Abstract: In an internal combustion engine in which a head cover 3 for covering a cam shaft 2 at an upper face of a cylinder head 1 is made of a synthetic resin, a cam angle sensor 10 for the cam shaft is securely attached to the cylinder head such that heat damage to the cam angle sensor is suppressed. The cam angle sensor 10 is inserted in a through-hole 12 perforated through the head cover, and a mounting portion 14 integral with the cam angle sensor is fastened to a member 6 of the cylinder head, with fixing members 15, 16 penetrating through the head cover on a side of the cam angle sensor.

Abstract: A gas turbine engine air valve assembly has first and second valving elements. The second element is rotatable about a first axis relative to the first element. The rotation controls a flow of air through the first and second elements. An actuator is coupled by a linkage to the second element. The linkage includes a spindle having a first portion coupled to the actuator to rotate the spindle about a second axis. A guided spherical bearing couples a second portion of the spindle to the second element.

Abstract: Methods for improving the efficiency of internal combustion engines are disclosed. In one embodiment, a method of improving the efficiency of an internal combustion comprises controlling the motion of an exhaust valve associated with a cylinder of the internal combustion engine. Camshafts and internal combustion engines configured for performing methods of the instant invention are also disclosed.

Abstract: A cam cover for a cylinder head of an internal combustion engine which has an aperture in the cam cover adapted to permit spark plug installation into the cylinder head and two tabs protruding vertically from the cam cover adapted to retain a boss extending from an ignition coil is disclosed. The ignition coil has a portion adapted to fit over the spark plug and an orifice through the boss. The cam cover also has a recess between the tabs with the recess extending into the cam cover which is adapted to accept a self-tapping screw in the event of a tab failure. The tabs have a varying cross-section along their length such that they allow the orifice to be slid over the tabs by them squeezing together and then snapping into place when the orifice clears the ramps on the side of the tabs.

Abstract: A method for repairing a gas turbine engine component includes applying a braze slurry to a first portion of the component, applying a pre-sintered preform to a second portion of the component that is different than the first portion, and brazing the component.

Abstract: A method of retrofitting for electrical power generation an internal combustion engine (including a plurality of pistons connected to a common crankshaft) includes applying to at least one and optionally to each piston a power converter operable to convert mechanical energy of the piston to and from electrical energy.

Abstract: Apparatus and method for improving the fuel efficiency of a 10 kW Tactical Quiet Generator (10 kWTQG) diesel generator in the field. The apparatus includes a small turbocharger adapted to operate at very low boost and a low back pressure exhaust system. The turbocharger provides between approximately 0.5 and 3 pounds of boost over the 10 kWTQG normal operating range. No modifications are required to the 10 kWTQG fuel injection and governor system. The design of the low back pressure exhaust takes advantage of the narrow RPM range of the 10 kWTQG, and when combined with the turbocharger, meets or exceeds ambient noise level requirements. The apparatus is field installable by personnel of general skill levels present for operation of the 10 kWTQG.

Abstract: A device is disclosed for sensing the speed of an EMD 567/645/710 two-cycle diesel engine having a crankcase, electronic fuel injectors and an electronic control system for controlling the electronic fuel injectors. The device includes a spline shaft sized for insertion into the crankcase of the engine so that the spline shaft rotates with the engine, a gear operably secured to the spline shaft to rotate with the spline shaft and sized to rotate with the engine in a 1:1 ratio, and at least one electronic sensor located adjacent the gear to sense rotation of the gear. The at least one electronic sensor is connectable to the electronic control system to provide electronic signals to the electronic control system for determining when to inject fuel with the electronic fuel injectors. Also disclosed is a method for retrofitting the engine and a kit for retrofitting the engine.

Abstract: A full time lean air fuel mixture running spark ignited air cooled aircraft piston engine. In one embodiment, a drop-in substitution is provided for an equivalent make, model, and engine size, wherein the new, rebuilt, or reconfigured engine provides as much or more horsepower when compared to the original engine, but runs at a lean air fuel ratio condition during normal operating modes, including takeoff, climb, and cruise, thus saving significantly on fuel. In yet another embodiment, a drop-in substitution having a somewhat larger cylinder displacement volume may be provided to attain equivalent or enhanced maximum horsepower while operating at lean air fuel ratios. Enhanced engine life may be anticipated, since cylinder head temperatures (CHTs) may be reduced, compared to engines using rich air fuel ratios for climb and cruise conditions. Aircraft using such engines are also disclosed.

Abstract: A modification method for reducing emissions from an annular shaped combustor of a gas turbine plant, having uniformly spaced circumferentially mounted premix burners (20), includes the steps of: removing at least one burner (20), thereby disrupting the spatial uniformity of the remaining the burners (20); and modifying the combustor air distribution system so as to compensate for the increased burner pressure drop of the remaining burners, thus enabling the modified combustor to operate at a load equivalent to the unmodified combustor. Emission reduction is enabled by the increase in the gas velocity of the burner for a given load further enabled by the flame stabilizing effect of disrupting the spatial uniformity.

Abstract: A restoration process for restoring surface porosity defects resulting from the casting process in metal cast products. The areas of a cast product having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create a cast product having less than 0.05% surface porosity.

Abstract: In order to increase the displacement of a motorcycle engine, the existing cylinder block of the engine is dismounted from its crankcase, and the existing piston is dismounted from its connecting rod. Then, a new piston having a greater diameter than the dismounted existing piston is mounted on the connecting rod, and a new cylinder block having a greater bore diameter than the existing dismounted cylinder block is connected to the crankcase while sliding the new large-diameter piston along the inner wall of the bore of the new cylinder block. The new cylinder block has a bottom end that is located above the top end of the crankcase when mounted on the crankcase. The new piston is short enough not to be inserted into the crankcase when moved to the bottom dead center. This eliminates the need to disassemble the crankcase or any parts in the crankcase. It is thus possible to easily increase the engine displacement.

Abstract: An engine block with a plurality of relatively large piston bores is provided. The engine block is adapted for use of relatively large bore pistons, and preferably duel connecting rod pistons. Configured in this manner the engine block has a relatively large displacement and is especially suited for use with low btu fuels, and more particularly hydrogen.

Abstract: A process for remanufacturing valve bodies such as fuel injector valve bodies includes receiving a salvaged valve body having a first segment, a second segment and a middle segment which includes a valve seat and a guide bore for a valve therein. The process further includes removing material of the valve body where the valve seat and the guide bore are disposed, and positioning an insert within the valve body in place of the removed material. A new valve seat and a new guide bore are then machined in the insert, including locating for machining the new valve seat and new guide bore on a timing face of the valve body.

Abstract: An example method of reverse engineering component modifications includes recording identification information for components and distributing a portion of the components for modification. The method receives the components after modification and reviews the components using the identification information.

Abstract: A system and method of redimensioning a ferrous object includes applying a localized heat source to a portion of the object and raising the portion to a temperature sufficient to cause a local expansion via the formation of martensite. Subsequently, the object is quenched while in a locally expanded state to cause a selective expansion of the object that persists at room temperature. The object may be cast iron or hardened steel in an embodiment. In a further embodiment, heat is applied via an inductive heater. In an embodiment the method includes machining the object after quenching.

Abstract: A method of repairing a turbine component with one or more craze cracks therein includes the steps of: (a) routing out the one or more cracks to form one or more routed areas; (b) applying a superalloy powder/paste in the one or more routed areas; (c) heat treating the component in place to form one or more repaired areas; and (d) blending the repaired area with adjacent areas of the component.

Abstract: A converter converts mechanical energy of a piston to and from electrical energy during each piston cycle.

Abstract: Support members for a reciprocating piston internal combustion engine are disclosed. Embodiments include an engine block with support members extending between portions of the cylinder cavity and/or enhancing coolant flow for cooling the combustion cylinders. Also disclosed are support members for connection to the side walls of the cylinder cavity and support members with ears and/or holes to enhance combustion cylinder cooling. Further disclosed are methods for modifying an internal combustion engine to increase its internal support and/or cooling.

Abstract: A piezo-ceramic device is attached to the power wire of an engine to facilitate cleaner burning of fuel and improve to improve fuel consumption. In the presence of an electrical field around the power wire, the device directs acoustical energy of a subsonic frequency towards the combustion chamber which acts to ionize the fuel and impart a thrust on the piston.

Abstract: Replacement of the fuel metering jets of an internal combustion engine carburetor, such as a Holley.RTM. or Demon.RTM. Carburetor is greatly simplified by fuel float bowls which permit the jets to face upward. The jets are removed through access holes in the upper wall of the float bowl by a screwdriver/gripping tool. The float has access holes which are aligned to the upper wall holes to provide direct access to the fuel metering jets.

Abstract: Apparatus and methods to retrofit a pre-existing vehicle with a fuel cell system. The fuel cell system incorporates a fuel cell for powering an electric motor that has its rotor or armature constructed as part of a driveshaft such that the driveshaft can be turned via the electric motor or by the force of the vehicle's OEM type engine for the purpose of driving at least one wheel of the vehicle without the need for an interconnecting gearbox. The apparatus of the fuel cell system also includes an electronic control unit for controlling the fuel cell system. The electronic control unit can also control aspects of the OEM engine. The engine's OEM Engine Control Module (ECM) and the vehicle's original emission control devices are not modified or replaced in this conversion.

Abstract: A method for restoring a crack formed within a turbo charger engine transition section, the method including preparing a crack in the transition section to receive a material within the crack, applying the material within the crack, and retaining structural integrity of the transition section proximate the crack while at least one of preparing the crack and applying the material.

Abstract: A method for restoring a length of at least one of a master rod and an articulating rod, the method including determining a length of the rod, if the rod is within an acceptable length, cleaning the rod, applying a masking material to a part of the rod to be protected, grit blasting the part of the rod not protected by the masking material, and applying a thermal spray to the part of the rod not protected by the masking material to increase the length of the rod.

Abstract: Bearing bores for engine mount components must be periodically repaired. A component is disassembled and a bearing is removed from the bearing bore. An inner surface of the bearing bore is machined to remove any damage. A sizing sleeve is selected to have a press fit with the machined inner surface of the bearing bore and with the outer surface of a new bearing. The bearing is press fit into the sizing sleeve and the sizing sleeve is press fit into the bearing bore. The outer surfaces of the sizing sleeve and the bearing are swaged to assist in retaining and preventing relative movement between the bearing, sizing sleeve and engine mount component.

Abstract: A turbocharger actuator and method of calibrating for a variable nozzle turbocharger. Included are an actuator housing having a diaphragm connected across it, a piston, and a compression spring arranged to be generally centered in the actuator housing biasing the piston. Three rivets connect the actuator housing to a bracket. The diaphragm is crimped to connect to the actuator housing, which is coated with an elastomeric bead. The bracket includes three plate sections, the first having a plurality of rivet holes, and second two each having an elongated hole to receive an attachment bolt and allow sliding movement of the actuator assembly relative to the turbocharger housing.

Abstract: A method of jointly fitting or removing a piston (1) and a cylinder liner (6) in or from an engine block of an internal combustion engine, wherein during the fitting or removal operation the cylinder liner (6) is supported or held on a contact shoulder (16) which is arranged at a connecting rod (3) of the piston (1) or at the piston (1).

Abstract: A method of repairing a combustor dome with a swirler assembly having a first deflector component attached to a swirler having a first joint configuration includes: removing the first deflector component; machining a second joint configuration different from the first joint configuration in the swirler; providing a replacement deflector component having a shape complementary to the second joint configuration; and securing the replacement deflector component to the swirler

Abstract: A restoration process for restoring surface porosity defects in engine blocks cast using a high pressure die cast method. The areas of an engine block having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create an engine block having less than 0.05% surface porosity.

Abstract: An improved system and method for disassembling the valve body assembly of a motor vehicle transmission. Air automatically ejects the internal components of a valve body assembly sub-assembly, thereby eliminating the need for an operator to manually “beat” the sub-assembly to remove said internal components. The process of separating the upper and lower sub-assembly, and of pre-washing the sub-assembly, remain the same as in the prior art. As before, the operator manually removes the valve retainers and plugs in each sub-assembly. The operator then loads either sub-assembly onto tooling specifically designed for that sub-assembly (either upper or lower). Once started, the tooling begins an automated, pre-programmed sequence of (1) clamping the sub-assembly, (2) injecting air into specific valve ports to eject internal components causing them to be automatically ejected into parts bins specified for each valve port, and (3) releasing the sub-assembly that no longer contains any internal parts.

Abstract: The present invention relates to a cylinder liner made from gray cast iron, an aluminum material or a ceramic material for an engine block for an internal combustion engine. According to the invention, it is provided that the cylinder liner has a thermally sprayed layer of a low-alloy iron alloy or a bonding layer, which consists of a nickel-aluminum alloy made up of 80 to 95% by weight of nickel and 5 to 20% by weight of aluminum, on its worn running surface, and has a layer serving as a tribological running surface on top of the bonding layer. The present invention also relates to a method for producing a cylinder liner of this type and to a composite part made up of an engine block for an internal combustion engine and at least one cylinder liner of this type. The invention allows the inexpensive repair of worn cylinder liners without the need to adapt new pistons.

Abstract: The invention relates to an internal combustion engine (1) comprising a housing (2) having at least one opening (4) into its inside, which is preferably the engine-oil feed inlet, and with a camshaft (5), mounted inside the housing for rotation about its geometric shaft. The camshaft (5) and the housing (2) have means cooperating with each other and with a device for locking a turnable shaft (6) with respect to the housing, insertable through this opening. In a second embodiment of the present invention, the device consists of a rod (6), the cooperating means in the housing consist in a bore (7) for receiving an end of the rod (6), and the cooperating means on the cam shaft consist of a notch (9) made in the surface of the shaft, which cooperates with the rod. In this way, when there is a need to adjust, repair and/or replace engine (1) components, the rod (6) is inserted through the opening (4) and locked in this bore (7) of the housing (2).

Abstract: A combined master cylinder and dump valve includes a piston slideable within a body bore that defines a master cylinder for pressurizing a brake port. The piston includes a piston seal for isolating a pressure port from a tank port, a piston bore, a first piston hole set for hydraulically connecting the pressure port to the piston bore and a second piston hole set for hydraulically connecting the piston bore to the tank port. A plunger slideably received in the piston bore has a plunger hole set for selectively connecting the first piston hole set with a plunger bore, and a plunger seal arrangement for selectively isolating the first piston hole set from the plunger bore. The plunger bore is hydraulically connected to the piston bore.

Abstract: The present invention is a novel non-splined shaft for connecting cam units (cam sections) in a series to construct a camshaft having zero degree backlash for use within an engine. Such engines typically use a camshaft comprised of a plurality of separate camshaft units (cam sections) which are connected in a series by one or more cam connecting shafts. The entire series of camshaft units and cam connecting shafts may be, for example, 40 feet in length. Examples of natural gas engines in which the cam connecting shafts described herein may be used include, but are not limited to, the Ingersoll-Rand KVR and KVT series of engines.

Abstract: The present invention provides an apparatus and method for an adaptive machining and weld repair process useful for repairing airfoils, particularly damage to an airfoil leading edge and tip. The process first machines away damaged portions of an airfoil. Filler material is then added to the machined area through a process such as laser welding. At this point, the actual profile of the welded airfoil is measured using a Coordinate Measuring Machine. This data is then used to generate a “deformation” profile, an airfoil profile that approximates the ideal shape of the airfoil. The airfoil is then machined using the date of the deformation profile to produce that shape. The adaptive technology minimizes the amount of stock on material that needs to be removed by hand. The technique thereby significantly reduces costly manual processing.

Abstract: The present invention is directed towards a kit for improving the repair of a transmission. The kit contains the components in a fashion that is well organized. Further, while some individual components are stored in the kit, others are preassembled into subassemblies. For example, a subassembly can be preassembled to factory level tolerances. Thus, during the repair, the defective subassembly can be removed and the preassembled replacement can be installed. This saves a great amount of time for the repair. It also makes the refurbished transmission less likely to fail. If the kit contains all of the transmission parts, then it is likely that all or only a portion of the parts will be used during the repair. In the event that all parts are not used, the repair man can place the unused parts back into the kit, along with the used parts, and the kit can be returned for a partial refund or a credit.

Abstract: A method of converting a diesel engine to a natural gas engine comprising inserting a spark plug into a diesel fuel injector opening in a cylinder head; installing a throttle body on the diesel engine; installing a throttle body adaptor between a throttle body and an intake manifold of said diesel engine; and modifying a piston, whereby the compression ratio of said piston is decreased during operation of said piston. The method also includes installation of a waste gate and waste gate adaptor and a timing mask.

Abstract: A method for locking the sprockets or gears of a dual overhead camshaft engine in a fixed position includes two spaced bars with studs for engaging against the inside rim of the sprockets and a means for adjusting the spacing of the bars to frictionally maintain the sprockets in a locked position against the inside rims.

Abstract: A method of converting a diesel engine to a natural gas engine comprising inserting a spark plug into a diesel fuel injector opening in a cylinder head; installing a throttle body on the diesel engine; installing a throttle body adaptor between a throttle body and an intake manifold of said diesel engine; and modifying a piston, whereby the compression ratio of said piston is decreased during operation of said piston. The method also includes installation of a waste gate and waste gate adaptor and a timing mask.

Abstract: A method and apparatus for achieving reliability in starting V-Twin chain or belt-driven motorcycle engines using a conventional motorcycle battery and specially modified automotive cranking motor. The apparatus in its preferred embodiment utilizes a direct drive cranking motor configuration employing a cammed bearing clutch which is placed onto the engine's crankshaft along with a ring gear. The ring gear engages the geared shaft of the cranking motor directly, thereby bypassing the chain or belt-drive and thus effectively removing the main drive chain or belt from the cranking system. The gear ratio between the cranking motor and the ring gear may thus be selected to be optimum for the cranking motor so that the battery and cranking motor may be operated at near optimum power capabilities simultaneously.

Abstract: An arrangement for straightening a bent crankshaft is provided. In a crankshaft manufacturing process, a hardened crankshaft is measured and compared to reference tolerance specifications. If the crankshaft is determined to be out tolerance, data identifying the out of tolerance location and quantity is generated and the crankshaft is selectively induction rehardened in predetermined areas as a function of the measurement data to remedy the out of tolerance condition. The crankshaft is then remeasured and the process repeated until the crankshaft is within the reference tolerance specifications. The results can be logged to facilitate matching of subsequent detected out of tolerance conditions.

Abstract: The present application is directed to methods and systems for improving the operation of transmissions for automotive vehicles, and in particular, the “factory installed” automotive transmission installed by an original automobile manufacturer. The methods and systems modify both the structural components and hydraulic circuitry of an original automotive transmission to adjust applied pressure and shifting patterns to improve the efficient operation of the automotive transmission.

Abstract: A tool to facilitate removal of a pitman-arm mounted on a shaft includes a main frame member with a threaded center drive rod and radially spaced, depending retention arms pivotally suspended from the frame member. Rotation of the threaded drive rod causes a wedge section at the leading end of the drive rod to separate the legs of the pitman-arm as the retention arms hold the tool in place on the pitman-arm.

Abstract: An apparatus and a method is provided for pushing back caliper pistons, such as for example, single, double or quadruple caliper pistons. The apparatus may be comprised of a first rod, a second rod, and a third rod. The first rod may be connected to the second and third rods so that when the first rod moves the second and third rods also move. The apparatus may also include a first plate, wherein the first rod, the second rod, and the third rod are connected to the first plate. The apparatus may further include a second or press plate which is connected to the second rod and the third rod. The apparatus may further include a third or tube plate and a fourth or wedge plate. The second and third rods may slide through first and second openings of the third and fourth plates.

Abstract: A method of repairing a combustion turbine component having damage located at or near a cooling hole or hollow or geometrically complex portion of the component is provided. The method comprises forming a preparatory groove that extends from a surface of the component to the damaged area but does not extend to the cooling hole or hollow or geometrically complex portion of the component, the groove extending 40-90% the distance from the component to the damaged area; spraying a filler material into the groove with a micro-plasma torch at a current of less than 50 amperes; and filling the groove with the filler material such that the heated filler material substantially extends from the cooling hole or hollow or geometrically complex portion of the component to a surface of the component.

Abstract: An apparatus and a method are provided for pushing back caliper pistons, such as for example, single, double or quadruple caliper pistons. The apparatus may be comprised of a first rod, a second rod, and a third rod. The first rod may be connected to the second and third rods so that when the first rod moves the second and third rods also move. The apparatus may also include a first plate, wherein the first rod, the second rod, and the third rod are connected to the first plate. The apparatus may further include a second or press plate, which is connected to the second rod and the third rod. The apparatus may further include a third or tube plate and a fourth or wedge plate. The second and third rods may slide through first and second openings of the third and fourth plates.

Abstract: A method for increasing displacement of an internal combustion engine having at least one cylinder liner received in a cylinder bore including the steps of removing the cylinder liner from the cylinder bore, and installing a replacement cylinder liner into the cylinder bore. The removed cylinder liner has an internal diameter and an external diameter, and the replacement cylinder liner has an internal diameter and an external diameter, the internal diameter of the replacement cylinder being larger than the internal diameter of the removed cylinder liner, and the external diameters of the removed cylinder liner and the replacement cylinder liner being substantially the same. Preferably, the replacement cylinder liner is made of compacted graphite iron.

Abstract: The present invention comprises a camshaft holding tool and corresponding method for operating the camshaft holding tool in double overhead camshaft engines. In one embodiment, the holding tool includes a body portion including first and second curved portions, where each of the first and second curved portions includes two or more teeth. Each tooth of the first and second curved portions engages adjacent teeth of respective one of first and second camshaft sprockets. A method of operating the tool includes placing the tool between the first and second camshaft sprockets and rotating the tool about an axis until the teeth of the first and second curved portions engage teeth of the first and second camshaft sprockets, respectively.

Abstract: Internal combustion engine performance can be enhanced by precise cylinder firing. To accomplish this objective, a preferred billet camshaft rebuilding method provides removing and replacing the distributor drive gear on the camshaft for precise alignment therewith. The method also demonstrates the detailed steps required to carry out the camshaft rebuilding process and the manufacture of a one-part distributor drive gear. An alternate method of using a two-part distributor drive gear on a camshaft is also described for camshafts having an interior distributor drive gear.

Abstract: When the proper puller is put into the body and adjusted to fit over the mushroomed glow plug, tighten the outer body down unit it tightens against the head of the engine. Using a ¼ inch drive ratchet with the size required extension. Turn the inside of the puller tool counter clockwise while holding the body in place. Turn until damaged glow plug is clear of the engine head. Repeat the method until all mushroomed plugs are out.