Abstract: A self-regulating direct injection fuel delivery system for a motor vehicle includes a common rail having an accumulator including a relatively large fuel volume. The accumulator is connected in fluid communication with a distributor having a relatively small fuel volume and at least one fuel injector nozzle is connected in direct fluid communication with the distributor. A high-pressure pump for delivering fuel to the common rail is provided and a flow control device is interposed between the pump and the common rail for selectively delivering fuel to one of the accumulator and the distributor and then the other of the accumulator and the distributor.

Abstract: A high pressure fuel supply pump comprising a housing (102) and a pump body (108) fixed within the housing along a body axis and including a plurality of radially oriented plunger bores (20), each bore having a plunger (22) disposed therein. An actuating assembly (116) is disposed around the plunger bores for producing reciprocal motion. A central cavity (120) extends along the axis and intersects the pumping bores to form a pumping chamber (18) in cooperation therewith. An inlet check valve (132) and a discharged check valve (124) are in communication with the pumping chamber.

Abstract: The pumping plungers are actuated radially outwardly and withdraw inwardly by an eccentric rotated by the pump drive shaft and associated captured sliding shoes. Because the shoes are forced to follow the eccentric over the full 360° of rotation, the shoes themselves can play an integral role for implementing the function of an inlet check valve which controls flow through a charging passage in each plunger in a radial outward direction, to a respective plunger pumping chamber. Relatively low pressure fuel in the pump cavity surrounding the drive member, is drawn through openings in the radially inner end of the plunger, through an inlet passageway in the plunger, and into the pumping chamber.

Abstract: An apparatus is provided for equalizing pressure between a lubrication fluid for lubricating a pump and a combustion fluid located at a low pressure side of the pump wherein the pump has a rotatable shaft. The apparatus includes a wall defining a bore within the pump wherein a first end of the bore is configured to receive a lubrication fluid and a second end of the bore is configured to receive combustion fluid. An equalizing element is disposed within the bore for separating the lubrication fluid and the combustion fluid and may be at least partially movable in response to pressure differences caused, e.g., by differences in thermal expansion between the lubrication fluid and the combustion fluid.

Abstract: Lift pump guard for a pump operable by an electrical motor. The lift pump guard monitors variable parameters and actuates a relay to electrically terminate operation of the pump motor when the pump is dry running. Also a method of protecting a pump from dry running compares a measured parameter to a predetermined value and terminates operation based on the comparison.

Abstract: A fuel filter cartridge has a plurality of retention tabs which radially integrally project along the roll seam structure which joins a top section of the housing to the cylindrical lower section. A base contains complementary slots which allow for the cartridge to be axially inserted and rotated to secure the replaceable cartridge in position. Various numbers and configurations of the retention tabs may be provided.

Abstract: A fuel supply pump having a plurality of radially disposed plunger sleeves each containing a pumping plunger with a driven end reciprocally movable within the plunger sleeve between a pumping position and a filling position. The fuel supply pump includes a rotatable drive member and a plurality of sliding shoes. Each shoe has a first face adjacent a respective plunger driven end and a second face adjacent the drive member. In one variation, each shoe first face includes a socket which the plunger driven end snaps into and is captured by, creating a sliding shoe assembly. A case couples all of the sliding shoe assemblies. In another variation, the cage includes apertures which the plunger driven end snaps through, thereby capturing the plunger. The plunger driven end engages a seat included on the sliding shoe first face. Rotation of the drive member moves each shoe, and thereby, each plunger toward the pumping position.

Abstract: A two stage pressure relief valve for releasing a fluid under pressure includes a body having a bore extending from an inlet and terminating in an outlet. A first chamber which communicates with the inlet and a second chamber which communicates with the first chamber and the outlet are provided and are dimensioned such that the cross sectional area of the second chamber is greater than that of the first chamber. An operator seat is disposed within the body and an operator is moveably disposed within the bore and engages the operator seat. The operator includes a blocking surface which blocks at least a portion of the flow of fluid. When the pressure of the fluid exceeds a threshold pressure, the operator is unseated whereby fluid flows at a first flow volume such that at least a portion of the fluid impinges the blocking surface causing the blocking surface to move within the second chamber whereby fluid flows at a second flow volume. The second flow volume being greater than the first flow volume.

Abstract: A hydro-mechanical device and methods therefor, for receiving fuel from a variable displacement fuel pump of a fuel-supply system and delivering the fuel to a common rail of the fuel-supply system, regulates the fuel-pressure in the fuel-supply system, at least in part, based on the output of the fuel pump such that optimal engine performance can be maintained under varying operating conditions.

Abstract: A fuel pump, a fuel-pressure intensifier sub-assembly and a method of producing intensified high-pressure fuel are disclosed. The pump has a metered fuel circuit, a plurality of low-pressure bores with low-pressure plungers disposed therein, an intensifier bore with a piston disposed therein, a resilient bias member acting on the piston, a high-pressure bore with a high-pressure plunger at least partially disposed therein and a fuel outlet port. The pump operates in alternating fuel-in-take and fuel-pumping phases of operation under the influence of a rotary drive shaft with a cam and cooperating cam followers. By selecting the pumping surface areas of the low-pressure plungers and the high-pressure plunger, it is possible to select the fuel-pressure generated by the fuel pump.

Abstract: A fuel injector having a needle valve and an injector body employs at least one movable needle-guide which having a plurality of movable members disposed between the needle valve assembly and the injector body. The movable members can be insulating members which are substantially entirely composed of insulating material such as ceramics. In applications which do not require electrical isolation, the movable members could be formed of conductive material. The movable members are preferably spherical elements which are partially cradled within an annular trough formed in the needle valve such that the movable members ensure that the needle valve is held in spaced relation to the injector body. While the movable members are preferably formed as solid ceramic spheres, other insulating materials and/or shapes could be utilized.

Abstract: A filter assembly including a base and a disposable filter cartridge. The container of the filter cartridge has a top portion of an upper section that is received in the base and which may deform into engagement with the interior receiving surface of the base when exposed to the fuel system operating pressure. A plurality of longitudinally extending keys or protrusions protrude from the bottom surface of the base. The protrusions are selectively dimensioned and positioned to provide a unique protrusion matrix for a given filter capacity, filtering quality or filtering parameter. The protrusions form corresponding depressions in the top portion of the upper section when the fuel system is operating, locking the top portion of the upper section to the base. The base structure supports the upper section of the cartridge, controlling the extent of deformation of the upper section.

Abstract: A pump and associated method including the steps of pre-metering successive quantities of fuel from a reservoir to a positive displacement transfer pump, then actuating the transfer pump to raise the pressure of the successive quantities of fuel by at least about 100 psi, preferably 200-300 psi. Each quantity of fuel which was pressurized in the transfer pump, is delivered to a high pressure pumping chamber so that each pumping bore receives a certain, i.e., predetermined, charge of fuel within a first time interval. A plurality of plungers in the respective pumping bores are then simultaneously actuated to increase the pressure in the pumping chamber to the desired high pressure, preferably at least about 15,000 psi, within a second time interval, and to discharge the quantity of fuel through a high pressure discharge valve. The second time interval is of longer duration than the first time interval.

Abstract: A fuel injector to inject fuel into a cylinder of an internal combustion engine when installed therein. The injector has an injector body which defines an interior cavity, a movable needle valve which cooperates with the interior body to define a variable-volume control chamber and a control valve for selectively blocking and permitting fluid communication among the control chamber, the high-pressure fuel supply, and the low-pressure fuel return. Such selectively controlled variation of the volume of the control chamber varies the position of the needle valve to selectively permit or prevent fluid communication between the high-pressure fuel supply and the engine cylinder. The control valve for selectively permitting fluid communication is preferably force balanced by relatively low forces acting thereon.

Abstract: A fuel filter assembly employs a hand primer and a disposable filter cartridge mounted to a header. The filter cartridge has a filter element which defines an interior chamber for receiving the filtered fuel. The hand primer includes a diaphragm which cooperates with the header to define a reservoir and a valve plate having a plurality of orifices and an axial opening for providing fluid communication between an exit passage of the header and the reservoir and between the chamber and the reservoir, respectively. A first check valve is mounted in the opening and a second check valve is mounted in an axial bore in the first check valve. The first and second check valves are moveable between an open position for allowing flow through the orifices of the valve plate and orifices in the first check valve, respectively, and a closed position for preventing such flow.

Abstract: The base assembly of a fuel filter assembly includes a base member and a bimetallic disc. The base member has a fuel supply inlet for receiving a flow of new fuel from a fuel tank and an inlet plenum in fluid communication with the fuel supply inlet and the filter cartridge. The base member also has an excess fuel inlet for receiving a flow of excess fuel from the fuel injection pump, an excess fuel outlet in fluid communication with the fuel tank, and a fuel passage providing fluid communication between the excess fuel inlet and the excess fuel outlet. The bimetallic disc is disposed in the fuel passage adjacent an opening in the wall separating the fuel passage from the inlet plenum. The edge portion of the bimetallic disc is flexed away from the wall to open the opening when the temperature of the excess fuel is below a predetermined value, warming the new fuel to prevent formation of wax crystals.

Abstract: A fuel injector employs at least one sensing device for sensing material deformations occurring in the injector components during usage to thereby monitor injector performance. The sensing device is preferably at least one of the many piezoelectric sensors available and is advantageously affixed within a cylinder of an injector to detect deformations of the injector cylinder within the needle valve/power piston column of an injector to detect deformations of the column which occurs when the high-pressure fuel in the control chamber is suddenly converted pressure and vice versa. Whereas the sensing devices of the invention can be placed at a variety of locations, they are advantageously arranged to detect material deformations within the injector cylinder or valve/piston column where such deformations are appreciably large during injector usage.

Abstract: An improved fuel filter cartridge comprises a housing which defines an opening, a filter element enclosed within the housing, and a flow-reversing insert disposed within the housing between the opening and the filter element. The improved filter cartridge is preferably used with a conventional header of the type having a fuel entry port, a fuel exit port, a central first conduit for interiorly defining a first axial fuel passage which is in fluid communication with the entry port of the header. Headers used with the improved filter cartridge also include a second conduit surrounding and cooperating with the first conduit to define a second axial fuel passage therebetween, the second fuel passage being in fluid communication with the exit port of the header, and a base for mounting the filter cartridge thereto.

Abstract: A fuel pump (10) for supplying fuel to an internal combustion engine employs at least one composite pumping plunger (43) disposed within a plunger bore (46) for reciprocation therein. Each composite plunger comprises at least a high-pressure plunger element (48), which is in contact with a high-pressure fuel charge to be delivered by the pump, and an abutting leak-off plunger element (47) disposed between the high-pressure element and a plunger actuating member (50, 52). The plunger elements of each composite plunger are stacked in the direction of reciprocation such that the abutting plunger elements form confronting end faces. The confronting end face of at least one of the elements in each composite plunger is contoured and the confronting end face of the abutting element is non-complementary in shape.