Abstract: A fuel injector is provided with a lower nozzle body which is cooled with a small amount of metered fuel. In one embodiment, a blind passage is formed to extend from the upper portion to the lower end of the injector nozzle valve element. A transverse passage is formed in the nozzle valve element connecting the blind passage and the nozzle bore. Rail pressure causes a metered amount of fuel to flow through the nozzle bore, the transverse passage and upwardly along the blind passage to the drain passage. Inward cooling occurs by providing more surface area over which the fuel flows. In another embodiment, a sleeve is formed to fit over an existing nozzle to form a passage surrounding the injector tip. An orifice is located in the nozzle housing to connect the nozzle cavity with the annular passage thereby providing a small amount of fuel to drain.

Abstract: A piezoelectric fuel injection system and a method of controlling same are provided which include a piezoelectric fuel injector having a piezoelectric element, a power source adapted to provide power to the piezoelectric element to actuate the piezoelectric fuel injector, and a controller adapted to charge the piezoelectric element to an initial voltage to begin said injection event, to decrease the voltage from the initial voltage to an intermediate voltage, and to increase the voltage from the intermediate voltage to a primary voltage to thereby control the injection rate shape. The initial voltage level is at least approximately equal to said primary voltage level and preferably approximately equal to a maximum voltage rating. The initial voltage duration, the intermediate voltage duration and the magnitude of the intermediate voltage can be changed or varied to modify the injection or rate shape.

Abstract: A preferred embodiment EGR valve permits exhaust gas to be induced into the intake line downstream of the compressor, while minimizing the need to reduce the size of the turbocharger. The preferred embodiment EGR valve exploits variations around the mean pressure in the EGR passage created by the engine cycle by selectively opening when the pressure in the EGR valve exceeds the pressure in the intake line. Thus, exhaust gas is recirculated even when the engine is running near torque peak. The preferred embodiment EGR valve also exploits the higher mean pressure in the exhaust line relative to the intake line at higher engine speeds by remaining open, in order to minimize the energy consumed in opening and closing the EGR valve.

Abstract: A piezoelectric fuel injection system and a method of controlling same, the system including a piezoelectric fuel injector having a piezoelectric element, a power source adapted to provide power to the piezoelectric element to actuate the piezoelectric fuel injector, and a controller adapted to cyclically modulate power provide to the piezoelectric element by the power source during at least a portion of the injection event. The controller cyclically modulates the power between a predetermined first voltage and a predetermined second voltage that is less than the first voltage to control the rate of fuel injected by the piezoelectric fuel injector during the portion of the injection.

Abstract: A multi-mode internal combustion engine and method of operating the engine is provided which is capable of operating in a variety of modes based on engine operating conditions to enhance fuel efficiency and reduce emissions. The multi-mode engine include a fuel delivery system and control system for permitting the engine to operate in a diesel mode, a homogeneous charge dual fuel transition mode, a spark ignition or liquid spark ignition mode and/or a premixed charge compression ignition mode. The control system and method permits the engine operation to transfer between the various modes in an effective and efficient manner by controlling one or more fuel delivery devices or other engine components so as to move along a continuous transfer path while maintaining engine torque at a substantially constant level.

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 fuel injector is provided with a lower nozzle body which is cooled with a small amount of metered fuel. In one embodiment, a blind passage is formed to extend from the upper portion to the lower end of the injector nozzle valve element. A transverse passage is formed in the nozzle valve element connecting the blind passage and the nozzle bore. Rail pressure causes a metered amount of fuel to flow through the nozzle bore, the transverse passage and upwardly along the blind passage to the drain passage. Inward cooling occurs by providing more surface area over which the fuel flows. In another embodiment, a sleeve is formed to fit over an existing nozzle to form a passage surrounding the injector tip. An orifice is located in the nozzle housing to connect the nozzle cavity with the annular passage thereby providing a small amount of fuel to drain.

Abstract: A multi-mode internal combustion engine and method of operating the engine is provided which is capable of operating in a variety of modes based on engine operating conditions to enhance fuel efficiency and reduce emissions. The multi-mode engine include a fuel delivery system and control system for permitting the engine to operate in a diesel mode, a homogeneous charge dual fuel transition mode, a spark ignition or liquid spark ignition mode and/or a premixed charge compression ignition mode. The control system and method permits the engine operation to transfer between the various modes in an effective and efficient manner by controlling one or more fuel delivery devices or other engine components so as to move along a continuous transfer path while maintaining engine torque at a substantially constant level.

Abstract: A fuel delivery device for a fuel delivery system incorporates an electronic compensation device that either incorporates information that is relevant to the specific fuel delivery device or includes a processor that generates an actuator control signal that is based at least in part upon the information contained in the memory device.

Abstract: A multi-mode internal combustion engine and method of operating the engine is provided which is capable of operating in a variety of modes based on engine operating conditions to enhance fuel efficiency and reduce emissions. The multi-mode engine include a fuel delivery system and control system for permitting the engine to operate in a diesel mode, a homogeneous charge dual fuel transition mode, a spark ignition or liquid spark ignition mode and/or a premixed charge compression ignition mode. The control system and method permits the engine operation to transfer between the various modes in an effective and efficient manner by controlling one or more fuel delivery devices or other engine components so as to move along a continuous transfer path while maintaining engine torque at a substantially constant level.

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 internal combustion engine operable in a premixed charge compression ignition mode and a method for operating the engine, the engine including an engine body with a piston assembly, a combustion chamber formed in the engine body by the piston assembly, an intake system for delivering intake air to the combustion chamber during an intake stroke, a mixing device that mixes a first fuel with the intake air to provide a premixed charge of air and the first fuel, a direct fuel injector adapted to directly inject a second fuel into the combustion chamber, and a control system adapted to control the direct fuel injector in a manner to provide at least one early control injection, and preferably, a plurality of early control injections of the second fuel into the combustion chamber before start of combustion of the premixed charge.

Abstract: A multi-mode internal combustion engine and method of operating the engine is provided which is capable of operating in a variety of modes based on engine operating conditions to enhance fuel efficiency and reduce emissions. The multi-mode engine include a fuel delivery system and control system for permitting the engine to operate in a diesel mode, a homogeneous charge dual fuel transition mode, a spark ignition or liquid spark ignition mode and/or a premixed charge compression ignition mode. The control system and method permits the engine operation to transfer between the various modes in an effective and efficient manner by controlling one or more fuel delivery devices or other engine components so as to move along a continuous transfer path while maintaining engine torque at a substantially constant level.

Abstract: A fuel delivery device for a fuel delivery system incorporates an electronic compensation device that either incorporates information that is relevant to the specific fuel delivery device or includes a processor that generates an actuator control signal that is based at least in part upon the information contained in the memory device.

Abstract: A fuel injector having a nozzle with improved cooling including a retainer and a nozzle housing received therein. The nozzle housing includes a nozzle shank, an outer peripheral surface and at least one injection hole at a tip of the nozzle shank. The nozzle shank is positioned in a nozzle support portion of the retainer. In one embodiment, the outer peripheral surface of the nozzle shank is tapered, and the inner peripheral surface of the nozzle support portion is correspondingly tapered and sized to engage the outer peripheral surface of the nozzle shank along a tapered interface. In another embodiment, the inner peripheral surface of the nozzle support portion has a diameter smaller than a diameter of the outer peripheral surface of the nozzle shank so that an interference fit exists at a seal interface.

Abstract: A novel and improved motion sensor for high pressure fluid delivery devices is provided which effectively senses movement of a component in a high pressure environment while minimizing the likelihood of fluid leakage through a receiving cavity containing at least a portion of the sensor. The motion sensor includes a sealing surface shaped and positioned relative to a force resisting surface formed on an annular cavity surface of the receiving cavity so as to apply a fluid, e.g. fuel, pressure induced sealing force against the force resisting surface due to the high pressure fluid forces acting on the sensor body. The sealing surface may be conically shaped for contacting a complementary conically shaped force resisting surface and/or the sealing surface may extend perpendicular to the direction of the fluid forces acting on the sensor body for abutment against a complementary positioned annular land containing the force resisting surface.

Abstract: A multi-mode internal combustion engine and method of operating the engine is provided which is capable of operating in a variety of modes based on engine operating conditions to enhance fuel efficiency and reduce emissions. The multi-mode engine include a fuel delivery system and control system for permitting the engine to operate in a diesel mode, a homogeneous charge dual fuel transition mode, a spark ignition or liquid spark ignition mode and/or a premixed charge compression ignition mode. The control system and method permits the engine operation to transfer between the various modes in an effective and efficient manner by controlling one or more fuel delivery devices or other engine components so as to move along a continuous transfer path while maintaining engine torque at a substantially constant level.

Abstract: An improved closed nozzle injector assembly for injecting high pressure fuel into the combustion chamber of an engine is provided which includes a first needle valve element associated with a first set of injector orifices, a first needle valve control device for controlling the opening and closing of the first needle valve, a second needle valve associated with a second set of injector orifices and a second needle valve control device for controlling the opening and closing of the second needle valve. Each needle valve control device includes a control volume positioned at one end of the respective needle valve, a control volume charge circuit for supplying high pressure fuel to the respective control volume and the respective injection control valve for controlling the flow of high pressure fuel from the respective control volume to a low pressure drain thereby controlling the movement of the respective needle valve.

Abstract: An improved closed nozzle injector assembly for injecting high pressure fuel into the combustion chamber of an engine is provided which includes a first needle valve element associated with a first set of injector orifices, a first needle valve control device for controlling the opening and closing of the first needle valve, a second needle valve associated with a second set of injector orifices and a second needle valve control device for controlling the opening and closing of the second needle valve. Each needle valve control device includes a control volume positioned at one end of the respective needle valve, a control volume charge circuit for supplying high pressure fuel to the respective control volume and the respective injection control valve for controlling the flow of high pressure fuel from the respective control volume to a low pressure drain thereby controlling the movement of the respective needle valve.

Abstract: An improved fuel injection system is provided which incorporates a common rail and a plurality of unit injectors which function together to efficiently produce various injection rate shapes and different combinations of discreet and blended pilot, main, post and after treatment fuel injection events during a single injection. The fuel injection system effectively permits flexible, responsively timed, square shaped, discreet low to mid pressure level injections utilizing the fuel pressure of the common rail while also allowing the unit injector portion to function independently to produce flexible and responsively timed and pressure controlled, triangular shaped high pressure fuel injection events and to recover excess energy. In one embodiment, a separate common rail pump is avoided by utilizing the unit injector plunger to replace fuel into the common rail which was previously injected.