Abstract: An injection rate shaping nozzle assembly for a fuel injector is provided which includes a closed nozzle valve element and a rate shaping control device including an injection spill circuit for spilling a portion of the fuel to be injected to produce a predetermined time varying change in the flow rate of fuel injected into a combustion chamber. The spill circuit includes a spill passage integrally formed in the nozzle valve element. The rate shaping control may include a spill valve for controlling the spill flow through the spill circuit to create a low injection flow rate followed by a high injection flow rate. The spill passage may communicate with the injector nozzle cavity between injection events or alternatively may be blocked to prevent spill flow between injection events. The rate shaping control device may include a spill accelerating device in the form of a spill chamber formed in the nozzle valve element for creating a rapid increase in the spill flow rate.

Abstract: EGR induction supercharged or turbocharged internal combustion engine having EGR and EGR cooling in which EGR cooling is obtained through jacket water coolers and/or an air-to-air aftercooler. EGR induction is obtained via either low pressure (ambient) induction to the system intake, or via venturi or passive pump induction into the pressurized intake. Bypassing of the EGR cooler is used to reduce condensation and fouling in the EGR cooler and to provide warmer air to reduce light load and cold ambient hydrocarbon production. A passive or catalyzed particulate trap and crankshaft driven supercharger boosting system are provided to address engine response deterioration and particulate increase problems associated with EGR.

Abstract: A gas flow network in combination with a highly turbocharged diesel engine for the blending of either EGR gas or blow-by gas from the crankcase vent with fresh charge air is disclosed. In the diesel engine assembly which incorporates the flow network for EGR gas, a venturi conduit and control valve combination is positioned between tile intake manifold and aftercooler and is connected to a flow line carrying the EGR gas. When the turbocharged diesel engine assembly is configured with a flow path for blow-by gas, the venturi and control valve combination is positioned between the intake manifold and aftercooler and is connected to a flow line carrying blow-by gas. These systems utilize a low static pressure at the narrow throat of the venturi so as to induce the flow of EGR gas or blow-by gas into the fresh charge air, the flow being controlled by the state of the control valve.

Abstract: A cam for controlling the injection rate of fuel in a fuel injection system having a four part cam profile is disclosed. The first 120.degree. is the plunger advancement segment. The next 80.degree. is the advanced dwell segment. The next 100.degree. is the plunger retraction segment and the last 60.degree. is the retracted dwell segment. The plunger advancement segment is divided into three subsegments: pre-injection stroke, injection stroke, and overtravel stroke. The pre-injection subsegment achieves minimum velocity and acceleration at the start of injection. In the injection subsegment, the cam follower acceleration is achieved as rapidly as can Hertz stress permits to increase the injection pressure and to achieve the maximum injection rate. The overtravel subsegment achieves a sharp and clean end of injection. Preferably, this cam causes injection of less than 20 mm.sup.3 of fuel per stroke during the first ten cam angle degrees of cam rotation.

Abstract: A system is provided for increasing the efficiency of internal combustion engines operating at high loads and more particularly to a multi-cylinder engine in which at least one cylinder is used as the power recovery device. The waste heat generated during operation of the engine is utilized for producing an amount of energy to perform the work by means of a Rankine cycle.