Abstract: The present disclosure generally relates to a pumping element of a fuel pump for an internal combustion engine wherein the pumping element comprises a pumping chamber and a check valve assembly having a first insert including an angled passage in flow communication with a fuel outlet, and a second insert being disposed adjacent the pumping chamber, the second insert including a central bore in flow communication with a fuel inlet, a plurality of through holes in flow communication with the pumping chamber.

Abstract: A stator assembly comprising: a stator having an inner diameter; a plurality of coils wrapped around the stator; and a seal plate positioned on the lower surface of the stator and spanning the inner diameter of the stator, the seal plate having at least one welded edge to form a hermetic seal along the stator.

Abstract: The present disclosure generally relates to a pumping element of a fuel pump for an internal combustion engine wherein the pumping element comprises a pumping chamber and a check valve assembly having a first insert including a passage in flow communication with a fuel outlet, and a second insert being disposed adjacent the pumping chamber, the second insert including a bore in flow communication with a fuel inlet, a plurality of through holes in flow communication with the pumping chamber, and an inlet check valve plunger disposed in the bore for movement between an opened position wherein inlet fuel from the fuel inlet flows past the inlet check valve plunger through the plurality of through holes to the pumping chamber and a closed position wherein outlet fuel from the pumping chamber flows through the plurality of through holes past the inlet check valve plunger to the passage of the first insert.

Abstract: A fuel pump is disclosed wherein a substantially cylindrical plunger bore is provided with an annular drain groove fluidically coupled to a drain duct. A pump plunger is driven by a drive system located in a separate mechanical compartment that holds a reservoir of lubricating oil. An annular seal is provided adjacent the drain groove substantially at the end of the bore and retained in position by a seal support. Exemplary embodiments provide the drain groove and seal as being positioned immediately adjacent one another so that the seal forms a lower wall of the drain groove.

Abstract: A fuel pump is disclosed wherein a substantially cylindrical plunger bore is provided with an annular drain groove fluidically coupled to a drain duct. A pump plunger is driven by a drive system located in a separate mechanical compartment that holds a reservoir of lubricating oil. An annular seal is provided adjacent the drain groove substantially at the end of the bore and retained in position by a seal support. Exemplary embodiments provide the drain groove and seal as being positioned immediately adjacent one another so that the seal forms a lower wall of the drain groove.

Abstract: A fuel injector including an injection control device valve spring preload adjustment device is disclosed. The fuel injector includes a transverse access passage extending at an acute angle to a longitudinal axis of the fuel injector. The preload adjustment device includes at least one transverse slot that creates a cantilevered thread portion. The cantilevered thread portion is deformed at a deformation angle to a plane perpendicular to the longitudinal axis to form a locking feature.

Abstract: An electromagnetic valve includes an extra-high pressure injection system control valve having soft metal powder particles in a magnetic stator core. Electroless nickel plating is applied to the stator core to provide an intermediate surface to absorb grinding wheel stress as a working face is exposed during manufacturing, as well as an external compression layer or casing to hold or encapsulate the powder particles in place and together during assembly and use.

Abstract: A closed nozzle fuel injector is provided which effectively controls the fuel injection flow rate, especially during an initial portion of an injection event, while also permitting accurate control over pilot and/or post injection flow rates at all operating conditions thereby advantageously reducing emissions and combustion noise. The injector includes a rate shaping orifice to restrict fuel flow during an initial portion of an injection event and a rate shaping sleeve mounted for movement to cause a greater flow of injection fuel during a later portion of the injection event. A damping chamber and orifice are also provided to control movement of the rate shaping sleeve.

Abstract: A device for evaluating magnetic component performance and methods of evaluating transient magnetic performance of such components are disclosed. Magnetic flux capacity and/or energy loss of a magnetic component is/are measured, and the measurement data is electronically processed to evaluate the magnetic performance of the component.

Abstract: A flow control valve for controlling the flow of fuel in a fuel system including a housing with a fuel passage, a valve device movable to close the fuel passage to block fuel flow through the fuel passage, and to open the fuel passage to permit fuel flow through the fuel passage, a valve plunger engaging the valve device, an actuator for reciprocally moving the valve plunger, an armature overtravel feature for permitting continued movement of the armature relative to the valve plunger from an engaged position into a disengaged position when the valve plunger reaches the extended position, and an armature stop for stopping overtravel of the armature.

Abstract: An improved fuel injector is provided which effectively controls fuel injection events using two injection control valves which operate in series to control the movement of a nozzle valve element. An outer injection control valve and actuator assembly operates to control fluid pressure in a control volume adjacent an inner injection control valve thereby controlling the movement of the inner control valve which, in turn, controls fuel pressure in an inner control volume adjacent one end of the nozzle valve element. A particular design of the inner injection control valve prevents control valve oscillations thereby minimizing unwanted fuel injection variations.

Abstract: An improved fuel injector is provided which effectively controls fuel injection events using two injection control valves which operate in series to control the movement of a nozzle valve element. An outer injection control valve and actuator assembly operates to control fluid pressure in a control volume adjacent an inner injection control valve thereby controlling the movement of the inner control valve which, in turn, controls fuel pressure in an inner control volume adjacent one end of the nozzle valve element. A particular design of the inner injection control valve prevents control valve oscillations thereby minimizing unwanted fuel injection variations.

Abstract: A wear and scuff-resistant plunger for use in high pressure fuel system components in internal combustion engines is provided. The plunger, which is formed of a high thermal expansion, high hardness ceramic with a thermal expansion coefficient preferably greater than 6.times.10.sup.-6 /.degree. C. and a hardness preferably greater than 800 Kg/mM.sup.2, maintains a desired optimum minimal diametral clearance while avoiding excessive fuel leakage and efficient plunger function without scuffing or sticking under the high axial, side and pressure loads and variable quality fuels encountered in the fuel system operating environment. Preferred high thermal expansion, high hardness ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A wear and scuff-resistant timing plunger for a timing assembly in a unit fuel injector for an internal combustion engine is provided. The timing plunger is formed of a high thermal expansion ceramic with a thermal expansion coefficient greater than 6.times.10.sup.-6 /.degree. C. and a hardness greater than 800 Kg/mm.sup.2, which maintains a desired diametral clearance and efficient plunger function without scuffing or sticking under the axial, tangential and pressure loads encountered in the fuel injector operating environment. Preferred high thermal expansion ceramics are zirconia, alumina-zirconia and alumina.

Abstract: A solenoid valve is disclosed including a valve housing having a central bore and a valve seat, a valve element movable between an open position allowing fluid to pass through said valve seat and a closed position in sealing engagement with said valve seat, a valve operator for moving the valve element between the open and closed positions including a reciprocating armature plunger member extending through the bore and an armature secured to the armature plunger, a valve adjustment for adjustably mounting the valve element relative to the valve operator for permitting adjustment to within an acceptable tolerance of a predetermined distance between the valve element and the valve seat when the valve element is in its open position without creating a path of leakage when the valve element is in its closed position.

Abstract: A pump-line-nozzle fuel injection system in which a supply pump is coupled to a high pressure pump having a plurality of pumping cylinders, each of which has a cam-driven timing plunger and a floating metering plunger. During the retraction stroke, flow to a timing chamber formed between the pistons is blocked by a solenoid valve while the fuel passes into a metering chamber, at the discharge side of the pump, which is closed relative to the high pressure delivery line by a delivery valve. Once the proper quantity of fuel has been metered, the solenoid valve opens allowing fuel to flow into the metering chamber, balancing the pressure on opposite sides of the metering piston, so as to prevent the metering plunger from retracting further as the timing plunger continues to retract. During the compression stroke, at the appropriate time for commencement of injection, the solenoid valve recloses creating a hydraulic link between the metering and timing plungers, so that the fuel is pressurized.

Abstract: Fuel injector for an internal combustion engine which has a timing chamber bore in its body intersecting at an acute angle with an auxiliary bore. These bores are fuel-receiving passages exposed to the pressure of injection. A radiused intersection between the walls of the respective bores reduces the concentration of stress within the fuel injector, allowing the injector to withstand the high injection pressures of mechanical pressurization. An electrochemical machining method and fixture for machining the intersection between the bores of a fuel injector body or other workpiece is also disclosed.

Abstract: Fuel injector for an internal combustion engine which has a timing chamber bore in its body intersecting at an acute angle with an auxiliary bore. These bores are fuel-receiving passages exposed to the pressure of injection. A radiused intersection between the walls of the respective bores reduces the concentration of stress within the fuel injector, allowing the injector to withstand the high injection pressures of mechanical pressurization. An electrochemical machining method and fixture for machining the intersection between the bores of a fuel injector body or other workpiece is also disclosed.

Abstract: A mechanically pressurized electronic fuel injector is for use in internal combustion engines and is actuated by the engine valve train. The fuel injector has an injection stroke for discharging fuel into the engine and a metering stroke for receiving a predetermined volume of fuel in the injector. During the injection stroke, a coupling member contacts a timing plunger and transmits a compressive force from the engine valve train. The coupling member and the timing plunger are not mechanically connected together and are capable of independent relative movement. During the metering stroke of the injector, the timing plunger is returned to its pre-injection position under the pressure generated by the fuel entering the timing and metering plunger chambers.

Abstract: A mechanically pressurized electronic fuel injector for use in internal combustion engines is actuated by the engine valve train during the injection stroke. A control solenoid is mounted to the injector and has its axis inclined with respect to the axis of the injector. A control valve passage has its axis generally coaxial with the central axis of the control solenoid. Machining of the control valve passage is accomplished through the receiving boss for the control solenoid. High pressure sealing plugs, previously required to seal orifices in the exterior surface of the injector body which were needed to provide access to drill or machine the control valve passage, are completely eliminated. The drilling and machining of the control valve passage is accomplished without drilling through the exterior surface of the injector body.