Caterpillar Inc.

G.w. Lisk Company, Inc.

Dale C Maley

Ronald Dean Shinogle

Oded Eddie Sturman

Dennis Henderson Gibson

Mark F Sommars

Gregory W Hefler

Dwayne E Tharp

Stephen Robert Lewis

Michael D Anderson

Darwin R Carrell

Dan R Ibrahim

Matthew S Touvelle

Steven B Coleman

David M Olson

Stephen T Konwinski

Doug Kinnear

Michel Blane Montgomery

Byron Reed Stalter

Karl Larry Sickmann

A valve-testing system for gathering information relating to the operation of a fuel injector. The valve-testing system may include a fluid-transfer system. The fluid-transfer system may include an inlet configured to receive fluid discharged by the fuel injector, an outlet, a reservoir having a first port and a second port, first plumbing connected between the inlet and the first port of the reservoir, and second plumbing connected between the second port of the reservoir and the outlet. The valve-testing system may also include a sensor configured to provide a signal relating to pressure in the first plumbing.

Valve-testing system and method employing a fluid-transfer system with a reservoir

Use of pump and line fuel injectors has become more common in fuel injection systems. While these fuel injectors do not typically include individual electrical actuators or fuel pressurization means, they still include a number of components that must be intricately machined in order for the fuel injector to perform as desired. The present invention is directed to reducing the number of machining steps, and therefore the cost, of producing such a fuel injector by utilizing a plastic component that can allow for a reliable and cost effective replacement of more intricately machined fuel injector components.

Partially plastic fuel injector component and method of making the same

A solenoid actuator, adapted for use in an electronic control valve for a fuel injector, having an electrically-energizable electromagnetic device, such as a winding, a pole member associated with the electrically energizable winding, and an armature movable with respect to the pole member. The armature occupies a first position relative to the pole member when the winding is not electrically energized and a second position relative to the pole member when the winding is electrically energized. The actuator has an adjustment screw which is movable with respect to the pole member to form an air gap of variable width internal to the pole member to change the magnetic characteristics of the solenoid actuator, and thus the response of the actuator.

Magnetically adjustable valve adapted for a fuel injector

A solenoid actuator, adapted for use in a fuel injector, has a pole member, an armature associated therewith, and an energizable winding associated with the pole member. The solenoid actuator is latchable by residual magnetism between the pole member and the armature without the aid of a permanent magnet. The pole member and the armature are composed of steel having a carbon content of between 0.8% and 1.2% and an RC hardness of between 40 and 60. The armature is reciprocable between a first position in which the armature makes physical contact with the pole member and a second position in which the armature is spaced from the pole member. The armature occupies the first position when the winding is energized and the second position when the winding is deenergized. The armature is held in the first position by residual magnetism between the pole member and the armature when the winding is deenergized after being initially energized. The actuator may also be embodied in the form of a dual-acting actuator having an armature and first and second pole members. The armature and pole member(s) of the actuator may be formed via a heat treating method which is based on the recognition of the relationship between the hardness of the pole member(s) and armature and the resultant residual magnetism of those components.

Method of forming a hard magnetic valve actuator

A hydraulically actuated fuel injector includes an injector body having a needle control chamber, a nozzle chamber, and a nozzle outlet that opens to the nozzle chamber. Fuel within the injector is hydraulically pressurized during each injection cycle. A needle valve is positioned to reciprocate in the nozzle chamber between an open position in which the nozzle outlet is open and a closed position in which the nozzle outlet is closed. The needle valve includes a closing hydraulic surface exposed to pressure in the needle control chamber. A needle control valve is mounted within the injector body and is moveable between an off position in which the needle control chamber is opened to a source of high pressure fluid and an on position in which the needle control chamber is opened to a low pressure passage.

Hydraulically-actuated fuel injector with direct control needle valve

An improved hydraulically-actuated fluid injector system comprises a hydraulically-actuated fuel pressurization member, a fluid storage chamber, and a direct-operated check. Pressurization of fluid in the storage chamber begins before the start of fluid injection. Fluid injection begins by hydraulically unbalancing the check. Fluid injection ends by hydraulically balancing the check to allow a biasing device to close the check. Preferably, actuating fluid that is spilled from the fuel pressurization member (to end fuel injection) is communicated to a hydraulic motor which drives a source of pressurized hydraulically-actuating fluid. The present invention provides improved control of several fluid injection parameters, including higher peak fluid injection capability and less fluid injection pressure drop at the end of injection, resulting in improved engine performance and lower emissions, noise, and wear. The present invention also improves efficiency of operation due to the above hydraulic energy recovery feature.

Hydraulically-actuated fluid injector having pre-injection pressurizable

A valve for use in a fuel injector includes a moveable valve member disposed in a first chamber and an armature coupled to the valve member and reciprocally disposed in a second chamber which dampens the motion of the valve member when fluid is present in the second chamber. A fluid passageway extends into the second chamber and delivers fluid to the second chamber while a further fluid passageway drains fluid from the second chamber when the fluid within the second chamber reaches a predetermined level.

Fluid damping of a valve assembly

A fuel injector assembly and a control valve for such an assembly which automatically compensate for changes in the emissions generated by the engine by changing the timing of fuel injection within the engine. The fuel injector assembly, which causes fuel to be injected during a fuel injection cycle having a start time and a stop time, includes a fuel injector nozzle, a fuel pump, and a fuel inlet associated with the fuel pump, which causes fuel to be periodically pumped from the fuel inlet through the fuel injector nozzle. A control valve, which is associated with the fuel pump and which controls the start time and the stop time of the fuel injection cycle, includes a valve body and a solenoid-actuated armature disposed in a recess in the valve body. The armature has a first side and an opposed second side and is reciprocable within the recess between a first position and a second position. A first spring is disposed on the first side of the armature to exert a first spring force on the armature in accordance with a first long-term spring characteristic, and a second spring is disposed on the second side of the armature to exert a second spring force on the armature in accordance with a second long-term spring characteristic different than the first long-term spring characteristic so that the start time of the fuel injection cycle changes over time.

Fuel injector with spring-biased control valve

A control valve assembly adapted for a fuel injector includes a valve seat with fluid inlet and fluid outlet. A poppet valve controls the flow of fluid through the valve seat. A pair of electrical actuators are selectively operably energized for releasing the poppet and moving the poppet to valve open and closed positions. Split fuel injection can be provided using either sequential operation or concurrent operation, i.e., phasing. Permanent magnets, holding current and residual magnetism enable the latching of the poppet valve in each of the valve open and closed positions.

Fuel injection control valve with dual solenoids

Hard magnetic valve actuator adapted for a fuel injector

A fuel injector assembly for a fuel injection system has a fuel pumping assembly with a fuel inlet and a fuel nozzle for causing fuel to be periodically pumped from the fuel inlet through the nozzle. The fuel injector assembly has an electro-hydraulic control valve associated with the fuel pumping means. The control valve comprises a housing, a first conduit formed in the housing and fluidly coupled to the fuel pumping means, a second conduit formed in the housing and fluidly coupled to a source of pressurized hydraulic fluid. A valve element is disposed in the housing and is reciprocable between a first position in which the first conduit is fluidly coupled to the second conduit and a second position in which the first conduit is fluidly isolated from the second conduit. The control valve also includes a pair of electrically energizable electromagnetic devices for controlling the reciprocation of the valve element. The components of the control valve are preferably composed of SAE 52100 steel so that the valve element remains latched in the first and second positions after electric current to the electromagnetic devices is turned off.

Electro-hydraulic spool control valve assembly adapted for a fuel

A fluid valve for controlling a high pressure fluid including a non-resilient valve seat with a flat seating surface. A non-resilient valve member has a concave end with an annular knife edge to sealingly engage the flat seating surface. A barrel slidably guides the valve member in movements with respect to the valve seat and forms a fluid chamber with the valve seat. The valve seat includes passageways between a high pressure valve inlet and the fluid chamber and between the fluid chamber and a valve outlet. An electrical actuator is operably energized to move the valve member into sealing engagement with the valve seat and return means disengage the valve member from the valve seat. The electrical actuator and valve member are part of an electronically-controlled fuel injector system with an injector body, a fuel injection pumping assembly with a nozzle receiving fuel from a fuel inlet to inject the fuel under pressure, and a pressure control valve assembly for controlling the fuel injection.

Electrically controlled fluid control valve of a fuel injector system

A solenoid actuator, adapted for use in an electronic control valve for a fuel injector, having an electrically-energizable electromagnetic device, such as a winding, a first pole member associated with the electrically energizable winding, and an armature movable with respect to the first pole member in a linear direction. The armature occupies a first position relative to the first pole member when the winding is not electrically energized and a second position relative to the first pole member when the winding is electrically energized. The actuator has a second pole member which is movable with respect to the first pole member in the linear direction so as to form an air gap of variable width between the first and second pole members to change the magnetic characteristics of the solenoid actuator, and thus the response of the actuator. The second pole member is movable to a position relative to the first pole member in which the second pole member is spaced from the first pole member, and biasing means are provided for maintaining the relative position of the first and second pole members. The biasing means may be provided as a spring for urging the second pole member towards the first pole member and adjustable stop means, such as a screw, disposed in contact with the second pole member.

A control valve assembly for a fuel injector includes a valve seat with fluid inlet and fluid outlet and a flat seating surface. A poppet valve has a concave end portion with knife edge for sealingly engaging the flat seating surface on the valve seat. The poppet valve is operated to close by a solenoid coil and is opened and maintained open by a return spring or a permanent magnet. Faster valve closing and faster valve opening is obtained.

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Fairbury, IL, United States of America

Dale C Maley