaft webs to rotate therewith. The ring encircles the crankshaft and has a number of angularly spaced indicators. A sensor is located proximate to the ring and detects the indicators to provide a sensor signal corresponding to a rotational characteristic of the crankshaft. The ring may be comprised of more than one piece to facilitate installation and removal without disassembly of the crankshaft. The indicators may be provided by defining a number of peripheral teeth for detection by the sensor.

Abstract: The present invention provides a knock sensing system for an internal combustion engine which utilizes only a single knock sensor associated with one of the engine cylinders. Operation of the engine is controlled such that the cylinder which is equipped with a knock sensor will be the first cylinder to experience combustion knock as compared to the remaining engine cylinders. This can be done by various methods, such as advancing the ignition timing on the designated cylinder. The knock sensor is then monitored by the engine control module in order to sense premature detonation on the designated cylinder, knowing that it is highly unlikely that knocking will occur on the other engine cylinders if knocking is not occurring on the designated cylinder. When knocking is sensed, appropriate action, such as shutting down the engine, may be taken by the engine control module. The knock sensor is preferably mounted to a capscrew which couples the intake manifold to the cylinder head.

Abstract: A fuel filter constructed and arranged for fuel-water separation which is designed with an integral fuel pump includes a unitary housing designed with a fuel filter cavity for receipt of a fuel filter cartridge, and a pump receptacle cavity for receipt of a fuel pump. A separating wall is disposed between the fuel filter cavity and the fuel pump cavity and this wall defines a flow passageway for fuel flow communication between the fuel pump and the fuel filter. Included as part of the fuel filter assembly is a lid designed to attach over the fuel filter cavity of the unitary housing and a lid designed to attach over the pump receptacle cavity of the unitary housing. The combining of the fuel filter cartridge and the cooperating fuel pump within the same unitary casting provides design efficiencies and economies.

Abstract: An exhaust gas recirculation (EGR) manifold received within an intake manifold. The EGR manifold includes a plurality of holes for delivery of recirculated exhaust gas within the flowpath of the intake manifold. Both linear and round shapes are contemplated for the EGR manifold.

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 combustion face insert is provided for connection to a bottom wall of an aluminum cylinder head adjacent a combustion chamber in an internal combustion engine which includes an insert body formed of a material having a predetermined hardness. The insert body includes a lower surface facing the combustion chamber and extending radially outwardly to form an outer peripheral extent having a predetermined size necessary to cause the lower surface to be positioned for engagement with an annular combustion seal to effectively seal the combustion chamber. This design allows a greater power density to be achieved in a heavy duty diesel engine utilizing an aluminum cylinder head, increases the thermal fatigue resistance of the valve bridge area and increases the resistance of an aluminum cylinder head to indentation by the combustion seal of the head gasket during deflection of the aluminum cylinder head.

Abstract: A fuel injector for periodically injecting fuel pulses of a variable quantity on a cycle to cycle basis as a function of the pressure of fuel supplied to the injector from a source of fuel and at a constant time during each cycle is set forth including an injector body containing a central bore and an injection orifice at the lower end of the body and a reciprocating plunger assembly including an upper plunger section and a lower plunger section serially mounted within the central bore to define a variable volume metering chamber located between the lower plunger section and the lower end of the injector body containing the injection orifice. The variable volume metering chamber communicates during a portion of each injector cycle with the source of fuel.

Abstract: An electronic air compressor control system and method including an actuator connected to an air compressor for regulating the loading and unloading of the air compressor based on predetermined conditions, a power supply electrically connected to the actuator for supplying a voltage thereto and a plurality of switches electrically coupled to the actuator and power supply for controlling the supply of voltage from the power supply to the actuator in order to control the operation of the air compressor based on a predetermined air compressor exhaust temperature threshold and minimum and maximum pressure thresholds. The unloading and loading of the air compressor is based on a predetermined air compressor exhaust temperature when the pressure within the wet tank is between the minimum pressure threshold and the maximum pressure threshold.

Abstract: A compact fluid flow control valve is provided which effectively and predictably controls the flow of fluid using a minimum number of components to permit inexpensive manufacture and assembly. The control valve includes a one-piece valve plunger guide and stop which extends through an aperture formed in a stator of the solenoid assembly. The valve plunger guide and stop includes an integral guide surface for guiding the valve plunger through reciprocal movement within the aperture of the stator, an integral stop surface positioned for abutment by the valve plunger when in the energized position to define a minimum air gap between an armature and the stator. The one-piece valve plunger guide and stop reduces the number of parts of the control valve to achieve simplicity in structure and lower costs while avoiding the need for a shim to set the minimum air gap. The present control valve also includes a plunger overtravel impact limiting device including a movable valve head and a hydraulic damping device.

Abstract: A technique is disclosed for operating an internal combustion engine near the lean burn limit. This technique includes sensing a first characteristic corresponding to a mean effective pressure of the engine and a second characteristic corresponding to fluid pressure in the intake manifold. An engine performance criterion is established as a function of the first and second characteristics. This performance criterion corresponds to an observed emission rate of a pollutant from the engine. A target for the performance criterion is selected which corresponds to lean burn operation of the engine with a limited emission rate of a pollutant. A mixture of air and fuel provided for combustion by the engine is controlled in accordance with the performance criterion and the target. The performance criterion may correspond to: ((BMEP.times.IMT)/IMP). Furthermore, this technique may be applied to lean burning, gaseous-fueled engines configured to drive an electrical power generator.

Abstract: A vented, unitary sealing grommet for establishing a first liquid-tight interface between a ignition coil and a spark plug adapter tube and a second liquid-tight interface between the ignition coil and a valve cover includes a hollow main body portion having a substantially cylindrical shape with a longitudinal axis and including a pair of annular sealing ribs, a planar flange portion which is disposed within a geometric plane which is substantially perpendicular to the longitudinal axis, the main body portion being designed to fit between the ignition coil and the spark plug adapter tube such that the annular sealing ribs are compressed due to the interference fit. The planar flange portion is designed to fit between ignition coil and the valve cover.

Abstract: A system for providing accurately time stamped vehicle operational messages following a real-time clock reset includes a vehicle control computer having a processor, a memory and a real-time clock powered by a constant power source. The processor is operable to store a current value of the real-time clock in memory at engine shut down and to determine whether a clock reset event occurred since the previous engine operational cycle by testing a clock error flag in memory. If such a clock reset event occurred, the processor is operable to reset the real-time clock at the clock value stored at engine shut down and store this value in an error buffer of the memory. Upon establishment of communications with a time correction device having a master real-time clock, the processor is operable to determine whether the error buffer contains any clock values therein.

Abstract: An exhaust valve system for an internal combustion engine including a turbocharger is provided for effectively increasing the turbocharged boost pressure at low load engine conditions thereby effectively improving engine transient response. The exhaust valve system includes an exhaust valve control device operable in a normal timing mode for permitting normal opening of one or more exhaust valves at a normal opening crank angle, and in an advanced timing mode for advancing the timing of the opening of the exhaust valve to an advanced opening crank angle prior to the normal opening crank angle while maintaining the timing of normal closing of the exhaust valves at a normal closing crank angle.

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 fuel system includes an electronically controllable high pressure fuel pump operable to supply high pressure fuel from a lower pressure fuel source to a high pressure fuel collection chamber 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 control computer is normally operable to drive the fuel pump as a function of fuel pressure and a reference pressure, which is based on requested fueling, and to control the valve as a function of commanded fueling, which is a function of engine speed and a reference speed based on requested fueling, and fuel pressure.

Abstract: A system for customizing the operation of a vehicle/engine control computer includes a memory card having control computer customizing information stored thereon and a memory card interface unit having at least one signal line connected to at least one existing input signal line of the vehicle/engine control computer. In one embodiment, the memory card interface unit includes a control device operable to control a number of switches each connected to one of a corresponding number of switched input signal lines of the vehicle/engine control computer. The control device is operable to read the control computer customizing information from the memory card and control the states of the number of switches to thereby transfer the control computer customizing information to the vehicle/engine control computer.

Abstract: A top stop assembly for a fuel injector is provided which includes a top stop housing having a threadless injector engaging portion positioned at one end of the housing for threadlessly engaging the outer diameter portion of an injector barrel to minimize inward bore distortion. The top stop is preferably formed integrally on the top stop housing body to create a predetermined axial length of the housing which defines a predetermined outer limit of a retraction stroke of an injector plunger assembly, i.e. a top stop position. The top stop position is set by selecting a top stop housing having a predetermined axial length corresponding to the desired top stop position thereby reducing costs and avoiding loosening problems associated with multi-part top stop assemblies.

Abstract: A piston head is provided which is lightweight and inexpensive yet capable of handling high mechanical and thermal loading during operation. The piston head generally includes a top head portion and a bottom head portion formed separately and connected by a friction weld. Importantly, the top head portion includes a first cooling gallery formed between the depending outer wall and a first inner depending wall and a second cooling gallery formed between the first inner depending wall and a second inner depending wall. The bottom head portion also includes corresponding first and second upper extending walls connected to the first and second inner depending walls to form the lower portion of each cooling gallery. The inner depending and upper extending walls are formed so that the ratio of the sum of the transverse thickness of the adjacent walls to the outer diameter of the piston head is approximately from 2% to 8%, and preferably 4% to 6%.

Abstract: An improved truing and dressing assembly and associated thru-feed centerless grinding machine is provided which effectively shapes the outer surface of a regulating wheel so as to allow the regulating wheel to follow the profile of the workpiece during grinding thereby avoiding interference between the regulating wheel and the workpiece outer surface thereby resulting in improved high precision grinding. The truing and dressing assembly of the present invention includes a truing wheel mounted on one side of the regulating wheel opposite the side on which the workpiece and workpiece support are mounted. The truing wheel is designed with an outer surface having a radius of curvature equal to the radius of curvature of the outer surface of the final ground workpiece. In addition, the truing wheel and workpiece are positioned at the same height above a reference plane extending through the rotational axis of the grinding wheel.

Abstract: A system for managing engine retarding torque during coast mode operation includes a control computer operable in one embodiment to control boost pressure, engine compression brake setting and/or engine accessory deactivation upon detection of coast mode operation with the engine compression brakes enabled. In another embodiment, the control computer is operable to determine a current engine retarding torque value, based either on an estimation thereof as a function of current boost pressure and engine compression brake setting or based on a mass estimation technique accounting for the grade of the road, and control boost pressure, engine compression brake operation and/or engine accessory deactivation to thereby control engine retarding torque upon detection of coast mode operation with the engine brakes enabled.