Abstract: A fuel injector including a nozzle portion, a solenoid operated valve assembly configured to control a flow of fuel to the nozzle portion, a housing, at least a portion of the solenoid operated valve assembly disposed in the housing, the housing formed of a first material having a first thermal conductivity value, and a heat transfer element associated with the solenoid operated valve assembly, the heat transfer element attached to the housing, the heat transfer element formed of a second material having a second thermal conductivity value, the second thermal conductivity value being greater than the first thermal conductivity value.

Abstract: A fuel injector includes an injector body having an internal surface and an external surface. A tappet assembly includes a non-guided tappet and a plunger assembly, and is mounted on the injector body. The tappet assembly is movable with respect to the injector body a displacement distance between an advanced position and an extended position. A portion of the plunger assembly is slidably guided along the internal surface of the injector body, while the non-guided tappet is free of contact with both the internal surface and the external surface of the injector body in the advanced and extended positions. The tappet assembly may be prevented from moving beyond the extended position using a snap ring positioned within a retention opening of the fuel injector body.

Abstract: A fuel injector includes an injector body having an internal surface and an external surface. A tappet assembly includes a non-guided tappet and a plunger assembly, and is mounted on the injector body. The tappet assembly is movable with respect to the injector body a displacement distance between an advanced position and an extended position. A portion of the plunger assembly is slidably guided along the internal surface of the injector body, while the non-guided tappet is free of contact with both the internal surface and the external surface of the injector body in the advanced and extended positions. The tappet assembly may be prevented from moving beyond the extended position using a snap ring positioned within a retention opening of the fuel injector body.

Abstract: A fuel system for an internal combustion engine includes a plurality of nozzle groups and a plurality of pump groups. A common rail is fluidly connected with each of the nozzle groups, and each of the pump groups includes a mechanically actuated pressure intensifier having a tappet which can selectively intensify a fuel injection pressure in a corresponding one of the nozzle groups. Each of the mechanically actuated pressure intensifiers is movable in response to rotation of a cam, and includes a spill valve having a first position at which fuel is displaced from the pump group to a low pressure space and a second position at which fuel is displaced to a corresponding one of the nozzle groups.

Abstract: A fuel injector includes a piezoelectric actuator subassembly having a casing and a piezoelectric element disposed within the casing. The piezoelectric element has an operating temperature range and includes a thermally contractive material having a negative thermal expansion coefficient over a second temperature range overlapping with the operating temperature range. A preload control element is coupled with the piezoelectric element and includes a thermally expansive material having a positive thermal expansion coefficient over the second temperature range. The preload control element maintains a constant preload on the piezoelectric element over a wide temperature range to inhibit temperature induced variability in operation, and can axially lengthen in opposition to axial shortening of the piezoelectric element, responsive to a temperature increase.

Abstract: A fuel system for an internal combustion engine includes a plurality of nozzle groups and a plurality of pump groups. A common rail is fluidly connected with each of the nozzle groups, and each of the pump groups includes a mechanically actuated pressure intensifier having a tappet which can selectively intensify a fuel injection pressure in a corresponding one of the nozzle groups. Each of the mechanically actuated pressure intensifiers is movable in response to rotation of a cam, and includes a spill valve having a first position at which fuel is displaced from the pump group to a low pressure space and a second position at which fuel is displaced to a corresponding one of the nozzle groups.

Abstract: A fuel system includes a plurality of fuel injectors fluidly connected to a common rail. Each of the fuel injectors has at least one body component and includes an intensifier control valve for controlling movement of an intensifier piston, a needle control valve for controlling movement of a needle valve member, and exactly one electrical actuator coupled with the intensifier control valve and the needle control valve via a coupling linkage. The intensifier control valve and the needle control valve each include a valve member that is movable with respect to a valve seat. The electrical actuator includes an intermediate position during which the valve member of one of the intensifier control valve and the needle control valve is in contact with the respective valve seat, and the valve member of the other of the intensifier control valve and the needle control valve is out of contact with the respective valve seat.

Abstract: A fuel injector and a method of assembly includes a determination of various flow areas through clearances or openings formed in various components of the injector. With the various flow areas determined, the various components can be classified according to their flow areas such that sets of components can be selected having desirable flow area characteristics for assembly of the fuel injector.

Abstract: A control valve assembly includes a one-piece valve movable between a first position at which the valve closes a seat defined by a housing and positioned fluidly between a fluid inlet and a first fluid outlet, and a second position at which the valve is out of contact with the seat. The valve includes an outer diameter having an annular seating shoulder located thereon which is configured to contact a frustoconical surface of the seat when the valve is at the first position, and the annular seating shoulder is further configured to deform in response to contacting the frustonical surface without changing a seating diameter associated therewith. Closing the seat with the annular seating shoulder reduces performance variability of the valve over time.

Abstract: A system for preloading piezoelectric actuators includes a fixture, a preloading mechanism configured to apply a mechanical force to a piezoelectric element supported by the fixture, and a sensor configured to sense an electrical property induced by the mechanical force in an electrical circuit having the piezoelectric element therein. A control device is coupled with the sensor and configured to generate a signal based on the sensed electrical property. A method of setting or testing preload includes applying a mechanical force to a piezoelectric element, and correlating an electrical property induced by the mechanical force with a magnitude of the mechanical force. Closed loop control allows preload to be set highly accurately.

Abstract: A power management system for a combustion engine is disclosed. The power management system has a fuel injector, a sensor, and a controller in communication with the sensor and the fuel injector. The fuel injector is operable to inject multiple shots of fuel into the combustion engine during a single injection event. The sensor is configured to sense a speed of the combustion engine and generate a signal indicative of the sensed speed. The controller is configured to limit the number of shots per injection event in response to the signal.

Abstract: A mechanically actuated electronically controlled unit injector includes an electronically controlled spill valve to precisely control timing of fuel pressurization within a fuel pressurization chamber. Cavitation bubbles may be generated in the region of the valve seat when the spill valve member is closed to raise fuel pressure in the fuel injector. This cavitation can cause erosion on the spill valve member and the surrounding injector body. In order to preempt cavitation damage, the valve member may be modified to include a compound annulus that includes a small annulus that corresponds to an identified cavitation damage pattern. Although the generation of cavitation bubbles may continue after such a strategy, cavitation erosion, and the associated liberation of metallic particles into the fuel system can be reduced, and maybe eliminated, by the preemptive cavitation reduction strategy.

Abstract: The invention relates to methods and apparatus for forming images on a display utilizing a control matrix to control the movement of MEMs-based light modulators.

Abstract: A relatively inexpensive robust attachment strategy that insures good perpendicularity between a valve member and an armature utilizes an intervening nut between the armature and valve member. A valve member is received in a guide bore of a valve body. A nut is threaded onto one end of a valve member. The armature is press fit onto a orientation neutral interface of the nut, and a fixture is utilized to set near perfect perpendicularity between an air gap plane of the armature and a centerline of the valve member. The armature is then welded to the valve member. The weld may be accomplished via laser welding while the valve assembly is firmly held in an appropriate position within the fixture. The valve assembly may be then incorporated into a fuel injector stack of components in a conventional manner.

Abstract: The invention relates to methods and apparatus for forming images on a display utilizing a control matrix to control the movement of MEMs-based light modulators.

Abstract: A power management system for a combustion engine is disclosed. The power management system has a fuel injector, a sensor, and a controller in communication with the sensor and the fuel injector. The fuel injector is operable to inject multiple shots of fuel into the combustion engine during a single injection event. The sensor is configured to sense a speed of the combustion engine and generate a signal indicative of the sensed speed. The controller is configured to limit the number of shots per injection event in response to the signal.

Abstract: A fuel injector for an internal combustion engine having a crankshaft is disclosed. The fuel injector has plunger to displace fuel and an electronically controlled spill valve. The fuel injector also has a nozzle member having at least one orifice and a valve needle disposed within the nozzle member, and movable against a spring bias to selectively inject pressurized fuel through the at least one orifice. The fuel injector also has an electronically controlled check valve. The valve needle is automatically moved to inject pressurized fuel when the pressure of the fuel within the fuel injector reaches a predetermined valve opening pressure determined by a spring bias. Valve elements of the electronically controlled spill and check valves are both in a flow blocking position before the pressure of the fuel within the fuel injector reaches the predetermined valve opening pressure. Injection terminates when the valve element of the electronically controlled check valve is moved to a flow-passing position.

Abstract: A fuel injection system includes a fuel pressurizer that may be cam actuated. The fuel injection system also includes an electronically controlled spill valve and an electronically controlled needle control valve. The energization of the electronically controlled spill valve closes a fuel pressurization chamber to a drain passage to allow fuel pressure in the fuel injector to build to injection levels. The electronically controlled needle control valve controls whether high or low fuel pressure is applied to a closing hydraulic surface associated with a direct control needle valve. The fuel injection system includes a hydraulic circuitry that allows for fuel injection to occur by either maintaining the electronically controlled needle control valve in a de-energized state, or by de-energizing the same, after fuel pressure within the fuel injector has built to injection levels.

Abstract: An electromagnetic control valve is provided. The control valve includes a housing defining a bore and a fluid passageway having a seat. A valve element is slidably disposed in the bore and is moveable between a first position where a flow of fluid passes by the seat and a second position where a flow of fluid relative to the seat is blocked. A solenoid having an armature is operatively connected with the valve element. The solenoid is operable to move the valve element from the first position to the second position. A biasing assembly is operatively engaged with the valve element and is adapted to move the valve element from the second position towards the first position. The biasing assembly exerts a first force on the valve element during a first predetermined travel distance from the second position and a second force on the valve element during a second predetermined travel distance. The first force is greater than the second force.

Abstract: An electromagnetic control valve is provided. The control valve includes a housing defining a bore and a fluid passageway having a seat. A valve element is slidably disposed in the bore and is moveable between a first position where a flow of fluid passes by the seat and a second position where a flow of fluid relative to the seat is blocked. A solenoid having an armature is operatively connected with the valve element. The solenoid is operable to move the valve element from the first position to the second position. A biasing assembly is operatively engaged with the valve element and is adapted to move the valve element from the second position towards the first position. The biasing assembly exerts a first force on the valve element during a first predetermined travel distance from the second position and a second force on the valve element during a second predetermined travel distance. The first force is greater than the second force.