Abstract: Position sensors and methods having a coil, a magnetic target movable into greater and lesser proximity to the coil responsive to the position to be sensed, and circuitry responsive to an inductance of the coil to provided a measure of the proximity of the magnetic target to the coil. Various embodiments are disclosed, including embodiments having improved sensitivity and shielding from stray fields and for shielding from magnetic fields generated by the coil excitation.

Abstract: A ride control system includes a shock absorber having a movable piston that divides the shock absorber into a lower and an upper volume and a center check valve that allows fluid to flow from the upper to the lower volume. A back pressure actuator provides a selectable back pressure to the lower volume. Three two way valves and a check valve allow the lower and upper volumes to be selectively coupled to either the selectable back pressure or a shock absorber fluid reservoir to provide passive, semi-active, or active ride control. The back pressure actuator pressurizes a hydraulic accumulator when shock absorber fluid flows into the back pressure actuator to provide energy recovery.

Abstract: Method and apparatus for controlling needle seat load in very high pressure diesel injectors. In accordance with the method, a needle control piston responsive to hydraulic forces for controllably forcing the injector needle against the needle seat is provided, as is a stop for the needle control piston to limit the needle control piston movement toward the needle seat. This provides a stop for the needle control piston, so that the compressive deflection between the needle control piston and the needle seat limits the force of the injector needle on the needle seat against increasing hydraulic forces on the needle control piston once the needle control piston reaches the needle control piston seat.

Abstract: Power steering systems and methods to improve efficiency and performance of vehicle power steering systems. In one embodiment, there is provided an engine driven positive displacement hydraulic pump, a rotary valve coupled to a steering shaft for receiving hydraulic fluid under pressure in a rotary valve inlet and providing a differential pressure to a steering rack piston for a steering boost responsive to a torque exerted on the steering shaft, valving coupled between an output of the hydraulic pump, the rotary valve inlet and the hydraulic pump input for controllably coupling the output of the hydraulic pump to the rotary valve inlet or an input of the hydraulic pump, and a controller coupled to valving to maintain a flow rate of hydraulic fluid coupled to the rotary valve responsive to a pressure sensor output. Other embodiments are disclosed.

Abstract: Micro-hydraulic supply and storage units capable of recovering waste energy and storing energy for later use, such as for operating hydraulic valve actuation and high pressure fuel injection systems. The system includes a sump, a pump motor, an accumulator and a supply rail. Valving is provided to couple the outlet of the pump motor to the accumulator to fill the accumulator with what otherwise would be waste energy, such as when a vehicle is using its engine for braking, directing the output of the pump motor to a supply rail to maintain the pressure in the supply rail, and directing the output of the pump to a sump. The valving also allows directing an outlet of the accumulator to an inlet of the pump motor for recover of the energy in the accumulator. Other aspects of the invention are disclosed.

Abstract: Oil intensified common rail injectors that combine a common-rail non-intensified injector with an oil-intensified injector. The invention also uses fuel (common rail) pumps that are commercially available since the injector does not rely on this pump for intensification function. Also, since the pressure of the fuel pump is limited to lower than the intensified pressure, the injected pressure is limited to the unit injector; this eases the rail and tube requirements to this lower fuel rail pressure. The injector operates up to this limited pressure with no intensification. Also a separate oil system is configured to operate a hydraulic intensifier. Thus the system is able to achieve very high injection pressure without common rail pump, rail, fitting and jumper tube limits. The oil system does not need to operate or run unless these elevated pressures are required. Embodiments using direct needle control are disclosed.

Abstract: A method of actuator coil temperature control for actuators that are not continuously operated, wherein when an actuation current is not being applied to the actuator coil, a) sensing a parameter indicative of the resistance of the actuator coil as an indication of the temperature of the actuator coil, b) if the sensed parameter indicates the temperature of the actuator coil is below a first predetermined limit, then initiating a series of successive actuation current pulses to the actuator coil, each actuation current pulse being terminated before actuation of the actuator occurs, and c) periodically repeating a) and b).

Abstract: Power steering systems and methods to improve efficiency and performance of vehicle power steering systems. In one embodiment, there is provided an engine driven positive displacement hydraulic pump, a rotary valve coupled to a steering shaft for receiving hydraulic fluid under pressure in a rotary valve inlet and providing a differential pressure to a steering rack piston for a steering boost responsive to a torque exerted on the steering shaft, valving coupled between an output of the hydraulic pump, the rotary valve inlet and the hydraulic pump input for controllably coupling the output of the hydraulic pump to the rotary valve inlet or an input of the hydraulic pump, and a controller coupled to valving to maintain a flow rate of hydraulic fluid coupled to the rotary valve responsive to a pressure sensor output. Other embodiments are disclosed.

Abstract: Three-way valves having reduced leakage and fuel injectors using the same. Three-way spool poppet valves are disclosed having a spool with a poppet valve thereon cooperating with a seat on the valve housing to provide a substantially leak free valve closing in one direction characteristic of a poppet valve while preserving the advantages of a spool valve. Three-way ball valves are also disclosed having substantially leak free valves closing in both directions, but further including reduced short circuit losses due to direct flow from a high pressure source to a low pressure vent during transition of the ball from one position to the opposite position. Fuel injectors with direct needle control using the three-way valves of the present invention are also disclosed.

Abstract: Three-way valves having reduced leakage and fuel injectors using the same. Three-way spool poppet valves are disclosed having a spool with a poppet valve thereon cooperating with a seat on the valve housing to provide a substantially leak free valve closing in one direction characteristic of a poppet valve while preserving the advantages of a spool valve. Three-way ball valves are also disclosed having substantially leak free valves closing in both directions, but further including reduced short circuit losses due to direct flow from a high pressure supply to a low pressure vent during transition of the ball from one position to the opposite position. Fuel injectors with direct needle control using the three-way valves of the present invention are also disclosed.

Abstract: Hydraulic valve actuation systems and methods to provide variable lift for one or more engine air valves by way of a variable position hard stop. Various embodiments are disclosed, including embodiments controlling lift by providing a choice of two different fixed stops, three different fixed stops, stops continuously variable throughout a range of lifts, and a fixed stop and stops continuously variable throughout a range of lifts. The valves controlled by a variable position hard stop may be a single engine intake or exhaust valve, or multiple valves of any number, and of either intake or exhaust valves or both, or of one intake or one exhaust valve for one or more cylinders in engines having more than one intake or exhaust valve per cylinder. Dashpot deceleration of engine valve velocity on opening to the hard stop and on engine valve closure is disclosed, as are other aspects and embodiments of the invention.

Abstract: Three-way poppet valves having a poppet valve body, first and second poppet valves disposed in a valve guide within the body for motion between first poppet valve open and first poppet valve closed positions, a first poppet valve seat disposed in the poppet valve body so as to have freedom in a plane perpendicular to the poppet valve axis, the first poppet valve, when moving to the closed position, engaging the first poppet valve seat and centering the first poppet valve seat with respect to the first poppet valve, and when in the closed position, holding the first poppet valve seat against the poppet valve body, and a second poppet valve connected with the first poppet valve, the poppet valve body having a second poppet valve seat, the second poppet valve being in the closed position when the first poppet valve is in the open position and being in the open position when the first poppet valve is in the closed position.

Abstract: Digital regulators using a plurality of latching solenoid actuators, each having a spring return, the springs being configured to provide a force on the valve member of a regulator, when the solenoid actuators are unlatched, in a binary progression. The solenoid actuators are selectively latched by an latching current pulse and retained in the latched condition by residual magnetism in a zero air gap magnetic circuit. Various embodiments are disclosed, including embodiments having the solenoid actuators side by side and in a stacked relationship, solenoid actuators having springs providing a spring force in a binary progression, solenoid actuators having equal springs and distributed in a binary progression from a hinge axis, and solenoid actuators not distributed in a binary progression from a hinge axis and not distributed in a binary progression from the hinge axis. Embodiments are also disclosed having the capability of interpolating between binary settings of the digital regulator.

Abstract: Direct needle control fuel injectors and methods disclosed. The preferred embodiment injectors have a needle within a needle chamber for movement between a closed position preventing injection of fuel and an open position allowing injection of fuel, a source of high pressure fuel coupled to the needle chamber to provide fuel for injection and to hydraulically urge the needle to the open position by pressurizing a first hydraulic area associated with the needle, a needle control hydraulic area having a second hydraulic area disposed to urge the needle to the closed position when the second hydraulic area is exposed to fuel under pressure, and valving coupled to the source of high pressure fuel and a vent to controllably couple the hydraulic area of the needle control member to the high pressure fuel or to the vent.

Abstract: Hydraulic valve actuation systems and methods to provide variable lift for one or more engine air valves by way of a variable position hard stop. Various embodiments are disclosed, including embodiments controlling lift by providing a choice of two different fixed stops, three different fixed stops, stops continuously variable throughout a range of lifts, and a fixed stop and stops continuously variable throughout a range of lifts. The valves controlled by a variable position hard stop may be a single engine intake or exhaust valve, or multiple valves of any number, and of either intake or exhaust valves or both, or of one intake or one exhaust valve for one or more cylinders in engines having more than one intake or exhaust valve per cylinder. Dashpot deceleration of engine valve velocity on opening to the hard stop and on engine valve closure is disclosed, as are other aspects and embodiments of the invention.

Abstract: Hydraulic valve actuation systems and methods to provide multiple lifts for engine valves using fixed or hard stops at each lift. The fixed or hard stops provide a very repeatable selection of engine valve lifts dependent on engine operating conditions. For full valve lift, unidirectional hydraulic dashpots are used to decelerate the engine valve, both as it approaches the full lift fixed stop, and as the engine valve approaches the valve seat from the engine valve full lift position. Various embodiments and methods of operation are disclosed.

Abstract: High efficiency, high pressure fixed displacement pump systems and methods of control. A typical application is for engine driven high pressure pumps for powering loads such as fuel injectors and/or hydraulic engine valve actuators. The pump systems include a control valve controllably coupling the pump output back to the pump input to stop the pumping when the desired pressure of the output is reached. Reinitiating pumping an increment in crankshaft angle before a load event based in the increment in pressure needed to reach the desired pressure at the crankshaft angle of the load event provides a simple control algorithm assuring accurate repeatability in the pressure at the beginning of a load event. Pumping throughout the load event minimizes the decrease in pressure during the load event. Providing underlap in the control valve minimizes pressure peaks and maximizes efficiently when starting and stopping the pumping action. Various embodiments are disclosed.

Abstract: Herein disclosed is a combustion cell adapted for an internal combustion engine, comprising i) a hydraulic engine valve actuation portion capable of providing a selection of two different and stable engine valve lift (i.e., open) positions per engine valve or per coupled engine valves and ii) a fuel injection portion capable of providing a selection of comprising i) a hydraulic engine valve actuation portion capable of providing two stable engine valve lift positions and ii) a fuel injection portion capable of providing a selection of one, two or three injection pressure levels for injection fuel. The combustion cell provides more flexibility in control of incoming intake air, outgoing exhaust gas, and/or incoming injection fuel relative to an engine combustion chamber so as to better match engine operating conditions that may change over time.

Abstract: Fuel injectors and methods of fuel injection allowing direct control of the flow of fuel at an intensified pressure to the needle. A valve, typically a spool valve, is placed in the fuel passage between the intensifier actuation piston and the needle, and controlled by a control valve which may be independent of the control valve controlling the coupling of actuation fluid and a vent to the intensifier actuation piston. This allows achievement of intensification before initiating injection, and control of multiple injections in a single injection event while maintaining fuel intensification throughout the duration of the injection event. Various embodiments are disclosed, including embodiments having multiple intensifiers, having control of pressure over the needle, having two stage control valve systems for control of intensifier actuation fluid, and combining control of one of the intensifiers and the valve controlling flow of intensified fuel to the needle for injection.

Abstract: Multi-stage intensifiers for injectors of pressurized fluid (e.g., fuel) allowing selection of intensified injection fluid pressure and thus fluid injection flow rate by selectively applying actuating fluid supply pressure to one or more of the multi-stage intensifiers. In a disclosed embodiment, two coaxial unequal sized intensifier pistons are used, with a control valve controlling selective pressurization of either the relatively smaller intensifier piston, or pressurization of both the relatively smaller intensifier piston and the relatively larger intensifier piston to control the intensified injection fluid pressure and flow rate of injection. Other embodiments, including ones using multi-stage intensifiers mechanically coupled together, controlled by different types of control valves and having more than two stages are also disclosed.