Abstract: A port fuel injection system includes a fuel pump configured to produce a flow of pressurized liquid fuel at a pressure between 10 and 50 bar. A fuel rail is connected to receive the flow of pressurized liquid fuel from the fuel pump, the fuel rail. A plurality of fuel injectors, including one fuel injector positioned in the intake port of each engine cylinder upstream of the intake valve for the engine cylinder are connected to receive pressurized fuel from the fuel rail. An engine control unit (ECU) receives signals from sensors on the internal combustion engine and is programmed to actuate the fuel injectors to deliver fuel to each engine cylinder over a full range of engine operating conditions. A port fuel injection system with high pressure and fast acting fuel injectors improves fuel delivery and performance over the full range of engine operating conditions.

Abstract: An electromagnetic fuel injection valve includes a coupling between an armature and the valve member that allows limited relative movement of the valve member and armature in both the opening and closing directions of the valve member. An injector body includes a non-magnetic section to focus magnetic flux and attractive force through the armature and pole. A modular power group reduces the cost of assembly and includes a plastic encapsulated coil that is protected from environmental moisture and corrosion. A valve seat incorporates a valve seal which improves fuel flow past the valve member when the fuel injection valve is in the open position.

Abstract: An actuator is driven by a brushless motor having a rotor with axially extended magnets, permitting axial movement of the rotor while maintaining overlap between the magnets and a stator secured in a fixed position. The rotor is engaged with a fixed structure by a connection such as a ramp or thread that translates rotation into axial movement of the rotor along a rotational axis of the actuator. A valve member coupled to the rotor moves axially between a closed position and a range of positions that regulate fluid flow through a valve. A motor control circuit applies power to the stator coils to rotate the rotor and coupled valve member to a desired axial position and maintain the rotor and valve member at the selected position. The rotor and valve member may be biased toward a rotational position corresponding to a closed position of the valve member.

Abstract: A high pressure fuel pump includes an inlet metering valve arranged to control a quantity of fuel delivered to the pumping chamber during retracting motion of the pumping plunger. The inlet metering valve includes a metering valve member movable between a closed position and an open position, movement of the metering valve member from the closed position to the open position defining a variable flow area that increases as the metering valve member moves from the closed position toward the open position. An actuator piston in an actuator bore is exposed to pressure in the common rail. The actuator piston is biased toward a first position corresponding to low pressure in the common rail and movable toward a second position corresponding to maximum pressure in the common rail. The actuator piston includes a valve stop that determines a metering position of the metering valve member.

Abstract: The disclosed inlet check valve is used in a high pressure fuel pump and is comprised of a valve member integrally connected to a valve stem which is coupled to an inlet valve armature. The valve member has a stroke along an axis between an open position and a closed position. An inlet valve solenoid generates a magnetic field in an inlet valve pole to attract the inlet valve armature and move the valve member from the open position to the closed position. In the open position, the valve member contacts an inlet valve stop and a gap greater than the stroke of the valve member is defined along the axis between the inlet valve armature and the inlet valve pole. In the closed position, an inlet valve seat mates with the valve member and an armature gap remains between the inlet valve armature and the inlet valve pole.

Abstract: In a high pressure fuel supply system, a variable speed motor asynchronously actuates a pumping piston with a drive mechanism including a circular cam with cam roller, having an axis that is offset from the axis of the cam drive shaft. A rolling or sliding cam follower is rigidly connected to the piston, and a piston retainer is operatively connected among the piston, the cam follower and the cam roller. As the cam shaft rotates, the cam roller rotates eccentrically relative to the cam shaft while maintaining contact with the cam follower, thereby reciprocating the follower and the piston along the actuation axis, in corresponding charging and pumping strokes of the piston.

Abstract: An energize-to-close solenoid operated spool type inlet control valve for a high pressure fuel pump is variably positionable relative to a sleeve having three inlet feed ports and the inlet check valve member, to implement three stages of pump operation: limp-home, low-pressure flow from the low-pressure feed pump to the common rail, no flow to the common rail, and metered quantity of flow to the common rail. The spool valve includes an axially extending internal passage fluidly connected to a fluid volume at the front end of the spool valve, and a control port at the back end of the spool valve, selectively alignable to fluidly connect the ports. Two springs of different lengths either alone or together, bias the spool valve toward opening of the inlet check valve.

Abstract: In a hybrid fuel supply system for the same high pressure supply pump used for gasoline direct injection (DI) is also used to supply the port injection (PI) system. For a given pumping stroke, fuel can be delivered only to the DI system, only to the PI system, or a first portion can be delivered to the DI system and a second portion delivered to the PI system. The pumping chamber always fills to maximum volume. Fuel metering for DI is by a control valve, which when closed delivers fuel into the DI system and when opened “spills” pumped fuel into the PI system. Any “spill” at high pressure opens a pressure regulating valve in the PI system that dumps fuel at excess pressure to a low pressure region to maintain the PI system at a constant target pressure.

Abstract: An inlet valve assembly for a fuel pump comprises a valve assembly inflow path and valve assembly outflow path; a magnetic valve member situated in an intermediate flow path fluidly linking the inflow path and the outflow path; a magnetic pole adjacent the valve member; and a selectively energizable coil for generating a magnetic flux directly magnetically coupling the pole and the valve member; whereby the valve member opens and closes fluid communication between the inflow path and the outflow path in response to the energized state of the coil.

Abstract: The proportional control valve for a fuel pump has a metering assembly within a tightly fit bore and a vent valve. The metering assembly includes a metering piston assembly, a piston biasing spring, an armature and a vent valve. The vent valve, such as a ball, is affixed to the armature and the metering piston assembly is configured around the vent valve in a manner that couples the metering piston to the armature. The metering piston assembly comprises a metering piston and a vent valve seat, permanently joined together, which contain a seal and a seat surface respectively between which the vent valve is permitted to move during the operation of the proportional control valve.

Abstract: In a fuel pump and method of operation, an infeed for low pressure fuel leads to a pumping chamber where in an intake phase low pressure fuel is drawn into the pumping chamber and in a pumping phase high pressure fuel is delivered to a common rail. An inlet metering valve and an inlet check valve are upstream of the pumping chamber, and a control system closes the metering valve when no fuel is to be pumped to the common rail. The inlet check valve is also opened while the inlet metering valve is closed and no fuel is to be pumped to the rail. The inlet metering valve can include a proportionally controlled piston that produces a variable quantity of feed fuel and is closable for the no-demand condition with a maximum travel that contacts and holds open the inlet check valve.

Abstract: In a hybrid fuel supply system for the same high pressure supply pump used for gasoline direct injection (DI) is also used to supply the port injection (PI) system. For a given pumping stroke, fuel can be delivered only to the DI system, only to the PI system, or a first portion can be delivered to the DI system and a second portion delivered to the PI system. The pumping chamber always fills to maximum volume. Fuel metering for DI is by a control valve, which when closed delivers fuel into the DI system and when opened “spills” pumped fuel into the PI system. Any “spill” at high pressure opens a pressure regulating valve in the PI system that dumps fuel at excess pressure to a low pressure region to maintain the PI system at a constant target pressure.

Abstract: In a tappet-driven single piston pump, piston side loads caused by return spring out-of-squareness are eliminated by effectively piloting the piston return spring, preferably the associated spring seat, by the tappet, thereby allowing the tappet to bear the spring side load. The piston engages and is returned by the spring seat, but radial clearance between the piston and spring seat is greater than radial clearance between the spring seat and tappet, thus eliminating side loading imparted to the piston. The spring seat can be considered a piston retainer, in which the piston is not closely attached to the retainer but instead exhibits a predefined radial clearance greater than the piloting clearance between the retainer and the tappet.

Abstract: An energize-to-close solenoid operated spool type inlet control valve for a high pressure fuel pump is variably positionable relative to a sleeve having three inlet feed ports and the inlet check valve member, to implement three stages of pump operation: limp-home, low-pressure flow from the low-pressure feed pump to the common rail, no flow to the common rail, and metered quantity of flow to the common rail. The spool valve includes an axially extending internal passage fluidly connected to a fluid volume at the front end of the spool valve, and a control port at the back end of the spool valve, selectively alignable to fluidly connect the ports. Two springs of different lengths either alone or together, bias the spool valve toward opening of the inlet check valve.

Abstract: A needle type fuel injector has a needle control chamber at a pressure subject to a control valve in a control valve chamber which in an opening phase is lifted from its seat to expose the control valve chamber, connecting passage, and needle control chamber to a low pressure drain and in a closing phase is urged against the seat to isolate the control valve chamber, connecting passage, and needle control chamber from the drain. The potential for cavitation at high fuel injection pressure is reduced by throttling the flow of fuel past the control valve seat when the control valve opens, thereby maintaining sufficient back pressure in the control valve chamber and upstream connecting passages.

Abstract: The pump delivered pressure is regulated to a substantially constant set value, and output flow is varied by an inlet metering valve (5) via feedback from the motion of, or flow from the spilled fuel through, a delivered pressure regulator (13, 19). The pressure regulating element can be biased to close a seal surface (12?) against flow from the outlet side of the pump (14) toward the inlet metering valve when the pump is turned off, thereby holding sufficient rail pressure to prevent boiling during hot soak conditions. In another aspect, a flow stabilization orifice (18) is provided between the outlet of the pump and the inlet metering valve, e.g., upstream of the pressure regulating element. In yet a further aspect, the inlet metering valve is hydraulically responsive (6, S, L) to changes in flow resulting from movement of the pressure responsive element (13).

Abstract: A fuel pump has a low pressure fuel inlet (40) and a single piston pumping chamber (10) for supplying high pressure fuel through a pump outlet to an inlet side of a common rail (16). The fuel pump comprises a primary pressure relief valve (12) having an inlet side in hydraulic communication with the inlet side of the common rail (16) and an outlet side in fluid communication with the pumping chamber (10); and an auxiliary pressure relief valve (19) having an inlet side (35) in hydraulic communication with the pumping chamber (10) and an outlet side in direct fluid communication with a fuel passage (37) at the low pressure of the pump inlet (40).

Abstract: A tubular debris shield and diverter mounted in a high pressure flow passage within a fuel injector, provide the dual functions of passing the main flow of high pressure fuel with large debris particles to relatively large discharge openings, such as the injector spray holes, while allowing some high pressure fuel to flow through a multitude of very small transverse holes to a sensitive hydraulic component, such an injector control valve circuit. In one embodiment, the tube has a wall thickness in the range of about 0.1 to 0.5 mm at least about 2000 holes with a diameter in the range of about 20 to 30 microns.

Abstract: An atomizing injector comprises a body having a central bore with a valve situated in the bore, leading to a chamber. An actuator moves the valve between closed condition and open conditions, selectively exposing the chamber to a flow of pressurized liquid. A discharge port extends from the chamber to a discharge orifice. A swirl element is situated in the chamber, while leaving a free space in the chamber immediately above the discharge port. When the valve is opened, liquid flows into the chamber, through the swirl element into the space, forming a whirl in the space before passing through the discharge port and exiting the discharge orifice as an atomized whirling spray.

Abstract: A fuel pump including a low pressure infeed leading to a pumping chamber, a pumping plunger for pressurizing fuel in the pumping chamber, an outlet valve for delivering pressurized fuel from the pumping chamber to a high pressure outlet line during pumping, and an overpressure relief valve connected between the high pressure outlet line and the pumping chamber. A ball type relief valve element is spring biased to close against the relief valve seat. The spring is in a spring chamber that is fluidly isolated from the pumping chamber while the valve element is closed, preferably in direct hydraulic communication with the low pressure infeed, thereby reducing dead volume during normal pumping. The spring can act on the valve element through a piston, and in an alternative embodiment, the piston can provide a spill path from the pumping chamber to the low pressure infeed.