Caterpillar Inc.

Mingchun Dong

Dana Ray Coldren

Alan Ray Stockner

Ronald Dean Shinogle

Scott Alan Leman

Daniel Richard Ibrahim

David E Martin

Sean Olen Cornell

Richard H Holtman

Avtar S Sandhu

Michael R Huffman

Virl R Voights

An electronically controlled fuel injector includes a reduced part count and complexity over similar fuel injectors without a substantial reduction in performance capabilities. This is accomplished by using a one-piece needle that is hydraulically balanced and biased toward a closed position with a spring positioned in the needle control chamber. Although subtle, this injector has some ability to control the fuel pressure when the needle valve is opening and closing by adjusting a relative timing of a pressure control valve opening relative to a needle control chamber, using separate electrical actuators. The invention is particularly applicable to fuel injectors that cycle through high and low pressure states during and between injection events, respectively. Cam actuated fuel injectors being particularly well suited.

Electronic unit injector with pressure assisted needle control

A fuel injector includes an auxiliary valve member that can assist in raising a mean injection pressure, increase a nozzle valve opening pressure, and hasten the closure rate of a nozzle valve member over an equivalent fuel injector without the auxiliary valve. The auxiliary valve member is fluidly positioned between a needle control chamber and a high pressure space, which includes a fuel pressurization chamber within the fuel injector. The auxiliary valve member includes a closing hydraulic surface exposed to fluid pressure in the high pressure space. The plumbing and the auxiliary valve member allow high pressure fuel to act upon a closing hydraulic surface of the nozzle valve member to increase valve opening pressure and mean injection pressure. The needle control chamber may be vented or may be a closed volume when the auxiliary valve member is in its closed position. The invention is potentially applicable to any fuel injector, but finds the preferred application in cam actuated fuel injectors that include an electronically controlled spill valve.

Fuel injector with auxiliary valve

Fuel injectors equipped with direct control needle valves can add new capabilities to a fuel injection system, but can sometimes have difficulty in achieving low hydrocarbon emissions at levels comparable to ancestor fuel injectors that utilize a simple spring biased needle. The present invention seeks lower hydrocarbon emissions by reducing fuel pressure before the direct control needle valve member has reached its closed position toward the end of an injection event. Reducing fuel pressure can be accomplished in a number of ways depending upon the particular fuel injection system, including spilling fuel pressure in a cam system or possibly relieving pressure on an intensifier piston. By employing this strategy, fuel spray from the fuel injector can effectively end before the direct control needle valve member reaches its closed position, thus avoiding hydrocarbon production that could be caused by a small amount of fuel pushed into the combustion space as the needle moves over the last portion of its movement toward its closed position.

End of injection rate shaping

A unit injector assembly is provided that helps to ensure maximum injection flow while minimizing the harmful affects of pressure waves within the unit injector assembly. The unit injector assembly has a first fuel passageway extending from the plunger piston pumping chamber to the tip check stem injection chamber and valve seat. The unit injector assembly has a second fuel passageway extending from the tip check stem injection chamber to a fuel control valve assembly. A flow restricting fuel passageway connects one of the pumping chamber and the first fuel passageway with the second fuel passageway and acts to minimize cavitation at the valve seat and effectively eliminates pressure waves within the unit injector assembly.

Unit injector with stabilized pilot injection

An actuator for adjusting a clearance between an end of a valve and an end of the actuator. The actuator has a piston therein having a central bore of which a portion is threaded. The piston has an end and has a flat defined near the end. The actuator has a stem member positioned therein. The stem member has a central portion which is threadedly positioned within the threaded portion of the central bore. The stem member defines a first end and a second end, and a threaded portion is located near the second end. The first end of the stem member and the end of the piston has a predetermined length which is adjustable. The predetermined length is adjusted by threadedly rotating the stem member relative to the piston. A locking device fixes the predetermined length during operation of the engine.

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Bloomington, IL, United States of America

Mingchun Dong