Abstract: A liner assembly for an internal combustion engine includes a liner bore in an engine block which receives a cylinder liner having an end extension which is received in an annular cylinder head groove. The end extension of the cylinder liner includes a outer circumferential surface thereon which is formed to define a very small gap with the outer circumferential surface of the cylinder head groove; the inner circumferential surface of the upper end is radially spaced from the inner circumferential surface of the cylinder head groove to form an annular seal space for a radial seal that is captured between the upper end and the cylinder head to form an active combustion gas seal between the cylinder liner and the cylinder head.

Abstract: A fuel injector having both stepped and infinitely variable timing is disclosed. The fuel injector includes an injector housing and a plunger wherein the plunger includes an axial bore formed in the top of the plunger. A plunger top is mounted within the axial bore and is translatable between an upper position and a lower position. A coil spring having a predetermined spring rate is disposed in the axial bore for biasing the plunger top in the upper position. An upper and a lower piston are disposed above the plunger and are translatable within the injector housing. A timing chamber is formed between the upper piston and the lower piston. When the timing chamber contains timing fluid, the fluid serves as a hydraulic link between the upper and lower pistons and the fuel injector operates at a first level of advanced timing.

Abstract: A method of forming curvilinear injector spray holes to produce an improved spray from the nozzle tip of a fuel injector is provided. The method uses electrical discharge machining in combination with a novel electrode to form a plurality of curvilinear spray holes in the injector nozzle tip which direct the fuel spray from the nozzle to produce an efficient, enhanced spray. The novel EDM electrode is preferably formed in the configuration of a constant pitch helix having a radius substantially equal to the radius of curvature of the curvilinear spray hole.

Abstract: A unit fuel injector for a fuel injection system for an internal combustion engine is described that is reciprocably driven from a camshaft by a drive train, and the unit injector includes a device for controlling the rate of fuel injection into an engine cylinder. The rate control device operates to divert or bleed off a quantity of fuel from the main metering chamber of an open-nozzle type fuel injector during an initial phase of injection, and the diverted fuel is returned to the metering chamber at a later phase in the injector operation. The rate control device includes an auxiliary metering chamber which receives the diverted fuel via an auxiliary passageway. An auxiliary plunger is mounted within the auxiliary metering chamber. A biasing device such as a helical spring or a fluid pressure spring, controls the inward and outward movement of the auxiliary plunger.

Abstract: A flow controlling system having a viscosity sensitive means for producing a simulated fluid pressure which varies in correspondence with a fluid pressure at a predetermined portion of a fluid flow circuit on the basis of the viscosity of the fluid flowing through the circuit, and a pressure regulating means, that is responsive to changes in the simulated pressure, for maintaining a predetermined pressure at that predetermined portion of the fluid flow circuit. In particular, in a preferred embodiment of the invention, the flow controlling system is utilized in an engine timing control tappet system of the type having at least one expansible tappet for controlling timing of a fuel injector using oil that is supplied by a pump to an engine lubrication circuit.

Abstract: A high pressure fuel injector installation and removal tool for use on internal combustion engines can be used to precisely locate the fuel injector during installation. The installation tool provides an alignment guide, as well as the mechanical impulse necessary to fully seat the fuel injector in the base cavity. The alignment guide forms a location skirt with projected ears around the perimeter of the fuel injector during the installation procedure and thus provides a means to assure sufficient clearance between the fuel injector and surrounding components without need for visual alignment.

Abstract: The test apparatus for an electric air intake manifold heater system according to the present invention includes a mechanism for simulating a temperature signal of the heater system thermistor and inputting this signal into the thermistor input of the electronic control module of the heater system. The temperature signal simulating mechanism is selectively operable to simulate a predetermined portion of the range of operating temperatures for the system. The test apparatus also includes a volmeter which measures the complete system voltage. The voltmeter can alternately be connected to the electrical supply of a fuel pump cold start system valve, where provided, to observe the actuation voltage and verify the actuation cycle thereof. Color coded lights indicate proper actuation of the heater elements.

Abstract: A system for reducing the emission of condensed unburned fuel from diesel engines is disclosed. The system includes an exhaust gas flow passage having a particulate filter positioned therein for trapping particulate matter entrained within the exhaust gas and a burner for selectively elevating the exhaust gas temperature. Sensors are provided for continuously monitoring the ambient air temperature and the exhaust gas temperature and relaying values indicative of these temperatures to a control module. The control module in turn compares these determined values to predetermined minimal values. If both the ambient air temperature and the exhaust gas temperature are less than the predetermined minimal values, the control module will activate the burner in order to raise the exiting exhaust gas temperature to reduce the emission of condensed unburned fuel.

Abstract: An injector drive train push-rod injector plunger connection for use in internal combustion engines is disclosed. The injector includes a body having an axial bore, a plunger, and a biasing mechanism which biases the plunger away from the injection chamber. The plunger is slidable within the bore. A push rod connects the plunger to a drive train assembly which includes a pivotable rocker arm. A first end of the push rod is connected to the plunger and a second end of the push rod is connected to the driven end of the rocker arm. The first end includes a spherical portion which is receivable in a complementarily-shaped concave portion disposed on the outer end of the plunger but not within the plunger. The spherical portion has a diameter at least equal to the outer diameter of the plunger. The load from the driving assembly is transmitted from the push rod to the plunger at the end of the plunger only.

Abstract: A unitary seal device having a dual seal system for sealing around a rotatable shaft between the rotatable shaft and its housing to separate a region of higher pressure from a region of lower pressure is disclosed. The unitary seal device includes an annular outer housing which forms the outer periphery of the unitary seal device. The outer housing has a through bore located substantially axially centrally thereon which divides the annular outer housing into an axially inner portion and an axially outer portion. First and second seal elements having an L-shaped cross-section, including a radially extending leg and an axially extending leg are disposed in the outer housing. The axially extending legs are spaced-apart from each other to form a central channel and the radially extending legs sealingly engaging the rotatable shaft around the entire circumference of the rotatable shaft.

Abstract: A valve tappet and control system is provided including expansible and collapsible hydraulic link; wherein the control system causes expansion of the hydraulic link and determines the timing of the collapse and thus the closing of an intake valve of an internal combustion engine. The timing is variable depending on engine operating conditions, such as output power and turbo charger boost pressure. In one embodiment, a rotary valve and fluid gating device is used to connect a pressure line used to expand the hydraulic link to a dump line at one instance during each cam shaft rotation to provide the early closing of the valve. In a second embodiment, a rotary cam follower with an oblique surface is used, wherein the orientations of the oblique surface is the determinative feature that is controlled to change early closing time as well as a delayed opening.

Abstract: An apparatus and method for generating a highly conductive channel for the flow of plasma current between the electrodes of an ignitor gap device are disclosed. A high voltage transformer having a high turns ratio is used to produce a high voltage spark across an ignitor gap. Subsequently, a high voltage low turns ratio transformer is used to supply a pre-plasma current signal to the ignitor gap at a predetermined time following the high voltage spark thereby ensuring that the ionized channel is developed to a more conductive state prior to introduction of the pre-plasma signal into the ignitor gap. Once the sustaining voltage for sustaining plasma flow through the channel has stabilized to a sufficiently low voltage, a high current main plasma signal is supplied to the ignitor gap thereby expanding plasma flow in the area surrounding the ignitor gap and providing a high quality ignition source for use in internal combustion engines.

Abstract: An exhaust gas aftertreatment system having an air supply system is disclosed and includes an air feeding pump for selectively creating a flow of air through a flow passage which directs the flow of air to a regeneration system. A check valve is provided including a valve element having a circular base portion surrounding and supported by the flow passage, a flexing portion extending from the circular base portion and converging to form a diametrically extending tip, and a diametrical slit formed in the tip. Also, a support structure is positioned to extend into the valve element to a position adjacent the tip for supporting the flexing portion such that the valve element permits the flow of air from the air feeding pump in one direction and prevents the flow of exhaust gas in an opposite direction with the support structure preventing the valve element from collapsing when the air feeding pump is inoperable.

Abstract: A fuel injector includes an injector housing having a plunger assembly disposed within a central axial bore and including a lower plunger, an intermediate plunger, and an upper plunger. The lower plunger reciprocates within the central bore to meter a variable quantity of fuel during downward portions of the reciprocating motion. A timing spring is wound around the upper portion of the lower plunger to bias the lower plunger upwardly. A timing chamber formed between the upper and intermediate plungers receives timing fluid to create a hydraulic link between the plungers. Timing fluid exits the timing chamber through a central passage, which may have a reduced area regulating orifice, formed through the intermediate plunger, which is ordinarily closed by a valve mechanism. The valve mechanism is acted upon in part by the timing spring. To improve the pressure regulation using a higher spring load and to accommodate a larger area drainage passage, a valve spring biases closed the passage.

Abstract: A piston cooling assembly for cooling each of the pistons in an internal combustion engine is provided. The piston cooling assembly of the present invention, which directs a spray of cooling fluid, typically oil, to a selected targeted area of the piston with which it is associated, is installed, adjusted and removed entirely from the exterior of the engine block. The piston cooling assembly is received in a specially configured bore in the engine block and includes a flange located exteriorly of the engine block to position and secure the assembly in its desired location. A nozzle tube support attached to the flange is sealingly engaged within the engine block bore and is fluidically connected with the engine cooling fluid supply to provide a supply of cooling fluid to a nozzle tube. The nozzle tube, one end of which is supported by the nozzle tube support, sprays cooling fluid toward the targeted piston area.

Abstract: A cylinder head gasket for an internal combustion engine is provided having a single first section of a hard gasket material, and a single second section of relatively soft gasket material which is disposed in spaced encompassing relation with the periphery of the first section. The first and second sections coact to form a narrow gap which substantially coincides with the peripheral configuration of the first section. At predetermined locations within the gap, the sections are interconnected whereby the sections will remain in assembled relation at least while the gasket is being positioned between the engine block and cylinder head of the internal combustion engine.

Abstract: An electronically controlled fuel supply system is provided for employing a plurality of fuel injectors which maximize SAC pressures under both low speed and high speed operating conditions and are capable of sustaining SAC pressures in excess of 30,000 psi. The fuel supply system of the present invention includes a gear pump which supplies pressure-modulated fuel to a fueling channel and to a timing channel and from there to a plurality of injectors. Fuel pressure regulator means and timing fluid pressure regulator means are provided in the fueling and timing channel, respectively. An electronic control unit receives information relating to engine operating conditions from a plurality of sensors and actuates the fuel pressure regulator means and the timing fluid pressure regulator means to adjust the pressure as required for the specific engine operating conditions.

Abstract: A ceramic-metallic interfacing joint assembly is disclosed. The joint assembly includes a pair of interfaced components in a highly loaded, sliding contact in which the contact stresses can be as high as 250,000 psi. Preferably, the pair of interfaced components includes a ball member and a complementarily shaped, mating socket member and is used in a diesel type internal combustion engine. One of the components is formed of a ceramic material having a density of at least 3.18 g/cm.sup.3 and the other component is formed of a metallic material. Preferably, the density of the ceramic material ranges from 3.18 g/cm.sup.3 to 3.25 g/cm.sup.3. This arrangement reduces the wear of the joint assembly in conjunction with the use of a lubricant which lubricates the components. Specifically, the metallic material is an iron based material while the ceramic material is a sintered silicon nitride. The ceramic material may be sintered with rare-earth metal oxides such as yttrium oxide.

Abstract: A cam for controlling the injection rate of fuel in a fuel injection system having a four part cam profile is disclosed. The first 120.degree. is the plunger advancement segment. The next 80.degree. is the advanced dwell segment. The next 100.degree. is the plunger retraction segment and the last 60.degree. is the retracted dwell segment. The plunger advancement segment is divided into three subsegments: pre-injection stroke, injection stroke, and overtravel stroke. The pre-injection subsegment achieves minimum velocity and acceleration at the start of injection. In the injection subsegment, the cam follower acceleration is achieved as rapidly as can Hertz stress permits to increase the injection pressure and to achieve the maximum injection rate. The overtravel subsegment achieves a sharp and clean end of injection. Preferably, this cam causes injection of less than 20 mm.sup.3 of fuel per stroke during the first ten cam angle degrees of cam rotation.

Abstract: A water injection system reduces nitrous oxide emissions in turbocharged internal combustion engines driving electrical power generators. A current-activated relay located in switchgear associated with the generator becomes energized asserted when the current output of the generator exceeds a value that corresponds to predetermined NOx permissible emissions level. The output of the relay activates a motor starter which controls a rotary vane pump. The pump draws distilled water from a water tank, forcing the water through a particle strainer, an adjustable flow regulator, a solenoid, a flow meter, and backflow check valves, to water injection nozzles located in the combustion airstream immediately after a turbocharger compressor. The nozzles provided include fine-mesh strainers and atomize the water to 100 micron particle sizes, and distribute the water particles in an 85-degree spray cone pattern.