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: 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: 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 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 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: 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: 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.

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 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.