Abstract: Fuel injectors equipped with direct control needle valves can add new capabilities to a fuel injection system, but can sometimes have difficulty in achieving low hydrocarbon emissions at levels comparable to ancestor fuel injectors that utilize a simple spring biased needle. The present invention seeks lower hydrocarbon emissions by reducing fuel pressure before the direct control needle valve member has reached its closed position toward the end of an injection event. Reducing fuel pressure can be accomplished in a number of ways depending upon the particular fuel injection system, including spilling fuel pressure in a cam system or possibly relieving pressure on an intensifier piston.

Abstract: An engine is provided comprising an engine housing defining at housing and has a different portion associated with each engine cylinder. Each different portion of the engine auxiliary system has a first electrical actuator coupled to a first valve and a second electrical actuator coupled to a second valve which are wired in series. For example, a fuel injection system is provided with a first electrical actuator operably coupled to a fuel pressurizer and a second electrical actuator operably coupled to a direct control needle valve. The electrical actuators are wired in series on an electrical circuit. A method of controlling a portion of the engine auxiliary system is also provided which consists of actuating a first electrical actuator with a relatively low current and actuating a second electrical actuator with a relatively high current.

Abstract: Controlling fuel injectors to create varying injection rates and injection rate shapes typically involves using multiple control valves to control fuel pressure and check valve opening pressure independently. The fuel injector of this application uses a single control valve positioned between a fuel supply passage and a tip supply passage. The control valve has at least three positions. In a second position allowing a first maximum fuel injection rate and allowing a second maximum fuel injection rate in a third position.

Abstract: A two stage intensifier capable of multiple intensification rates comprises a stepped top portion and a shoulder portion, each being actuated by separate fluid passages. A stepped top portion is received into an upper bore of a piston bore and a shoulder is received into a lower bore. The stepped top forms a seal with the upper bore to prevent direct fluid communication between a first actuation cavity above the stepped top and a second actuation cavity above the shoulder.

Abstract: In dual fuel engines, it is desirable to have injection of two distinct quantities of liquid fuel. Engines with these operating requirements have typically used two separate fuel injectors, or two separate nozzle assemblies, to satisfy this need. However, these systems can be rather complex and difficult to control. In addition, engineers have learned that fuel injectors having direct control have better performance which can increase engine efficiency. Therefore, the present invention addresses the needs of engines desiring injection of two distinct quantities of fuel, such as dual fuel engines, by utilizing a direct control fuel injector having a dual concentric check having separate orifices for the pilot and main injections.

Abstract: Inclusion of a direct control needle valve in fuel injectors can allow for independent control of injection pressure and timing. Engineers have learned that it is desirable to position the control valve assembly in close proximity to the needle valve member to improve response time. However, by placing the control valve assembly in a central portion of the fuel injector, at least one fluid passage must often be routed through the electrical actuator included in the valve assembly. The present invention seeks to address this problem by providing a direct control valve assembly for a fuel injector that directs fluid around the electrical actuator without increasing the size of the fuel injector. Thus, the present invention includes an electrical actuator having an actuator centerline that is oriented at an angle, which is preferably perpendicular, with respect to a centerline of the fuel injector.

Abstract: The present invention finds application in engines using mechanically actuated electronically controlled fuel injectors having direct control needle valves. In valves such as these, a spill control valve member controls fuel pressurization within the injector while a needle control valve member controls the timing and duration of the injection event. However, when the momentum of fuel exiting the fuel injector past the spill valve is greater than that of the tappet and plunger moving toward their downward positions, engine components upstream of the tappet can briefly separate and re-engage, which can result in increased mechanical noise levels. Therefore, the present invention is directed to maintaining sufficient contact force in the various engine components to reduce the mechanical noise levels by positioning a flow restriction between the fuel pressurization chamber of the fuel injector and a fuel source.

Abstract: An electronically-controlled fuel injector includes a pressurized fluid chamber that communicates high pressure fluid to first and second pressure control chambers. A direct-operated check moves between closed and open positions in response to a difference in fluid pressure in the first and second pressure control chambers. A thermally pre-stressed bender actuator is used to operate a control valve that controls the fluid pressure in the first pressure control chamber to effectively control opening and closing of the check during portions of an injection sequence.

Abstract: An engine is provided comprising an engine housing defining at least one cylinder. At least one engine auxiliary system is attached to the engine housing and has a different portion associated with each engine cylinder. Each different portion of the engine auxiliary system has a first electrical actuator coupled to a first valve and a second electrical actuator coupled to a second valve which are wired in series. For example, a fuel injection system is provided with a first electrical actuator operably coupled to a fuel pressurizer and a second electrical actuator operably coupled to a direct control needle valve. The electrical actuators are wired in series on an electrical circuit. A method of controlling a portion of the engine auxiliary system is also provided which consists of actuating a first electrical actuator with a relatively low current and actuating a second electrical actuator with a relatively high current.

Abstract: Inclusion of a direct control needle valve in fuel injectors can allow for independent control of injection pressure and timing. Engineers have learned that it is desirable to position the control valve assembly in close proximity to the needle valve member to improve response time. However, by placing the control valve assembly in a central portion of the fuel injector, at least one fluid passage must often be routed through the electrical actuator included in the valve assembly. The present invention seeks to address this problem by providing a direct control valve assembly for a fuel injector that directs fluid around the electrical actuator without increasing the size of the fuel injector. Thus, the present invention includes an electrical actuator having an actuator centerline that is oriented at an angle, which is preferably perpendicular, with respect to a centerline of the fuel injector.

Abstract: An actuator carrier comprises an aperture being adapted to receive actuator and a bore being adapted to carry high pressure fluid through the carrier. The actuator carrier can be incorporated into a unit pump allowing for a more efficient design and manufacture process, including linear alignment of all of the unit pumps primary components.

Abstract: The present invention finds application in engines using mechanically actuated electronically controlled fuel injectors having direct control needle valves. In valves such as these, a spill control valve member controls fuel pressurization within the injector while a needle control valve member controls the timing and duration of the injection event. However, when the momentum of fuel exiting the fuel injector past the spill valve is greater than that of the tappet and plunger moving toward their downward positions, engine components upstream of the tappet can briefly separate and re-engage, which can result in increased mechanical noise levels. Therefore, the present invention is directed to maintaining sufficient contact force in the various engine components to reduce the mechanical noise levels by positioning a flow restriction between the fuel pressurization chamber of the fuel injector and a fuel source.

Abstract: In dual fuel engines, it is desirable to have injection of two distinct quantities of liquid fuel. Engines with these operating requirements have typically used two separate fuel injectors, or two separate nozzle assemblies, to satisfy this need. However, these systems can be rather complex and difficult to control. In addition, engineers have learned that fuel injectors having direct control have better performance which can increase engine efficiency. Therefore, the present invention addresses the needs of engines desiring injection of two distinct quantities of fuel, such as dual fuel engines, by utilizing a direct control fuel injector having a dual concentric check having separate orifices for the pilot and main injections.

Abstract: A fuel injection system includes a plurality of mechanical unit pumps, each of which has a pump outlet. A pressure-intensifying hydraulically-actuated electronically-controlled fuel injector is provided for each of the plurality of mechanical unit pumps. Each of the fuel injectors has a direct control needle valve and an injector body that defines an actuation fluid inlet, a fuel inlet, an actuation fluid cavity and a fuel pressurization chamber. Each fuel injector also includes a moveable pumping element with a large hydraulic surface exposed to fluid pressure in the actuation fluid cavity, and a small hydraulic surface exposed to fluid pressure in the fuel pressurization chamber. An actuation fluid supply line is provided for each of the plurality of mechanical unit pumps. Each supply line has one end connected to one pump outlet and an other end connected to one actuation fluid inlet of an individual fuel injector.

Abstract: A fuel injection system includes a plurality of mechanical unit pumps, each of which has a pump outlet. A pressure-intensifying hydraulically-actuated electronically-controlled fuel injector is provided for each of the plurality of mechanical unit pumps. Each of the fuel injectors has a direct control needle valve and an injector body that defines an actuation fluid inlet, a fuel inlet, an actuation fluid cavity and a fuel pressurization chamber. Each fuel injector also includes a moveable pumping element with a large hydraulic surface exposed to fluid pressure in the actuation fluid cavity, and a small hydraulic surface exposed to fluid pressure in the fuel pressurization chamber. An actuation fluid supply line is provided for each of the plurality of mechanical unit pumps. Each supply line has one end connected to one pump outlet and an other end connected to one actuation fluid inlet of an individual fuel injector.

Abstract: A fuel injector nozzle assembly comprises a lower tip component which includes a first locating surface. The lower tip component defines a lower guide bore with a first centerline and a nozzle outlet. The nozzle assembly also includes an upper tip component which is in contact with the lower tip component. The upper tip component includes a second locating surface and defines an upper guide bore with a second centerline. The first centerline is concentrically coupled with the second centerline by an interaction of the first locating surface with the second locating surface. A needle valve member includes an upper guide portion that is positioned in the upper guide bore and a lower guide portion that is positioned in the lower guide bore. The needle valve member is moveable between an open position, in which the nozzle outlet is open, and a closed position, in which the nozzle outlet is blocked.

Abstract: A single pole solenoid assembly includes a coil attached to a stator that is in a fixed position relative to a body component. An armature with a centerline is positioned adjacent to the stator. A magnetic flux ring has a central axis and an interior surface that at least partially surrounds the armature. The stator, armature and magnetic flux ring are positioned and arranged such that magnetic flux line generated by the coil pass through the stator and the magnetic flux ring through the armature. The central axis and the centerline are concentrically coupled via an interaction between the magnetic flux ring and the armature via the body component. The single pole solenoid is preferably attached to valving components and incorporated as part of an electronically controlled fuel injector.

Abstract: A valve comprises a valve body that includes an upper valve seat and a bore wall that defines a bore. A seat component is at least partially positioned in the bore and includes a lower valve seat. The seat component is radially out of contact with the bore wall. The upper valve seat and the lower valve seat are concentrically coupled via a valve member which is movable between the upper valve seat and the lower valve seat. The valve finds preferred application as a needle control valve in a fuel injector.

Abstract: A fuel injector includes first and second valves and a solenoid including a solenoid coil and an armature assembly wherein the first and second valves are coupled to the armature assembly. A solenoid drive circuit is coupled to the solenoid coil and delivers a first current waveform portion to the solenoid coil at a first time to cause the armature assembly to operate the first valve without operating the second valve. A second current waveform portion different than the first current waveform portion is applied to the solenoid coil at a second time later than the first time to operate the second valve.

Abstract: An electronically controlled device, such as a fuel injector, includes a first solenoid and a second solenoid attached to the injector body. An electrical circuit is attached to the injector body, and includes a positive terminal and a negative terminal connected to the first solenoid and the second solenoid. The electrical circuit permits energization of one of the first solenoid and the second solenoid when electrical current flows in either direction between the first terminal and the second terminal. However, the electrical circuit permits energization of the other of the first solenoid and the second solenoid only when current flows in a single direction between the first terminal and the second terminal.