Abstract: Described herein are methods for controlling a piezoelectric element, for example, for use in a fuel injector, safely and efficiently at higher frequencies without causing damage to the fuel injector due to excessive heating. Methods incorporating features of the present invention can utilize waveform generation, waveform scaling and power amplification to drive a piezoelectric element. In some embodiments, various operating conditions are utilized to determine a scaling value which is compared to a target value to determine the level of scaling to be utilized with a generated waveform.

Abstract: A direct fuel injection method and an internal combustion engine provided with appropriate sensors and data input lines to an Engine Control Unit (ECU) for performing this method. The method includes inputting at least data inputs representing a piston position, a rotational speed of the internal combustion engine, and a torque demand into an ECU, calculating in the ECU a calculated start of injection (SOI) for the direct fuel injection that is next based on the data inputs, calculating based on the data inputs and the calculated SOI a desired fuel temperature prior to the direct fuel injection that is next, heating fuel with a system delay not to exceed 5 seconds to the desired heated fuel temperature prior to a direct fuel injection, injecting the heated fuel, and repeating the aforementioned method steps for subsequent direct fuel injections.

Abstract: Set forth herein are apparatuses and systems that utilize high temperature fuel injection to eliminate knocking within a combustion systems, and more particularly internal combustion engines. In some embodiments, the combustion system of the present invention can eliminate knocking through the use of high compression ratios and high intake boost pressures. The combustion system can have a high exhaust gas recirculation (EGR) tolerance, as well as an increased range of fuel-air ratio with improved ignitability and increased combustion speed of the system. In some embodiments, combustion in the present invention takes place using a compression ignition process, a spark assisted compression ignition process or a combination thereof.

Abstract: A fuel injection method in an internal combustion engine and an internal combustion engine for performing the fuel injection method. The method includes heating fuel to a temperature between 300° F. and 840° F. (150 and 450° C.); pressurizing the fuel to a pressure exceeding 40 bar; pre-injecting at least 10% of the fuel charge as a pre-injected fuel during the intake stroke; injecting a fuel charge over at least part of the compression stroke into the cylinder; and injecting an ignition-injection of at least 10% of the fuel in a supercritical condition during the compression stroke at a rotational angle between 90° BTDCF and TDCF into the cylinder. The method and related combustion engine create a good mix of premix combustion and diffusion combustion increasing efficiency and consequently reducing emissions to the environment while also keeping noise and vibrations low.

Abstract: Methods and systems for efficiently utilizing a fuel heating system incorporating an exhaust gas recirculation (“EGR”) stream and an EGR cooling system are disclosed. Waste heat energy in an exhaust gas recirculation stream of an engine system is used to heat the fuel being fed to the combustion chambers of the engine. A conventional EGR cooler can be replaced with a fuel heat exchanger/EGR cooler. Utilizing these components allows fuel heating to be accomplished simultaneously with partial EGR gas cooling by using waste EGR heat. This reduces the heat rejection requirement of the engine coolant and also reduces the electrical power requirements of the fuel heater.

Abstract: The present invention provides a fuel injector for an internal combustion engine. The fuel injector comprises a housing with an injector stem positioned inside the housing such that the injector stem comprises lower and upper portions. A first fluid chamber is located at the lower portion and a second fluid chamber is located at the upper portion with a seal positioned between the fuel chambers. A fuel duct is connected to the first fluid chamber and input and output ducts are connected to the second fluid chamber to allow fuel to fill and drain from the second fluid chamber. A first valve is attached to the output duct and is selectively actuable to open and close. The fuel injector further comprises a spring biasing the injector to a closed position, an orifice needle hole in the input duct for controlling flow of fluid, a heating element and a controller element.

Abstract: The present invention provides a fuel injector for an internal combustion engine. The fuel injector comprises a housing with an injector stem positioned inside the housing such that the injector stem comprises lower and upper portions. A first fluid chamber is located at the lower portion and a second fluid chamber is located at the upper portion with a seal positioned between the fuel chambers. A fuel duct is connected to the first fluid chamber and input and output ducts are connected to the second fluid chamber to allow fuel to fill and drain from the second fluid chamber. A first valve attached to the input duct and a second valve attached to the output duct are selectively actuable to open and close. The fuel injector further comprises a spring biasing the injector to a closed position, a heating element and a controller element.

Abstract: The present invention provides an injector-ignition fuel injector for an internal combustion engine, comprising an input fuel metering system for dispensing a fuel charge into a pressurizing chamber, a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber in the presence of a catalyst, and an injector nozzle for injecting the fuel charge into a combustion chamber of the internal combustion engine.

Abstract: The present invention provides a fuel injector, comprising a housing having a sealable injector seat; a fuel injector pin disposed within the housing proximate to the injector seat such that the injector seat may be sealed and unsealed by displacing the fuel injector pin; a resilient element biasing the fuel injector pin in an unsealed direction; a piezoelectric actuator disposed within the housing proximal to the fuel injector pin configured to actuate to force the injector pin towards the injector seat to seal the injector seat; and a thermal compensating unit disposed within the housing proximal to the actuator and configured to compensate for thermal expansion or contraction of a component of the fuel injector.

Abstract: The present invention provides an apparatus for enabling operation of a piezoelectric actuator, comprising a spring configured to provide a compressive force to a piezoelectric element of a piezoelectric actuator, wherein the compressive force varies with displacement of the piezoelectric element such that the compressive force is less at a first displacement than at a second displacement, and wherein the first displacement is greater than the second displacement.

Abstract: One embodiment of the present invention features a circuit for driving a piezoelectric actuator, comprising a first transmission line to provide an input signal having a time-varying voltage; a second transmission line to provide a predetermined voltage current; a piezoelectric element; and a switch coupled to the second transmission line and the piezoelectric element, the switch configured to electrically connect and disconnect the predetermined voltage current to and from the piezoelectric element based on the input signal.

Abstract: The present invention provides a heated catalyzed fuel injector that dispenses fuel substantially exclusively during the power stroke of an internal combustion engine, wherein ignition occurs in a fast burn zone at high fuel density such that a leading surface of the fuel is completely burned within several microseconds. In operation, the fuel injector precisely meters instantly igniting fuel at a predetermined crank angle for optimal power stroke production. Specifically, the fuel is metered into the fuel injector, such that the fuel injector heats, vaporizes, compresses and mildly oxidizes the fuel, and then dispenses the fuel as a relatively low pressure gas column into a combustion chamber of the engine.

Abstract: According to various embodiments of the invention, a map of injection pin profiles is experimentally determined at various locations spanning an engine operating plane. Injector pin profiles at points within the continuum spanned by the experimentally determined profiles are determined by interpolating between surrounding experimentally determined injector pin profiles. Various methods are used to adjust the interpolation procedure in cases where one injector pin profile has more or fewer points than the other injector pin profile.

Abstract: The present invention provides an injector-ignition fuel injector for an internal combustion engine, comprising an input fuel metering system for dispensing a next fuel charge into a pressurizing chamber, a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber in the presence of a catalyst, and an injector nozzle for injecting the heated catalyzed fuel charge into a combustion chamber of the internal combustion engine.

Abstract: The present invention provides a fuel injector, comprising a housing having a sealable injector seat; a fuel injector pin disposed within the housing proximate) the injector seat such that the injector seat may be sealed and unsealed by displacing the fuel injector pin; a resilient element biasing the fuel injector pin in an unsealed direction; a piezoelectric actuator disposed within the housing proximal to the fuel injector pin configured to actuate to force the injector pin towards the injector seat to seal the injector seat; and a thermal compensating unit disposed within the housing proximal to the actuator and configured to compensate for thermal expansion or contraction of a component of the fuel injector.

Abstract: The present invention provides a heated catalyzed fuel injector that dispenses fuel substantially exclusively during the power stroke of an internal combustion engine, wherein ignition occurs in a fast burn zone at high fuel density such that a leading surface of the fuel is completely burned within several microseconds. In operation, the fuel injector precisely meters instantly igniting fuel at a predetermined crank angle for optimal power stroke production. Specifically, the fuel is metered into the fuel injector, such that the fuel injector heats, vaporizes, compresses and mildly oxidizes the fuel, and then dispenses the fuel as a relatively low pressure gas column into a combustion chamber of the engine.

Abstract: The present invention provides an injector-ignition fuel injection system for an internal combustion engine, comprising an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a next fuel charge, wherein the ECU uses a one firing cycle look-ahead algorithm for controlling fuel injection. The ECU may further incorporate a look-up table, auto-tuning functions and heuristics to compensate for the rapid rotational de-acceleration that occurs near top dead center in lightweight small ultra-high compression engines as may be used with this invention. The ECU may further ramp heat input to the injector in response to engine acceleration requests and, under such circumstances, may extend its look-ahead for up to four firing cycles.

Abstract: The present invention provides a fuel injector, comprising a housing having a sealable injector seat; a fuel injector pin disposed within the housing proximate to the injector seat such that the injector seat may be sealed and unsealed by displacing the fuel injector pin; a resilient element biasing the fuel injector pin in an unsealed direction; a piezoelectric actuator disposed within the housing proximal to the fuel injector pin configured to actuate to force the injector pin towards the injector seat to seal the injector seat; and a thermal compensating unit disposed within the housing proximal to the actuator and configured to compensate for thermal expansion or contraction of a component of the fuel injector.

Abstract: The present invention provides an injector-ignition fuel injector for an internal combustion engine, comprising an input fuel metering system for dispensing a next fuel charge into a pressurizing chamber, a pressurization ram system including a pressurization ram for compressing the fuel charge within the pressurizing chamber, wherein the fuel charge is heated in the pressurization chamber in the presence of a catalyst, and an injector nozzle for injecting the heated catalyzed fuel charge into a combustion chamber of the internal combustion engine.

Abstract: The present invention provides an injector-ignition fuel injection system for an internal combustion engine, comprising an ECU controlling a heated catalyzed fuel injector for heating and catalyzing a next fuel charge, wherein the ECU uses a one firing cycle look-ahead algorithm for controlling fuel injection. The ECU may further incorporate a look-up table, auto-tuning functions and heuristics to compensate for the rapid rotational de-acceleration that occurs near top dead center in lightweight small ultra-high compression engines as may be used with this invention. The ECU may further ramp heat input to the injector in response to engine acceleration requests and, under such circumstances, may extend its look-ahead for up to four firing cycles.