Abstract: A method for controlling operation of an opposed piston engine is provided, comprising: determining a direction of rotation of the engine; comparing the determined direction of rotation to a correct direction of rotation of the engine; and responding to the determined direction of rotation being different from the correct direction of rotation by taking corrective action.

Abstract: An opposed-piston engine includes an electronic sensor located in a charge air channel, at position between an outlet of a charge air cooler and an air intake component that distributes charge air to cylinder intake ports of the engine. The electronic sensor is disposed to measure a rate of mass airflow between the outlet of the charge air cooler and the intake component and generate electronic signals indicative of the rate of mass airflow from the charge air cooler. A control mechanization of the opposed-piston engine is electrically connected to the electronic sensor for controlling air handling devices, fuel provisioning devices, and/or EGR devices in response to the electronic signals.

Abstract: A main bearing cap having a bearing cap body defining a vertical centerline, the bearing cap body having a top surface opposite a bottom surface, a pair of upper protruding parts and a pair of lower protruding parts that extend in a horizontal direction that is orthogonal to a longitudinal axis of a crankshaft, and a pair of posts that extend between the upper and the lower protruding parts. Each of the posts having a profiled side surface that is recessed to a profiled surface depth to reduce contact pressure and fretting between the bottom surface of the bearing cap and a joint surface of a bulkhead of a cylinder block when the parts are assembled. The profiled side surfaces also reduce the stiffness of the bearing cap to match more closely that of the cylinder block and direct load or force towards a centerline of the bearing cap.

Abstract: A main bearing cap having a bearing cap body defining a vertical centerline, the bearing cap body having a top surface opposite a bottom surface, a pair of upper protruding parts and a pair of lower protruding parts that extend in a horizontal direction that is orthogonal to a longitudinal axis of a crankshaft, and a pair of posts that extend between the upper and the lower protruding parts. Each of the posts having a profiled side surface that is recessed to a profiled surface depth to reduce contact pressure and fretting between the bottom surface of the bearing cap and a joint surface of a bulkhead of a cylinder block when the parts are assembled. The profiled side surfaces also reduce the stiffness of the bearing cap to match more closely that of the cylinder block and direct load or force towards a centerline of the bearing cap.

Abstract: An opposed-piston engine includes an electronic sensor located in a charge air channel, at position between an outlet of a charge air cooler and an air intake component that distributes charge air to cylinder intake ports of the engine. The electronic sensor is disposed to measure a rate of mass airflow between the outlet of the charge air cooler and the intake component and generate electronic signals indicative of the rate of mass airflow from the charge air cooler. A control mechanization of the opposed-piston engine is electrically connected to the electronic sensor for controlling air handling devices, fuel provisioning devices, and/or EGR devices in response to the electronic signals.

Abstract: A method of making a piston for an opposed-piston engine comprises providing a piston. The piston comprises a substantially cylindrical portion including a sidewall and a piston crown located at an end of the piston. The piston crown comprises an end surface structured to form a combustion chamber when disposed within a cylinder bore in cooperation with an end surface of a cooperating opposing piston. A bonding layer including a bonding material is deposited on the end surface of the piston crown using a high velocity oxy-fuel spray process. At least one thermal barrier layer comprising ceramic material is deposited above the bonding layer.

Abstract: A piston for an opposed-piston engine has a thermal barrier coating on at least the piston crown. The piston, at least the piston crown, is made of titanium or a titanium alloy. The thermal barrier coating includes a bonding material and a ceramic material. The bonding material can be present in the thermal barrier coating at an interface of the thermal barrier coating and the bulk of the piston material. The ceramic material can be a high R-Value material. In particular, the piston with a thermal barrier coating can be an exhaust piston for an opposed-piston engine.

Abstract: A method for controlling operation of an opposed piston engine is provided, comprising: determining a direction of rotation of the engine; comparing the determined direction of rotation to a correct direction of rotation of the engine; and responding to the determined direction of rotation being different from the correct direction of rotation by taking corrective action.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: A method of making a piston for an opposed-piston engine comprises providing a piston. The piston comprises a substantially cylindrical portion including a sidewall and a piston crown located at an end of the piston. The piston crown comprises an end surface structured to form a combustion chamber when disposed within a cylinder bore in cooperation with an end surface of a cooperating opposing piston. A bonding layer including a bonding material is deposited on the end surface of the piston crown using a high velocity oxy-fuel spray process. At least one thermal barrier layer comprising ceramic material is deposited above the bonding layer.

Abstract: A piston for an opposed-piston engine has a thermal barrier coating on at least the piston crown. The piston, at least the piston crown, is made of titanium or a titanium alloy. The thermal barrier coating includes a bonding material and a ceramic material. The bonding material can be present in the thermal barrier coating at an interface of the thermal barrier coating and the bulk of the piston material. The ceramic material can be a high R-Value material. In particular, the piston with a thermal barrier coating can be an exhaust piston for an opposed-piston engine.

Abstract: A piston for an opposed-piston engine has a thermal barrier coating on at least the piston crown. The piston, at least the piston crown, is made of titanium or a titanium alloy. The thermal barrier coating includes a bonding material and a ceramic material. The bonding material can be present in the thermal barrier coating at an interface of the thermal barrier coating and the bulk of the piston material. The ceramic material can be a high R-Value material. In particular, the piston with a thermal barrier coating can be an exhaust piston for an opposed-piston engine.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: An improved method and system for automatically continuously removing an engine's used lubricating oil and injecting the used oil into the engine's fuel system throughout operation based on engine operating conditions is disclosed. The present system includes a lube oil replacement pump system for injecting small amounts of used lube oil into the engine's fuel system and recycling controlled quantities of removed used oil into the engine's lube oil system. The process periodically determines an engine operating severity value, i.e. fuel consumption value, for an interval of engine operation and calculates a base line quantity of oil for injection based on the current fuel consumption of the engine during the current interval. The lube oil pump system may be in the form of a compact, unitized lube oil replacement pump assembly integrating the various components of the system.

Abstract: An improved method and system for automatically continuously replacing an engine's used lubricating oil with fresh lubricating oil throughout operation based on engine operating conditions is disclosed. The present system includes an lube oil replacement pump system operable in a replacement mode for injecting small amounts of used lube oil into the engine's fuel system and directing controlled quantities of fresh oil into the engine's lube oil system to replace the removed oil. The process periodically determines an engine operating severity value, i.e. fuel consumption value, for an interval of engine operation and calculates a base line quantity of oil for injection based on the current fuel consumption of the engine during the current interval. The lube oil replacement pump may also be operated in a makeup mode for adding quantities of fresh oil to the engine lube oil sump to compensate for oil consumed by the engine.