Abstract: An improved plunger and barrel assembly is provided which includes a plunger reciprocally mounted in a cavity formed in the barrel and a leakage flow reduction device positioned in the cavity for reducing fluid leakage flow around the plunger thus increasing system efficiency. The leakage flow reduction device includes a sealing sleeve removably mounted in the cavity between the plunger and the barrel, which includes a bore for slidably receiving the plunger to form an annular clearance gap between the plunger and the bore. The sealing sleeve is designed to resiliently flex in response to fluid pressure forces to reduce the annular clearance gap so as to minimize fluid leakage through the annular clearance gap. The sealing sleeve is formed as a separate piece from the barrel to permit simple, low cost replacement. The sealing sleeve is preferably applied to a fuel pump having a pump plunger for pressurizing fuel in a high pressure chamber.

Abstract: A wear and scuff-resistant timing plunger for a timing assembly in a unit fuel injector for an internal combustion engine is provided. The timing plunger is formed of a high thermal expansion ceramic with a thermal expansion coefficient greater than 6.times.10.sup.-6 /.degree. C. and a hardness greater than 800 Kg/mm.sup.2, which maintains a desired diametral clearance and efficient plunger function without scuffing or sticking under the axial, tangential and pressure loads encountered in the fuel injector operating environment. Preferred high thermal expansion ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A fuel injector assembly is provided which operates to effectively creating a low injection flow rate followed by a high injection flow rate during all engine operating conditions, including idle and low engine speed conditions, to produce a high quality fuel spray with proper atomization and thus improved fuel air mixing resulting in improved emissions abatement and fuel economy. The assembly includes two biased valve elements designed to sequentially open and close to initially open a limited number of orifices followed by the opening of a remainder of the orifices thereby effectively varying the available cross sectional flow area from the nozzle cavity into the combustion chamber of the engine during the injection event. The nozzle valve elements may be spring biased or fluid pressure biased and include biasing surfaces sized to cause the sequential opening and closing of the elements.

Abstract: An improved cam operated, open nozzle, unit injector is disclosed including an injector body formed by a barrel, spring housing, and nozzle and containing a central bore for receiving a variable length plunger assembly mounted for reciprocal movement within the injector body wherein the variable length plunger is formed by an outer plunger and inner plunger combined with a timing plunger, mounted between the inner and outer plungers to form a collapsible timing chamber into which a variable quantity of fuel may be metered and expelled on a cycle by cycle basis to provide a variable effective length to the plunger assembly to cause controlled variation in injection timing based on variation in the timing fluid supplied to the injector and wherein the timing plunger is provided with a radial flange for engaging a stop formed in the injector barrel to hold the timing plunger in a predetermined precise location during metering of timing fluid into the collapsible timing chamber and to render the injector timing i

Abstract: Fuel injection rate shaping is integrated into the pressure intensification stage of a hydraulically actuated fuel injector having a pressure intensifier. In a first embodiment, the pressure intensification plunger is formed of two parts creating a damping chamber therebetween from which fluid is forced out through orifices in a lower one of the plunger parts during an initial phase of displacement of the upper part. Thus, injection will be performed initially at a lower pressure and rate, which increases once the plunger parts make contact. In a second embodiment, a throttled flow is set via a restrictor housing that telescopingly receives the upper plunger part, so that a lower injection rate occurs while fluid is bled off through a restricted flow path between the restrictor housing and the upper plunger part, and a higher injection rate is produced once a port in the upper plunger clears the restrictor housing.

Abstract: A constant horsepower throttle progression control system and method. In order to improve driveability of a vehicle compared to prior art engine controllers, the present invention operates an engine so as to either produce a constant (or nearly constant) output horsepower at all engine speeds for any throttle position, or so as to produce an output horsepower equal to a predetermined percentage of the range between full rated power and motoring horsepower at all engine speeds for any throttle position. The predetermined percentage may or may not be equal to the percentage of full throttle represented by the throttle position, and may or may not be linearly related thereto.

Abstract: An improved fuel injector for providing precise control over injection timing, quantity and rate shape is provided which includes a piezoelectric actuator for compressing actuating fluid in an actuating fluid circuit which includes a fluid chamber positioned adjacent a needle valve element and fluidically separate from a fuel supply circuit for supplying high pressure fuel for injection. Actuating fluid pressure in the chamber acts on the needle valve element to initiate injection. A fuel pressure balancing device is provided for balancing the fuel pressure forces acting on the needle valve element while the element is in both the closed and open positions thereby permitting the piezoelectric actuator to more precisely and predictably control the rate of movement, and the extent of movement, of the needle valve element.

Abstract: An effervescent fuel injector, particularly one suitable for diesel and direct injection engine applications, which is capable of injecting, particularly intermittently, an atomized fuel spray with droplets of a size in the range of 5-6 micron SMD without requiring high pressures is achieved in a preferred embodiment effervescent fuel injector of the valve covered orifice (VCO) type having primary and secondary nozzle valves which remain closed when the control valve is not actuated, but which open one or two sets of nozzle orifices depending on fuel volume requirements. A three-way, on-off control valve is used to trigger commencement of the supply of gas via a control valve simultaneously with opening of at least some of the nozzle orifices. Gas and fuel are mixed in a mixing chamber located upstream of the nozzle valves in a manner creating a gas-fuel aeration, and as the aeration is sprayed from the nozzle orifices, the gas expands rapidly breaking the fuel into fine droplets.

Abstract: In an internal combustion engine, a barring adapter member is mounted on an auxiliary engine component, such as an air compressor shaft which is geared to the engine crankshaft. The barring adapter member is configured to receive a barring tool, permitting manual rotation of the air compressor shaft for desirably positioning engine crankshaft-driven components during engine repair or adjustment. In an arrangement according to the invention, the air compressor gear is enclosed by a gear casing, but the adapter is accessible through an aperture closeable by a removable cap. The barring adapter member facilitates barring the engine from a convenient position and is particularly advantageous in an engine designed to eliminate most externally-exposed rotational shaft seals and associated external pulleys conventionally used as barring locations.

Abstract: A separable gasket for use in sealing the interface between a gear housing and an engine block as well as the interface between an air compressor and the gear housing includes a first gasket portion constructed and arranged for sealing the interface between the gear housing and the engine block and a second gasket portion constructed and arranged for sealing the interface between the air compressor and the gear housing. A third gasket portion in the form of a perforated score line is positioned between the first gasket portion and the second gasket portion. In the event the air compressor requires servicing, the present invention enables the second gasket portion to be manually flexed and ultimately separated from the first gasket portion so that a replacement gasket can be assembled when the air compressor is reassembled to the gear housing.

Abstract: An improved 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 intermittent injection control device for intermittently injecting small amounts of used lube oil into the engine's fuel 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 system 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. The system may also include an auxiliary flow control device for directing controlled quantities of fresh oil into the engine's lube oil system for maintaining the engine's oil sump at a proper level.

Abstract: A system for processing output signals associated with multiple vehicle condition sensors includes a first sensor producing a pair of output signals indicative of a first vehicle condition and a second sensor producing an output signal indicative of a second vehicle condition. One of the first sensor output signals and the second sensor output signal are received by an interface circuit which produces an output signal that is a function of its two input signals. A vehicle control computer receives the output of the interface circuit and the other of the first sensor output signals and processes these signals to provide diagnostic information related to each of the two sensors. The diagnostic information may include fault codes associated with individual ones, or a combination, of the two sensors which are stored in memory, and may further include energizing signals for energizing warning means associated with each of the two sensors.

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: A PCMCIA card for use in electronic equipment includes a glass laminate circuit board including a pair of substantially planar, oppositely disposed component-mounting surfaces. Printed circuitry is designed and arranged on at least one of the component-mounting surfaces. At least one integrated circuit package is assembled onto the printed circuitry and has a length dimension direction and a shorter, width dimension direction. In order to reduce the stresses which the integrated circuit package is subjected to during handling of the PCMCIA card, the integrated circuit package is arranged on the circuit board such that the integrated circuit package length dimension direction is substantially parallel to the width dimension direction of a cooperating metal case which is part of the PCMCIA card. The assembled circuit board is encapsulated with a flexible potting compound and enclosed within the metal case to complete the PCMCIA card assembly.

Abstract: An improved engine gear drive train arrangement is provided which effectively minimizes the crankshaft torsional vibrations at the location of the gear train, for engines with a front gear train. A flywheel is resiliently connected to the rear end portion of the crankshaft so as to resiliently connect a driven unit to the crankshaft. An extra inertial device is connected to the front end portion of the crankshaft and includes an inertia so selected as to cause a nodal point of the first torsional vibration mode of the crankshaft to be located in the vicinity of the crank gear to minimize the amplitude of torsional deflection of the crankshaft at the crank gear. Also, the device for resiliently connecting the flywheel to the rear end portion of the crankshaft may include resilient members positioned in cavities formed by engaging rings.

Abstract: An engine system with a gear train to provide engine timing is disclosed. A technique to minimize backlash and noise caused by the gear train is included. An anti-backlash gear assembly useful to reduce backlash in the gear train is also disclosed. One disclosed gear assembly has at least two gear wheels with the circular thickness of the teeth of one gear wheel being less than the circular thickness of the other gear wheel. A gear assembly is also disclosed that has a bias torque of at least about 100 foot-pounds. A device carried on an anti-lash gear assembly to generally align teeth of the assembly for installation is also provided.

Abstract: A cruise control governor which is able to dynamically define and switch between various goal droop curves in order to find the best goal droop curve for use with the current vehicle driving situation. For instance, the present invention will dynamically define and select different goal droop curves when the vehicle is lugging up a hill, coasting down a hill, cruising on level ground, preparing to crest a hill, or preparing to transition off of a downhill slope.

Abstract: A piston for reciprocal movement within a combustion chamber (4) of a compression ignition engine (2) having a fuel injector (20) for forming a fuel injection plume (40) having a relatively deep angle (7.degree. to 40.degree. from a plane perpendicular to the central axis of the combustion chamber) and a piston (8) having a centrally located symmetrical upwardly opening cavity for forming a combustion bowl (30) especially arranged to complement the plume in a manner to maintain very low entrainment of soot in the lubrication oil of the engine and to maintain other engine emissions, e.g., CO and smoke, within acceptable ranges suitable to meet TALuft standards. In particular, the combustion bowl (30) as formed by an upwardly opening cavity formed as a surface of revolution having a centrally raised floor section (42) with relatively large radius of curvature R.sup.1 and an upwardly flared outer bowl section 48 having relatively smaller radius of curvatures R.sub.2. The ratio of R.sub.2 divided by R.sub.

Abstract: An improved nozzle assembly for servo-controlled fuel injectors is provided which includes a needle valve control device including a rate shaping control device for effectively producing a predetermined time varying change in the flow rate of fuel injected into the combustion chamber during an injection event so as to reduce emissions. The rate shaping control device includes an injection control valve positioned along a drain circuit connected to a control volume positioned at one end of the needle valve element. The injection control valve includes an actuator for controlling the flow of fuel through the drain circuit to variably control the rate of movement of the needle valve element between the open and closed positions so as to provide the desired shaping to the flow rate of fuel into the combustion chamber.

Abstract: A control system for controlling automatic shifting of a manual/automatic transmission is disclosed including a cruise control system and an auto-shift mode for controlling automatic upshift and downshift operations between the top two gears of a heavy duty truck transmission. Certain failures of equipment or incorrect driving habits of operators are corrected for with algorithms which prevent undesirable operating conditions which compromise the acceptability of an electronically controlled heavy duty truck transmission equipped vehicle. The mechanism by which auto-shift operation of the transmission is requested is also compared with parameters such as vehicle speed and engine speed in order to determine whether gears should be engaged or disengaged, the gears being those subject to auto-shift control of the system controller.