Abstract: A fuel system for an internal combustion engine includes a nozzle, a fuel pump, a spill valve assembly, and a pumping control unit. The spill valve assembly includes a first spill valve and a second spill valve fluidly in parallel between a plunger cavity in the fuel pump and a low pressure space. A pumping control unit commands closing of the first spill valve and then the second spill valve to adjust the spill valve assembly to start pressurization in the fuel pump, and commands opening the first spill valve to end pressurization in the fuel pump. A pumping duration is determined based on a timing of the commanded closing of the second spill valve and a timing of the commanded opening of the first spill valve.

Abstract: A fuel system for an internal combustion engine includes a nozzle, a fuel pump, a spill valve assembly, and a pumping control unit. The spill valve assembly includes a first spill valve and a second spill valve fluidly in parallel between a plunger cavity in the fuel pump and a low pressure space. A pumping control unit commands closing of the first spill valve and then the second spill valve to adjust the spill valve assembly to start pressurization in the fuel pump, and commands opening the first spill valve to end pressurization in the fuel pump. A pumping duration is determined based on a timing of the commanded closing of the second spill valve and a timing of the commanded opening of the first spill valve.

Abstract: A method of increasing parasitic load on an internal combustion engine includes injecting a fuel into a combustion chamber of an active cylinder of the internal combustion engine, combusting the injected fuel in the combustion chamber of the active cylinder, and determining that increasing a temperature of an exhaust aftertreatment device is required. The method includes increasing a parasitic load on the internal combustion engine by deactivating a cylinder, wherein no fuel is injected in the deactivated cylinder for a combustion cycle of the internal combustion engine, and further increasing the parasitic load by pulsing a spill valve member of a spill valve of a fuel injector in the deactivated cylinder between a fully closed position and an at least partially open position.

Abstract: A fuel supply system for a reciprocating-piston engine includes a storage tank; a wall of the storage tank defining a first aperture and a second aperture therethrough; a first fuel injector fluidly coupled with the first aperture of the storage tank via a pressure control module and a first fuel injector supply conduit; a pump fluidly coupled with the second aperture of the storage tank; and a second fuel injector fluidly coupled with an outlet port of the pump via a second fuel injector supply conduit. The pressure control module is configured to maintain a pressure in the first fuel injector supply conduit within a pressure range that includes a pressure value that is less than a pressure inside the storage tank. The pump is configured to maintain a pressure inside the second fuel injector supply conduit that is greater than the pressure inside the first fuel injector supply conduit.

Abstract: A fuel supply system for a reciprocating-piston engine includes a storage tank; a wall of the storage tank defining a first aperture and a second aperture therethrough; a first fuel injector fluidly coupled with the first aperture of the storage tank via a pressure control module and a first fuel injector supply conduit; a pump fluidly coupled with the second aperture of the storage tank; and a second fuel injector fluidly coupled with an outlet port of the pump via a second fuel injector supply conduit. The pressure control module is configured to maintain a pressure in the first fuel injector supply conduit within a pressure range that includes a pressure value that is less than a pressure inside the storage tank. The pump is configured to maintain a pressure inside the second fuel injector supply conduit that is greater than the pressure inside the first fuel injector supply conduit.

Abstract: A dual fuel system includes a plurality of fuel injectors that each have a non-injection configuration, a liquid fuel injection configuration, a gaseous fuel injection configuration and a combined fuel injection configuration. Each of the fuel injectors includes a liquid control valve member with a guide segment that defines a portion of a leak path from a liquid fuel inlet to a drain outlet, and a gas control valve member with a guide segment that defines a second leak path from the liquid fuel inlet to the drain outlet. Each injector body includes a tip component that defines both a liquid nozzle outlet set and a gas nozzle outlet set. A dual solenoid actuator has a first armature coupled to the liquid control valve member, a second armature coupled to the gas control valve member, and a shared stator.

Abstract: A fuel system includes a plurality of fuel injectors each defining a nozzle supply passage, a nozzle outlet and a low pressure space. The fuel system includes a plurality of mechanically actuated pressure intensifiers each including a tappet and being positioned partially within one of the fuel injectors, and a common rail fluidly connecting with each of the fuel injectors. Each of the fuel injectors further includes an injection pressure control mechanism having an injection pressure control valve. Each injection pressure control valve blocks the corresponding pressure intensifier from the common rail and fluidly connects the pressure intensifier with the low pressure space at a first position, and fluidly connects the pressure intensifier with the common rail and blocks the pressure intensifier from the low pressure space at a second position.

Abstract: A dual fuel system includes a plurality of fuel injectors that each have a non-injection configuration, a liquid fuel injection configuration, a gaseous fuel injection configuration and a combined fuel injection configuration. Each of the fuel injectors includes a liquid control valve member with a guide segment that defines a portion of a leak path from the a liquid fuel inlet to a drain outlet, and a gas control valve member with a guide segment that defines a second leak path from the liquid fuel inlet to the drain outlet. Each injector body includes a tip component that defines both a liquid nozzle outlet set and a gas nozzle outlet set. A dual solenoid actuator has a first armature coupled to the liquid control valve member, a second armature coupled to the gas control valve member, and a shared stator.

Abstract: A fuel system includes a plurality of fuel injectors each defining a nozzle supply passage, a nozzle outlet and a low pressure space. The fuel system includes a plurality of mechanically actuated pressure intensifiers each including a tappet and being positioned partially within one of the fuel injectors, and a common rail fluidly connecting with each of the fuel injectors. Each of the fuel injectors further includes an injection pressure control mechanism having an injection pressure control valve. Each injection pressure control valve blocks the corresponding pressure intensifier from the common rail and fluidly connects the pressure intensifier with the low pressure space at a first position, and fluidly connects the pressure intensifier with the common rail and blocks the pressure intensifier from the low pressure space at a second position.

Abstract: A fuel injector includes first and second electrical actuators positioned within an injector body. First and second pairs of electrical conductors extend from a socket connector outside of the injector body to the first and second electrical actuators, respectively. The electrical conductors extend through an elastomeric sealing member that seals against fuel leakage from the fuel injector. The elastomeric sealing member provides annular sealing ridges in sealing contact with an access passage of the injector body and includes individual conductor seal passages that form seals around the outer surface of the individual electrical conductors. The elastomeric sealing member includes features that facilitate assembly of the fuel injector in a manner that reduces risk of damage to the sealing strategy.

Abstract: A fuel injector includes first and second electrical actuators positioned within an injector body. First and second pairs of electrical conductors extend from a socket connector outside of the injector body to the first and second electrical actuators, respectively. The electrical conductors extend through an elastomeric sealing member that seals against fuel leakage from the fuel injector. The elastomeric sealing member provides annular sealing ridges in sealing contact with an access passage of the injector body and includes individual conductor seal passages that form seals around the outer surface of the individual electrical conductors. The elastomeric sealing member includes features that facilitate assembly of the fuel injector in a manner that reduces risk of damage to the sealing strategy.

Abstract: A fuel injector includes first and second electrical actuators positioned within an injector body. First and second pairs of electrical conductors extend from a socket connector outside of the injector body to the first and second electrical actuators, respectively. The electrical conductors extend through an elastomeric sealing member that seals against fuel leakage from the fuel injector. The elastomeric sealing member provides annular sealing ridges in sealing contact with an access passage of the injector body and includes individual conductor seal passages that form seals around the outer surface of the individual electrical conductors. The elastomeric sealing member includes features that facilitate assembly of the fuel injector in a manner that reduces risk of damage to the sealing strategy.

Abstract: A parasitic load control system is provided. The system may include an exhaust producing engine and a fuel pumping mechanism configured to pressurize fuel in a pressure chamber. The system may also include an injection valve configured to cause fuel pressure to build within the pressure chamber when in a first position and allow injection of fuel from the pressure chamber into one or more combustion chambers of the engine when in a second position. The system may further include a controller configured to independently regulate the pressure in the pressure chamber and the injection of fuel into the one or more combustion chambers, to increase a load on the fuel pumping mechanism, increasing parasitic load on the engine, thereby increasing a temperature of the exhaust produced by the engine.

Abstract: An apparatus and method for controlling fluid flow is disclosed. An electromagnetic actuator may include a stator having an inner pole member and an outer pole member. The outer pole member may have a fluid passageway therein for transmitting fluid through the outer pole member. The actuator may further include a coil disposed around the inner pole member and arranged between the inner pole member and the outer pole member. The actuator may also include an armature moveable under the influence of a magnetic field generated by the stator and coil and operable to affect transmission of the fluid through the fluid passageway.

Abstract: A spring design method is disclosed. The method begins with inputting a first set of design parameters for a spring. The design parameters include a parameter that provides an estimate of non-linearity in the spring. The spring design method determines a spring design based on the first set of design parameters. A spring design and analysis method is disclosed. The method begins with creating a spring design. The spring design includes a parameter that provides an estimate of non-linearity in the spring design. The spring design and analysis method creates a spring animation file that enables stress levels in a spring design to be identified at the coil level. The spring design method next identifies the coil in the spring design having the lowest dynamic fatigue factor and determines whether the lowest dynamic fatigue factor is acceptable.

Abstract: An electronically controlled fuel injector includes a reduced part count and complexity over similar fuel injectors without a substantial reduction in performance capabilities. This is accomplished by using a one-piece needle that is hydraulically balanced and biased toward a closed position with a spring positioned in the needle control chamber. Although subtle, this injector has some ability to control the fuel pressure when the needle valve is opening and closing by adjusting a relative timing of a pressure control valve opening relative to a needle control chamber, using separate electrical actuators. The invention is particularly applicable to fuel injectors that cycle through high and low pressure states during and between injection events, respectively. Cam actuated fuel injectors being particularly well suited.

Abstract: Common rail fuel injectors typically have difficulty in changing an injection rate during an injection event. Fuel injectors for this common rail fuel injection system include a multi-position admission valve. The admission valve is stoppable at a middle position to inject fuel at a low rate. The lower rate is accomplished by leaking some fuel to drain to reduce injection pressure. The admission valve is also stoppable at a fully open position to inject fuel at a high rate. Fuel injection events are ended, and the fuel injectors maintained between injection events, with the admission valve member in contact with a supply seat to close the high pressure supply passage. This strategy can be used in conjunction with a spring-biased needle valve member to expand fuel injector capabilities.

Abstract: A fuel injector includes an auxiliary valve member that can assist in raising a mean injection pressure, increase a nozzle valve opening pressure, and hasten the closure rate of a nozzle valve member over an equivalent fuel injector without the auxiliary valve. The auxiliary valve member is fluidly positioned between a needle control chamber and a high pressure space, which includes a fuel pressurization chamber within the fuel injector. The auxiliary valve member includes a closing hydraulic surface exposed to fluid pressure in the high pressure space. The plumbing and the auxiliary valve member allow high pressure fuel to act upon a closing hydraulic surface of the nozzle valve member to increase valve opening pressure and mean injection pressure. The needle control chamber may be vented or may be a closed volume when the auxiliary valve member is in its closed position.

Abstract: The present invention relates to fuel injectors having a free floating plunger. Traditional tappet assemblies include a plunger that is mechanically coupled to the tappet, and therefore, cannot be uncoupled over a portion of its movement during an injection event. In the event of a plunger seizure in a traditional tappet assembly, the tappet spring can be prevented from expanding, which can cause major valve train and engine damage. In addition, because the plunger in traditional tappet assemblies is moved to its upward position under the action of the tappet spring, the fuel passages can depressurize if fuel cannot refill the fuel pressurization chamber as quickly as the plunger retracts, causing cavitation bubbles. Therefore, the present invention utilizes a plunger that is not mechanically coupled to the tappet and can uncouple from the tappet during the injection event to address these and other problems related to plunger wear and failure.

Abstract: The present invention relates to fuel injectors having a free floating plunger. Traditional tappet assemblies include a plunger that is mechanically coupled to the tappet, and therefore, cannot be uncoupled over a portion of its movement during an injection event. In the event of a plunger seizure in a traditional tappet assembly, the tappet spring can be prevented from expanding, which can cause major valve train and engine damage. In addition, because the plunger in traditional tappet assemblies is moved to its upward position under the action of the tappet spring, the fuel passages can depressurize if fuel cannot refill the fuel pressurization chamber as quickly as the plunger retracts, causing cavitation bubbles. Therefore, the present invention utilizes a plunger that is not mechanically coupled to the tappet and can uncouple from the tappet during the injection event to address these and other problems related to plunger wear and failure.