Abstract: The disclosure provides a fuel injection nozzle. The fuel injection nozzle includes a nozzle body, with the nozzle body defining a central bore. A fuel atomizer is disposed in the central bore. The fuel atomizer defines a spill-return bore and a swirl chamber. The swirl chamber is in fluid communication with the central bore. The spill-return bore includes a return swirler approximate the swirl chamber. An air supply pump is coupled to the fuel atomizer and is in fluid communication with the spill-return bore. The air supply pump is configured to selectively inject air into the swirl chamber through the spill-return bore.

Abstract: An air cooled core mounted ignition system for gas turbine engine applications is provided. The ignition system includes an ignition exciter component directly mechanically and electrically connected to an igniter component. The housing member of the exciter component includes an air plenum configured to receive bleed air from the engine fan or compressor sections of the turbine engine, or other source. The bleed air provides a relatively low temperature air source for the purpose of cooling of the exciter. As such, the exciter component can be directly secured to the igniter, thereby eliminating the need for an ignition lead.

Abstract: A system and method for joining a tube to a header is provided. The system includes a header, tube and internal ferrule, wherein the ferrule is fixed inside the tube. This design reduces manufacturing cost and time, as well as reducing and more evenly distributing stress along the tube-header assembly.

Abstract: An improved fuel injection apparatus and method have a variable area injector arrangement in which a pintle defines a pilot orifice extending through a tip of the pintle for supplying a pilot flow of fuel through the fuel injector at low fuel pressures, and in particular when the pintle tip is sealed against a variable flow orifice of the variable area injector arrangement.

Abstract: Integrally formed, multi zone fuel manifolds for gas turbine engines and methods of construction are provided. The fuel manifold includes a plurality of annular channel members positioned adjacent each other, aligned and coupled together at the inner and outer peripheral sides thereof, with each pair of channel members defining a separate fluid conduit or passage within the manifold assembly. The fuel manifold can be constructed of any number of stacked and secured channel members to provide a compact multi zone fuel manifold having the desired number of fluid conduits or passages with a minimum number of sealed joints.

Abstract: A fuel nozzle is provided. The fuel nozzle includes a heat shield, a fuel tube and a plurality of support members. The support members are radially interposed between the heat shield and the fuel tube. The support members are preferably cylindrical tubes, thus creating voids or pockets between the heat shield and the fuel tube. The cylindrical tubes are connected to one another at a first end are free at an opposed end. As such, the tubes can move or slide relative to one another. Further, the tubes preferably only contact one another with at most line contacts. The fuel nozzle may also include a tip portion that includes a tip heat shield that extends radially outward from the primary heat shield. The tip heat shield defines a cavity that connects with the central cavity of the heat shield. The fuel tube extends through the tip heat shield.

Abstract: A fail safe mechanism having a return member, valve stem extension, energy storage member, and locking assembly. The valve stem extension is driven by an electrical actuator and configured to drive the return member in a first direction and to be driven by the return member in a second direction. The energy storage member is configured to store energy when the electrical actuator causes the valve stem extension to drive the return member in the first direction and to release the energy stored therein when a disruption of power causes the return member to drive the valve stem extension in the second direction. The locking assembly is configured to hold the return member in a cocked position such that the valve stem extension rotates with the valve independently of the return member and free of influence from the energy storage member while the power is applied to the electrical actuator.

Abstract: A common regulator valve is provided for a variable displacement pump fuel metering scheme in which the common regulator valve both controls working output to a pump actuator to control displacement of the variable displacement pump and also to control bypass of excess fuel flow. The regulator valve also includes a differential piston which generates a compensation force off of the bypass flow in order to compensate for changes in spring force and flow reaction force at different system pressures and operational states. As a result, errors in the metered fuel flow can be either eliminated or substantially reduced.

Abstract: A system for metering fuel to an engine. The system includes a fuel metering valve having a throttled inlet and a throttled outlet. The system also provides regulation of redundant pump supplies of fuel to the engine. The throttling of the inlet to the fuel metering valve is provided by a valve that also functions to selectively couple a second fuel pump to the fuel metering valve.

Abstract: Fabrication processes for manufacturing and connecting a semiconductor switching device are disclosed, including an embodiment for dicing a wafer into individual circuit die by sawing the interface between adjacent die with a saw blade that has an angled configuration across its width, preferably in a generally V-shape so that the adjacent die are severed from one another while simultaneously providing a beveled surface on the sides of each separated die. Another embodiment relates to the manner in which damage to a beveled side surface of the individual die can be smoothed by a chemical etching process.

Abstract: A method and apparatus to maximize spark plug life in pre-chamber spark plugs operating with ultra-lean mixtures and/or elevated engine BMEP is presented. Electrode erosion is reduced by spreading discharge energy over a wider surface area, maintaining fuel concentration in the spark gap, controlling gas static pressure during discharge, and maintaining safe electrode temperature. Energy is spread via a swirling effect created by periphery holes in an end cap, resulting in a lower specific energy discharge at the electrodes. Divergently configured electrodes reduce the spark voltage at high operating pressures and the energy required for ignition. The flow field generated at the electrodes prevents electrical shorts due to water condensation and avoids misfire. The center electrode insulation provides an effective heat transfer path to prevent electrode overheating and preignition.

Abstract: A passive secondary air delivery system for a two bed catalyst is provided. The system delivers passive secondary air to the second catalyst bed to facilitate oxidation of CO and remaining unburned HC. In a turbocharged engine, the secondary air may be provided from the compressor side of the turbocharger. Control of the amount of air bled from the turbocharger is provided by an orifice in the pipe connecting the turbocharger to the catalyst bed. No active controls are required. In non-turbocharged engines, passive secondary air may be provided by a venturi mixer ported to ambient positioned between the two catalyst beds. In either embodiment, no moving parts or active controls are required.

Abstract: Presented is a device that provides a correction factor to compensate for varying fuel and air properties in an ion signal sensed in combustion chamber of reciprocating and continuous combustion engines, on a predetermined basis during the combustion of conventional petroleum-based fuels, other alternate fuels, and renewable fuels. The device uses an ion current reference sensor device and a processing module to provide a correction factor to the ion signal(s). The ion current reference sensor device is positioned near the chamber(s) of the engine and fuel provided to the chamber(s) is routed to provide a diffusion flame and the resultant ion current from the flame is measured and provided to the processing module at discrete intervals during the combustion process. Alternatively, a pre-mixed flame is used. The processing module provides a scaling factor to be applied to the ion signal and/or calibration points used to detect combustion conditions.

Abstract: A valve assembly includes a valve housing located between a fluid inlet region maintained at a first pressure and a fluid outlet region maintained at a second pressure. A movable metering plate is located within valve housing. A fixed metering plate interacts with the movable metering plate to meter fluid flow through the valve housing. An armature is coupled to the movable metering plate and is configured to move the movable metering plate from a closed position toward an open position. The fluid admission system further includes a balancing region to balance pressure related forces acting on the movable portions of the valve, including the metering plate. A balance passageway is in communication with the balancing region and the fluid outlet region to maintain the balancing region at the second pressure of the fluid outlet region when the movable metering plate is in the closed position.

Abstract: A method and apparatus to maximize spark plug life in pre-chamber spark plugs operating with ultra-lean mixtures and/or elevated engine BMEP is presented. Electrode erosion is reduced by spreading discharge energy over a wider surface area, maintaining fuel concentration in the spark gap, controlling gas static pressure during discharge, and maintaining safe electrode temperature. Energy is spread via a swirling effect created by periphery holes in an end cap, resulting in a lower specific energy discharge at the electrodes. Divergently configured electrodes reduce the spark voltage at high operating pressures and the energy required for ignition. The flow field generated at the electrodes prevents electrical shorts due to water condensation and avoids misfire. The center electrode insulation provides an effective heat transfer path to prevent electrode overheating and pre-ignition.

Abstract: A coupling arrangement coupling and thermally isolating a continuously variable electrical actuator rotationally coupled to and from a butterfly valve is provided. The valve may be used to modulate high temperature exhaust gas flow through an engine turbocharger. The actuator provides a continuously variable control of the valve. The coupling arrangement provides a thermal block to reduce heat transfer and vibration insulation between the actuator and the valve. The coupling arrangement generally includes a coupling shaft rotationally coupled at opposite ends to the input and output shafts by torsion spring mechanisms. The torsion spring mechanisms include yokes rotationally locking the coupling shaft to the input and output shafts. The torsion spring mechanisms allow a limited range of axial and pivotal translation between the coupling shaft and the input and output shafts and are preloaded to prevent rotational hysteresis in the valve.

Abstract: A fuel control system is provided. The fuel control system includes an electronic control system coupled to a pair of control valves for blending pipeline fuel with waste fuel at a blend ratio for controlling fuel flow to an internal combustion engine. The fuel control system can estimate energy content of the fuel mixture to compensate the blend ratio. The fuel control system can use engine operational parameters to compensate the blend ratio. Typically, the system will use the operational parameter of output power or exhaust emissions to compensate the blend ratio. Further, the fuel control system can prioritize variation from the blend ratio or variation from a desired power output when the blend ratio cannot generate the desired power output. The fuel control system can also be equipped with engine speed/load controls, misfire, ignition timing and knock detection capabilities.

Abstract: A trim system for controlling an equivalence ratio in a fuel system is provided. The fuel system includes an air duct, a mixer disposed in the air duct, and a converter. The mixer has a reference pressure port and an air valve vacuum port. The converter has an outlet port and a bias port. The trim system comprises the mixer, the converter, a balance line, one or more orifices, and first and second trim valves. The outlet port is operably coupled to the mixer to deliver vaporized fuel to the mixer. The balance line is operably coupled to the reference pressure port, the bias port, and the air valve vacuum port. The balance line provides pressure to the bias port. The first and second trim valves are disposed in the balance line and operable such that the equivalence ratio in the fuel system is controlled.

Abstract: An exhaust aftertreatment system is provided. The exhaust aftertreatment system includes a mixing arrangement for mixing flows of exhaust along a flow path. The mixing arrangement radially and angularly rearranges segments of two different portions of flow to mix the different portions of flow. The mixing arrangement initially converts a generally radially stratified temperature profile into an angularly stratified temperature profile to increase surface area between cool segments of exhaust gas and hot segments of exhaust gas. The aftertreatment system may also include a combustion chamber, a combustor housing and a combustor liner. The mixing arrangement is downstream from the combustion chamber to direct radially outward hot gas passing through the combustor liner and to direct radially outer cool gas passing between the liner and the combustor housing radially inward in an interleaving fashion.

Abstract: Systems and methods to determine when regeneration of a diesel particulate filter (DPF) are presented. Such determination is made by indirectly determining soot accumulation in the DPF by monitoring soot accumulation on a regeneration burner spark plug based on the correlation between spark plug fouling and DPF soot loading. An ion current sensing circuit is used during periods of no flame to determine soot loading on the spark plug. When soot loading on the spark plug approaches an amount that could cause fouling of the spark plug, the ignition controller initiates a hot spark to burn the soot off the spark plug. The number of such cleaning events is tracked and used to determine when the DPF soot loading is at a level that regeneration should be initiated. Temperature rise across the DPF is monitored and used to adjust the number spark plug cleaning events needed before initiating regeneration.