Abstract: An apparatus for sensing engine speed and engine angular position. A tone wheel with a plurality of reference indicators and a position indicator is mounted to a camshaft gear. The reference and position indicators rotate past a Hall effect sensor which generates a sensor signal suitable for use by a controller for determination of engine speed and engine angular position.

Abstract: A system for controlling ignition energy of 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 operable to induce 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 for controllably shunting the primary coil to thereby control the duration of discharge current across the spark gap of the ignition plug. In accordance with another aspect of the present invention, means are further provided for drawing discharge current away from the ignition plug to thereby limit the magnitude of the discharge current within some time period after the transfer of energy from the primary coil to the secondary coil begins.

Abstract: An intermetallic bond between a ferrous metal and a non-ferrous metal wherein an intermetallic bond layer that is substantially free of graphic inclusions joins the two. The graphite is effectively eliminated from the bond layer by either removing it from the ferrous metal or by sealing it off from the bond layer. Graphite removal may be accomplished in a variety of ways, including electrochemical cleaning and laser surface treatment. Alternatively, the graphite may be prevented from incursing into the bond region by sealing it off with a layer of metal, such as a chromium plating, that prevents it from penetrating through the bond layer and into the non-ferrous metal.

Abstract: A closed crankcase ventilation system for a turbocharger internal combustion engine which uses differential pressure between the turbo compressor inlet and the crankcase to force blow-by gases through a separation device. The zone of low pressure of the turbo compressor inlet is located at the innermost diameter of the compressor inlet shroud. The difference between the pressure in the compressor inlet and the crankcase creates a vacuum which pulls gas from the crankcase into the ventilation system. The ventilation system includes a high restriction separator for removing oil from the blow-by gases. A control valve bypasses the separation device when insufficient pressure differential exists to drive the separator.

Abstract: A combination heat exchanger and expansion tank are provided having an integral housing with a self-de-aerating design. Particularly suitable for cooling marine internal combustion engines, the housing holds an elongated heat exchanger core configured with at least one straight seawater passage, such that an embodiment of the housing facilitates access to opposite passage ends for cleaning through respective openings in the housing, eliminating a need to remove the core. The housing forms an upper expansion chamber, a lower collection chamber, and a coolant channel in communication with these chambers. The coolant channel receives and directs a main flow of engine coolant over the core; the coolant flow subsequently dropping into the lower collection chamber, from where the coolant exits for recirculation through the engine. The upper expansion chamber includes vents which receive vented coolant flow from remote engine components.

Abstract: A replaceable cylinder liner for an internal combustion engine. The position of the liner within the block is established by a midstop. An interference fit below the midstop seals the bottom end of a cooling passage that extends around the liner. The top end of the cooling passage is sealed by an o-ring, and when the engine is warmed up by an interference fit also. The top of the cooling passage is close to the top dead center position of the top piston ring, and reduces the temperature of the top piston ring.

Abstract: Check valves (500) are incorporated into a fuel injector so as to form a controlling orifice in the system between the solenoid vales which direct fuel to the respective injection and timing chambers of the fuel injector and the chambers themselves. The precision fuel metering capability of the valve (500) is determined by an annular clearance created between the plunger (512) of the valve and the valve body (510) when the valve is in its maximum stroke. For achieving a bi-stable operation of the valve, the ratio of the plunger valve seat (510d) area to the maximum plunger valve (512b) area and the spring (514) are key parameters. The check valves (500) are formed as cartridge type check valves that can be calibrated outside of the injector prior to the installation thereof.

Abstract: Both an apparatus and method for truing and dressing a grinding wheel with a constant tangentially dressing force is provided. The apparatus includes a rotatable diamond dressing roll, an engagement assembly including a servo-motor for forcefully engaging the dressing roll against the peripheral work surface of the grinding wheel, a sensor for sensing the force of engagement between the dressing roll and the grinding wheel, and a microprocessor connected to both the sensor and the power supply for the servo-motor for modulating both the voltage and polarity of a DC current connected to the servo-motor so that the engagement assembly presses the diamond dressing roll against the grinding wheel with a constant force during the entire dressing operation.

Abstract: An assembly including an engine component, such as a fuel injector, seated against a seating surface of a cylinder head is provided with a positive seal contact an uppermost point of contact between an injector sleeve and a seating surface of the cylinder head. The positive seal contact prevents coolant from the water jacket from travelling below the uppermost point of contact, thereby avoiding cavitation damage which might otherwise occur by the entrapment of liquid between the cylinder head seating surface and the injector sleeve. In an embodiment, a raised annular ridge is formed in the seating surface of the cylinder head at the location of the uppermost point of contact. This ridge becomes embedded in the injector sleeve. Also, in an embodiment, the cylinder head includes a circular recess upwardly from the uppermost point of contact.

Abstract: A diagnostic system for an engine is provided for which a plurality of annunciators are energized according to particular fault code sequences. A self-diagnosis mode is controlled by use of the vehicle throttle. The self-diagnosis mode can be initiated by a predetermined number of cycles of the vehicle throttle, in which a cycle corresponds to depressing and releasing the throttle beyond upper and lower limits. In one aspect of the invention, a timer is used to determine whether the predetermined number of throttle cycles occurs within a fixed time limit. If not, then the self-diagnosis mode is not activated. Once the self-diagnosis mode is activated, subsequent cycles of the vehicle throttle will increment the annunciators among the sequential fault codes.

Abstract: Apparatus and method for adjusting a gear in a gear train assembly. A first gear with a first rotational center and a second gear with a second rotational center are coupled to an engine. A third gear with a third rotational center is provided to form a first mesh with the first gear. The first mesh has a predetermined minimum backlash. The third gear also forms a second mesh with the second gear. The third gear includes an adjustable positioning mechanism which allows the rotational center of the third gear to be adjusted along a predetermined adjustment path that is substantially tangent to the first mesh. The adjustment mechanism of the third gear allows the minimum backlash of the first mesh to be maintained while the second mesh is adjusted to likewise achieve a generally minimized backlash.

Abstract: A servo-controlled fuel injector is provided which includes a leakage limiting valve device for limiting the quantity of high pressure fuel available for leakage into the combustion chamber in the event the closed nozzle valve element fails to sealingly engage its seat between injection events. The servo-controlled fuel injector includes a control volume positioned adjacent an outer end of the nozzle valve element, a control volume charge circuit for supplying fuel to the control volume, a drain circuit for draining fuel from the control volume to a low pressure drain and an injection control valve positioned along the drain circuit for controlling the flow through the drain circuit so as to cause reciprocal movement of the nozzle valve element. The leakage limiting valve is integrated into the fuel injector body and positioned along a fuel transfer passage to block the flow of high pressure fuel to a nozzle cavity between injection events.

Abstract: An improved turbocharged internal combustion engine is provided having a system and method for preventing a rapid decrease of turbocharger power during rapid fuel reduction transients in engine operation due to reductions in fuel flow rate to the engine. The engine includes a turbocharger power enhancing system including an exhaust valve control device capable of varying the timing of opening of the engine exhaust valves. The turbocharger power enhancing system also includes a processor which generates a control signal when a reduction in the fuel delivery rate is detected. The control signal operates the exhaust valve control device to advance the timing of opening of the exhaust valves to cause additional exhaust gas to be delivered to the turbine thereby preventing a rapid decrease of compressor speed and preventing compressor surge.

Abstract: A system and method for detecting a fault condition in an internal combustion engine utilizes the intake air temperatures at each of a plurality of cylinder sections of the engine. An average value of the plurality of intake air temperatures is compared to each of the individual temperatures at discrete time increments. The rate of change of each intake air temperature relative to the average temperature value is assessed to determine if a valve-related fault condition has occurred. In a further feature of the system and method, a plurality of temperature differential values over several time increments are differentiated. The resulting plurality of differentiated values are integrated, or summed, over the time period, which result is compared to a threshold value indicative of a valve-related failure.

Abstract: A multi-cylinder internal combustion engine is provided with an intake port injection system capable of effectively delivering port injected quantities of fuel to each cylinder while minimizing the number and size of the fuel injectors. The intake port injection system of the present invention includes a siamese or shared port arrangement having a plurality of common intake inlets, each delivering air from an intake manifold to one intake port of one cylinder and an intake port of a different cylinder. Two single intake inlets are also provided for delivering intake air solely to a single respective cylinder. Importantly, in a multi-cylinder engine having a total number of cylinders equal to N, the number of intake inlets, both common and single, equals N+1. Importantly, the total number of injectors also equals N+1. Although each intake inlet is served by only one injector, two injectors operate simultaneously to deliver fuel to a single cylinder via respective intake inlets.

Abstract: A vehicle having an internal combustion engine with a throttle control is disclosed. The throttle control is responsive to a vehicle operator to generate a throttle setting signal to adjust vehicle speed. An operator-controlled input device is also provided to generate a selected signal corresponding to a selected one of a number of predetermined engine control relationships. A controller responds to the selection signal to govern engine operation in accordance with the selected one of the relationships and the throttle setting signal. The throttle control has a different performance characteristic for each of the relationships and is adjustable by the operator to increase or decrease speed for each of the relationships. The relationships may each correspond to a different type of engine governing technique and include different droop characteristics.

Abstract: A vehicle having an internal combustion engine with a throttle control is disclosed. The throttle control is responsive to a vehicle operator to generate a throttle setting signal to adjust vehicle speed. An operator-controlled input device is also provided to generate a selected signal corresponding to a selected one of a number of predetermined engine control relationships. A controller responds to the selection signal to govern engine operation in accordance with the selected one of the relationships and the throttle setting signal. The throttle control has a different performance characteristic for each of the relationships and is adjustable by the operator to increase or decrease speed for each of the relationships. The relationships may each correspond to a different type of engine governing technique and include different droop characteristics.

Abstract: An improved method and 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 injection control device for injecting small amounts of used lube oil into the engine's fuel system and an auxiliary flow control device for directing controlled quantities of fresh oil into the engine's lube oil 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 process 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.

Abstract: An apparatus for diagnosing and controlling an ignition system of an internal combustion engine includes an ignition coil controllable by an ignition control circuit, a spark voltage sensor electrically connected to the high tension side of the ignition coil secondary and an ion voltage sensor electrically connected to the low tension side of the ignition coil secondary. A computer processes the spark voltage signal by comparing the signal to a number of predefined spark voltage waveforms in memory. If the spark voltage signal matches any of the spark voltage waveforms in memory that correspond to a predefined ignition system failure mode, a corresponding error code is stored in memory. The computer is further operable to process a voltage peak of the spark voltage, wherein the voltage peak corresponds to the breakdown voltage in the spark gap of a spark plug connected to the secondary coil.

Abstract: An electronically controlled lube oil and fuel blending system is provided which controls the amount of lube oil delivered from an engine lube oil supply system to an engine fuel supply system based on the amount of fuel added to the fuel supply system thereby maintaining a constant lube oil/fuel ratio or lube oil concentration in the fuel supply system 16 regardless of variations in engine operation thereby minimizing emissions, such as particulate matter. The system includes a lube oil injection circuit connecting the engine lube oil supply system to the fuel supply system and an emission compliance lube oil concentration control system for controlling a lube oil concentration in the fuel supply system to maintain compliant engine emissions during engine operation.