Abstract: A fuel flow limiter assembly includes a limiter body forming a central bore, and including a shutoff piston within the central bore having a closing hydraulic surface exposed to a fluid pressure of the fuel inlet, and being movable from an open position, to a closed position based on a fuel pressure drop from a fuel inlet to a fuel outlet in the limiter assembly. A fuel filter is resident in the limiter assembly and supported in a connector coupled to the limiter body. The fuel filter is elongate and projects from the connector into a fuel flow path from the fuel inlet to the fuel outlet.

Abstract: A filtration device may include a securement section and a filter. The securement section may be configured to be threadably secured to and extend within an interior of a common rail fuel injector. The securement section may include a passage for fuel. The passage may extend in a direction along a central axis of the securement section. The filter may be configured to be positioned within the interior of the common rail fuel injector to filter the fuel flowing through the common rail fuel injector. The filter may include a plurality of holes that are fluidly connecting to the passage of the securement section. The diameter of the filter may be smaller than a diameter of the securement section.

Abstract: A fuel flow limiter assembly includes a limiter body forming a central bore, and including a shutoff piston within the central bore having a closing hydraulic surface exposed to a fluid pressure of the fuel inlet, and being movable from an open position, to a closed position based on a fuel pressure drop from a fuel inlet to a fuel outlet in the limiter assembly. A fuel filter is resident in the limiter assembly and supported in a connector coupled to the limiter body. The fuel filter is elongate and projects from the connector into a fuel flow path from the fuel inlet to the fuel outlet.

Abstract: A common rail fuel injector includes a fuel inlet, a set of nozzle outlets, a drain outlet, a nozzle chamber and a needle control chamber. A needle control valve includes a ceramic control valve member movable between a closed position in contact with a flat valve seat to block the needle control chamber from the drain outlet, and an open position at which the needle control chamber is fluidly connected to the drain outlet. A solenoid actuator is mounted in the injector body and includes an armature movable between an overtravel position and an energized position, but the armature has a stable un-energized position between the overtravel position and the energized position. A needle valve member is positioned in the injector body and includes an opening hydraulic surface exposed to fluid pressure in the nozzle chamber, and a closing hydraulic surface exposed to fluid pressure in the needle control chamber.

Abstract: A common rail fuel injector includes a needle valve member that moves to open and close nozzle outlets for a fuel injection event responsive to pressure in a needle control chamber. Between injection events, the needle control chamber is fluidly connected to the fuel inlet by a first pathway that includes a Z orifice, and fluidly connected to the fuel inlet by a second pathway that includes an F orifice, an intermediate chamber and an A orifice. During an injection event, the needle control chamber is fluidly connected to a drain outlet by a third pathway that includes the A orifice, the intermediate chamber and an E orifice. Different performance characteristics are achieved by adjusting the sizes of the respective of F, A, Z and E orifices.

Abstract: A solenoid actuator includes a stator assembly with a stator core of formed powder metal received in a stator housing. A ferromagnetic protective sleeve is in contact with and covers a majority of an inner end face and a cylindrical wall of the stator core, while a flux ring is in contact with and covers an outer end face of the stator core. An armature assembly includes an armature attached to a stem that is movable in an air gap relative to the ferromagnetic protective sleeve. A spring is operably positioned in the ferromagnetic protective sleeve but electrically isolated from the stator housing. The stator core is encapsulated to protect against erosion and fragmentation. A magnetic flux line around a solenoid coil passes through the stator core, the ferromagnetic protective sleeve, the armature, the flux ring and back to the stator core.

Abstract: A solenoid actuator includes a stator assembly with a stator core of formed powder metal received in a stator housing. A ferromagnetic protective sleeve is in contact with and covers a majority of an inner end face and a cylindrical wall of the stator core, while a flux ring is in contact with and covers an outer end face of the stator core. An armature assembly includes an armature attached to a stem that is movable in an air gap relative to the ferromagnetic protective sleeve. A spring is operably positioned in the ferromagnetic protective sleeve but electrically isolated from the stator housing. The stator core is encapsulated to protect against erosion and fragmentation. A magnetic flux line around a solenoid coil passes through the stator core, the ferromagnetic protective sleeve, the armature, the flux ring and back to the stator core.

Abstract: A common rail fuel injector includes a fuel inlet, a set of nozzle outlets, a drain outlet, a nozzle chamber and a needle control chamber. A needle control valve includes a ceramic control valve member movable between a closed position in contact with a flat valve seat to block the needle control chamber from the drain outlet, and an open position at which the needle control chamber is fluidly connected to the drain outlet. A solenoid actuator is mounted in the injector body and includes an armature movable between an overtravel position and an energized position, but the armature has a stable un-energized position between the overtravel position and the energized position. A needle valve member is positioned in the injector body and includes an opening hydraulic surface exposed to fluid pressure in the nozzle chamber, and a closing hydraulic surface exposed to fluid pressure in the needle control chamber.

Abstract: A common rail fuel injector includes a needle valve member that moves to open and close nozzle outlets for a fuel injection event responsive to pressure in a needle control chamber. Between injection events, the needle control chamber is fluidly connected to the fuel inlet by a first pathway that includes a Z orifice, and fluidly connected to the fuel inlet by a second pathway that includes an F orifice, an intermediate chamber and an A orifice. During an injection event, the needle control chamber is fluidly connected to a drain outlet by a third pathway that includes the A orifice, the intermediate chamber and an E orifice. Different performance characteristics are achieved by adjusting the sizes of the respective of F, A, Z and E orifices.

Abstract: A system for selectively intensifying fuel for injection utilizing a fuel injector having an intensifier piston connected to a drain and a pressurized fuel source. The intensifier piston includes a control chamber co-axially positioned opposite from an intensification chamber, and a pressurization chamber co-axially positioned between the control chamber and the intensification chamber. The control chamber selectively fluidly communicates with the pressurized fuel source and the drain. The intensification chamber fluidly communicates with the pressurized fuel source and the pressurization chamber fluidly communicates with the pressurized fuel source and a nozzle assembly.

Abstract: A common rail fuel system includes a reverse flow check valve fluidly positioned between each of a plurality of common rail fuel injectors and an outlet of a high pressure pump. The reverse flow check valves divide the overall system fluid volume into an upstream common volume and a plurality of separate downstream volumes. The upstream common volume is greater than the sum of the separate downstream volumes. The reverse flow check valve is movable between a first configuration with a large flow area and a second configuration with a small flow area. The reverse flow check valve associated with each of the individual fuel injectors may be housed in a quill that fluidly connects the fuel injectors to the high pressure common rail.

Abstract: A method is provided for predicting the likelihood of cavitation damage occurring on a surface of a hydrodynamic component. The method may include creating a computational fluid dynamics (CFD) simulation of the hydrodynamic component, wherein creating the CFD simulation includes simulating fluid flowing relative to the hydrodynamic component. The method may also include selecting a location on the surface of the hydrodynamic component, wherein the selected location is exposed to the simulated fluid flow. The method may also include determining and analyzing at least one of a mean pressure and standard deviation, a standard deviation of the rate of change in pressure, a mean void percentage and standard deviation, and a standard deviation of the rate of change in void percentage for the flowing fluid at the selected surface location to predict the likelihood of cavitation damage occurring at the selected surface location.

Abstract: A valve assembly is disclosed. The valve assembly has a housing having a first recess disposed on an interior surface of the housing and at least one valve-supporting element disposed within the housing. The valve assembly also has a washer disposed within the housing, the washer having a first washer surface and a projection for transferring torque. The first washer surface abuts against a first valve-supporting element surface of the at least one valve-supporting element and the projection is received in the first recess. The valve assembly also has a first fastener disposed within the housing and having a first fastener surface abutting against a second washer surface of the washer.

Abstract: A fluid leak limiter for a high-pressure fuel injection system is disclosed. The fluid leak limiter may have a body at least partially defining a central bore and having a fluid inlet and a fluid outlet, a piston reciprocatingly disposed within the central bore, and a spring located to bias the piston toward a first flow-blocking position at which fluid from the fluid inlet is inhibited from flowing to the fluid outlet. The fluid leak limiter may also have a pin configured to selectively lock the piston in a second flow-blocking position at which fluid from the fluid inlet is inhibited from flowing to the fluid outlet.

Abstract: A fluid leak limiter for a high-pressure fuel injection system is disclosed. The fluid leak limiter may have a body at least partially defining a central bore and having a fluid inlet and a fluid outlet, a piston reciprocatingly disposed within the central bore, and a spring located to bias the piston toward a first flow-blocking position at which fluid from the fluid inlet is inhibited from flowing to the fluid outlet. The fluid leak limiter may also have a pin configured to selectively lock the piston in a second flow-blocking position at which fluid from the fluid inlet is inhibited from flowing to the fluid outlet.

Abstract: A valve assembly is disclosed. The valve assembly has a housing having a first recess disposed on an interior surface of the housing and at least one valve-supporting element disposed within the housing. The valve assembly also has a washer disposed within the housing, the washer having a first washer surface and a projection for transferring torque. The first washer surface abuts against a first valve-supporting element surface of the at least one valve-supporting element and the projection is received in the first recess. The valve assembly also has a first fastener disposed within the housing and having a first fastener surface abutting against a second washer surface of the washer.

Abstract: A method is provided for predicting the likelihood of cavitation damage occurring on a surface of a hydrodynamic component. The method may include creating a computational fluid dynamics (CFD) simulation of the hydrodynamic component, wherein creating the CFD simulation includes simulating a fluid proximal to the surface of the hydrodynamic component. The method may also include selecting a location on the surface of the hydrodynamic component, wherein the selected location is exposed to the simulated fluid. The method may further include determining the mean pressure and standard deviation, the standard deviation of the rate of change in pressure, the mean void percentage and standard deviation, and the standard deviation of the rate of change in void percentage for the fluid at the selected surface location.