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.

Abstract: A pump system for preventing hot start knock in a diesel engine following engine shut down carried by fuel leakage into one or more of the combustion chambers of a multiple-cylinder internal combustion engine equipped with a fuel system including open nozzle injectors connected with a common rail. The system includes a transfer pump (46) in fluid communication with the common rail (50) and the fuel tank (48) for pumping fuel out of the common rail and into the fuel tank. A transfer pump control module (82) is provided for actuating the transfer pump (46) for a period of time following engine shut down to remove a sufficient amount of fuel from the common rail to prevent fuel from leakage through the open nozzles. The control system module may include a timer (96) and a voltage sensor (86) to sense condition of a fuel shut off valve (64). A retrofit kit (FIG. 5) is provided including a control module bracket (98) and a transfer module bracket (102).

Abstract: A reinforcing insert for an engine block formed of an engine block material is provided which is positioned in the bearing saddle area of the block for increasing the strength and stiffness of the bearing saddle area to ensure a secure connection of the main bearing cap throughout engine operation thereby ensuring proper crankshaft support and operation. The reinforcing insert is formed of a material having a higher modulus of elasticity than a modulus of elasticity of the engine block material. The insert includes a lower transverse surface for positioning at a lowermost position in the engine block, an upper surface positioned farthest from the crankshaft, a first and second linear side surfaces for positioning on opposite sides of the crankshaft. The linear sides extend from the lower surface along respective planes in nonparallel relation to each other. The linear sides may extend either in a converging or a diverging manner from the lower surface.

Abstract: A method and apparatus for real-time data stamping via datalink and volatile ECM timer/clock. An engine control module (ECM) includes a volatile time-keeping mechanism, such as time-keeping software code inserted into the ECM software, which is capable of keeping track of elapsed time as long as the ECM microprocessor is powered. The ECM initially sets the volatile time-keeping mechanism with real time (RT) at ECM power up by retrieving the current RT over an attached datalink from a non-volatile RT clock (i.e. a clock that keeps track of time even during ECM power down). Thereafter, the ECM microprocessor may time stamp stored data using RT from the volatile time-keeping mechanism. The present invention thus precludes the need to provide a dedicated RT clock for the ECM, or the need for the ECM to request RT over the datalink every time the ECM wishes to time stamp data to be stored.

Abstract: A fuel system includes a pair of electronically controllable high pressure fuel pumps 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 accumulator pressure profile is processed in accordance with various techniques forming part of the present invention for diagnosing pressure sensor in-range failures, fuel pump injector valve blow shut failures and failure of one of the fuel pumps.

Abstract: A system and a method for hydraulic actuation of poppet valves. The poppet valve is opened by application of hydraulic pressure to a piston, and is closed by action of a mechanical spring. Hydraulic pressure comes from either a high pressure source of a low pressure source, the low pressure source being higher than ambient pressure. Application of hydraulic pressure is made by a pressure control device based upon signals received from an electronic controller. Hydraulic pressure is applied in a way that minimizes the power required to actuate the valve by making use of valve inertia.

Abstract: A dual throttle system for an internal combustion engine includes first foot pedal throttle and a second hand controller throttle. The system includes a throttle position signal generator that produces a throttle position signal at an input to an electronic engine control module (ECM). The engine control module uses the throttle position signal input to determine an engine speed and issues appropriate commands to a fuel system controller. The throttle position generator includes a first potentiometer having its wiper mechanically connected to the first throttle and its output electrically connected to the throttle position signal input of the ECM. The first potentiometer is connected in series between a voltage source in the ECM and the wiper of a second variable resistance component driven by the second throttle. The output of the second component is connected to ground to complete the series circuit.

Abstract: The present invention relates to an engine governor which interpolates between several fueling power curves based upon throttle position and engine speed. Each of the curves are chosen so as to provide a consistent power rise with decreasing engine speed at throttle positions less than maximum. The curves are chosen so as to eliminate an abrupt transition between the given fueling curve and the 100% fueling curve. This is preferably accomplished by having the fueling curve exhibit a knee at the transition to the 100% fueling curve. This gives the driver an indication that the throttle position will not maintain the desired speed under the current loading conditions, thereby prompting the driver to increase the throttle position, thereby allowing the throttle to be used to simulate infinite gear shifts between actual transmission gear shifts.

Abstract: A flow control valve having a controllable flow area which varies with the valve displacement. The flow control valve includes a poppet-type valve element mounted to reciprocate between a closed and open position in a valve cavity formed in a valve housing. The valve housing has an inlet and outlet passage to allow fluid to flow therethrough. A removable insert having a flow passage is positioned in the valve cavity adjacent the poppet-valve for controlling the flow rate of gaseous fluid from the inlet passage to the outlet passage while the poppet valve is in an open position. Movement of the poppet valve from a closed to an open position varies the effective cross-sectional flow area of the flow passage.

Abstract: An improved rotary fuel distributor is provided which effectively dynamically centers the rotor during operation while actively cooling the rotor and refilling fuel passages to minimize cavitation. A pressure balancing system is provided which includes pressure area defining grooves formed adjacent a rotor outlet port to control the pressure gradient in the clearance between the rotor and the distributor housing thereby effectively providing a more predictable force component which can be controlled to more effectively balance the rotor in conjunction with two balancing ports positioned on the opposite side of the rotor from the outlet port. A refill and cooling system is provided to continuously and actively cool the rotor with cool, low pressure fuel throughout rotation thereby displacing the hot fuel with cool fuel and effectively preventing thermal seizure of the rotor.

Abstract: A solenoid actuated valve assembly is provided which achieves accurate control of valve movement while maximizing valve seat life. Specifically, the solenoid actuated flow control valve assembly includes a valve plunger, a solenoid actuator including a coil and an armature, and an armature overtravel feature for permitting continued movement of the armature relative to the valve plunger from an engaged position into a disengaged position when the valve plunger reaches a closed position. The armature overtravel feature includes an overtravel biasing spring for returning the armature from the disengaged position to the engaged position prior to subsequent energization of the actuator coil. As a result, the overtravel feature minimizes the mass impacting the valve seat thereby extending valve seat life while, importantly, avoiding lost motion in the armature during the next actuation cycle thereby minimizing valve response time.

Abstract: The present invention gathers and processes engine speed and position information gathered during cranking, without fuel injection or combustion, in order to derive a set of parameters that are shown to correlate very well with the presence of cylinder compression leakage. Using engine speed and position information from, for example, camshaft gear targets, crankshaft tonewheels, or the flywheel itself, etc., a parameter designated as "metric distance" between adjacent firing cylinder speed fluctuation pulses is determined. For engines with well-balanced cylinder compression, the values of the metric distances measured between all cylinders should be close to each other within a certain threshold. If a cylinder exhibits leakage, the metric distance of the cylinder from its adjacent firing cylinders will significantly exceed the threshold, thereby detecting a leaking cylinder. The method of the present invention also provides a relative estimation of the percentage compression loss from the leaking cylinder.

Abstract: A fuel system includes a pair of electronically controllable high pressure fuel pumps operable to supply high pressure fuel from a lower pressure fuel source to a high pressure fuel accumulator 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 accumulator pressure signal is processed in accordance with the present invention for diagnosing erratic pressure sensor failures. The control computer is operable to compute error pressure values based on differences between peak accumulator pressure values and a target pressure value, and compute pressure error variance values based on subsets of the pressure error values.

Abstract: A method for controlling a vehicle engine coolant fan. Because operation of the engine coolant fan creates a power drain upon the engine, it is undesirable to operate the coolant fan when the engine is fueled. Conversely, a power drain upon the engine is desirable when an attempt is being made to slow the vehicle. Consequently, the present invention requests activation of the coolant fan whenever a power drain upon the engine is desirable. Not only is this desirable in order to slow the vehicle, but it also lowers the coolant temperature, thereby reducing the chance that the coolant fan will have to be operated in the future when such operation is undesirable.

Abstract: A control valve comprising a valve housing including a valve cavity, an inlet means formed in the valve housing for directing fluid into the valve cavity, and an outlet means formed in the valve housing for directing fluid out of the valve cavity. The control valve further includes a valve element mounted for reciprocal movement in the valve cavity between open and closed positions and biased toward the closed position by fluid pressure forces. A valve seat is associated with the valve element which engages the valve seat when in the closed position and permits flow between the valve seat and the valve element when in the open position. A flow force inducing means is positioned adjacent the valve element for redirecting fluid from the inlet means through a predetermined flow path arranged relative to the valve element to cause fluid flow to impact the valve element and create flow induced forces of sufficient magnitude necessary to advantageously counteract the fluid pressure forces.

Abstract: A cover assembly for closing off the opening in a panel so as to establish a sealed interface around the opening includes a cover member with a four corners arrangement of clearance holes for attachment of the cover to the panel which also includes a matching pattern of clearance holes. The cover assembly includes a gasket member which is constructed with a carrier and a cooperating edge seal. The carrier includes a substantially planar surface which faces the cover member and extending outwardly from this facing surface are two series of pin-like projections. The cover member is cooperatively arranged with two substantially straight and elongated channels which are constructed and arranged to receive the outwardly extending projections. The two channels act as abutment surfaces for the projections so as to restrict outward or lateral movement of the gasket relative to the cover and panel.

Abstract: A system for controlling air flow to an engine cooling system includes a control computer responsive to a number of engine and/or engine accessory operating conditions, and to various engine operational states to control operation of an engine cooling device. The engine operational states are each a function of at least engine fueling commands and include a "free energy" state corresponding to zero fueling, an "absorbing additional torque" state corresponding to zero fueling and activation of either service brakes or engine brakes, and a "needs additional torque" state corresponding to a rapid positive change in fueling, recent gear shifting to the lower gears of the transmission with fueling above a predefined level or a high rate of change in fueling rate. All other engine operational states are defined as a don't care state.

Abstract: An improved cylinder liner, and method for making the liner, is provided which includes a top section and a bottom section connected by a friction weld. The top section is formed from a material having a higher resistance to wear and/or a higher resistance to thermal distortion while the bottom section is formed of a less expensive material thereby minimizing costs while achieving a durable liner. A liner durability and cost optimizing arrangement is provided which limits the predetermined axial extent of the top section to an area corresponding to the greatest amount of mechanical and thermal loading thereby limiting material costs, maintaining structural integrity and maximizing durability. The method of the present invention creates an effective seamless connection between the top and bottom sections while permitting materials of different resistance properties to be utilized to maximize durability and minimize costs.

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: A system for controlling operation of an internal combustion engine includes a control computer responsive to a number of engine/vehicle operating conditions to control engine operation to thereby control engine speed and engine or vehicle acceleration. In one embodiment, the control computer is configured to determine an engine or vehicle acceleration limit value based on current engine or vehicle speed, and an engine speed limit value based on current engine load, and to control engine fueling and/or speed to thereby limit engine speed to the engine speed limit value and/or engine/vehicle acceleration to the engine/vehicle acceleration limit value.