US 4,957,085 A · Fuel injection system for internal combustion engines

Abstract

An improved fuel injector (10) having a needle valve (31) is mounted within a separate removable guide (26) for sliding movement between seated and unseated positions on a valve seat (18). Fuel injector (10) is adapted for operation in a primary fluid control mode (FIG. 5) under the influence of pressurized control fluid in a fluid chamber (30) adjacent the outer end of the needle valve (31), and for alternate operation in a secondary mechanical control mode (FIG. 6) under a mechanical mode spring (96) in the event of a decrease in operating fluid control pressure of the pressurized control fluid below a predetermined minimal amount. Continuous operation of the fuel injector (10) in the alternate operation under the mechanical spring (96) mode is automatic upon the reaching of a predetermined minimum pressure in the operating control fluid. A shutdown system is illustrated in FIG. 7 which overrides both the primary fluid control mode of operation and the secondary mechanical spring mode of operation to hold the needle valve (31) in seated position on its seat ( 18) under a fluid control pressure when certain engine conditions outside safe operating ranges are sensed. A microprocessor (98) receives input signals from sensors (98A-98H) for sensing various predetermined operating parameters of the engine and provides an output signal to a pressure regulator for controlling the pressure in the control fluid in response to the sensors (98A-98H).

Claims46

Dependent claims

An improved fuel injector adapted for use with a fuel injection system for a multi-cylinder internal combustion engine including a control fluid pressure source and a pressurized fuel source;

said fuel injector comprising:
an elongate body having a bore therein;
a fuel nozzle at an inner end of said body for projecting within an associated cylinder combustion chamber for delivery of fuel therein, a fuel chamber adjacent the fuel nozzle and having pressurized fuel therein, and a valve seat between the fuel nozzle and fuel chamber;
a valve mounted within said bore on said valve seat and movable between open and closed positions relative to said valve seat and said nozzle, said valve being in communication with pressurized fuel in said fuel chamber and urged toward an open unseated position by said pressurized fuel for providing fuel to said nozzle for discharge into an associated cylinder;
a pressurized control fluid chamber in said body adjacent said valve and having pressurized control fluid therein for urging said valve toward a closed seated position on said valve seat to block the flow of fuel to said nozzle under a primary fluid control mode of operation;
a mechanical mode spring in said body operable upon the decrease in pressure of said control fluid below a predetermined minimum amount for urging said valve toward a seated closed position on said valve seat, said mechanical mode spring comprising a compression spring acting against the outer end of said valve for urging said valve toward a seated position;
and
means to maintain said mechanical mode spring in an inoperable position during the primary fluid control mode of operation;
said bore of said body including a guideway in which said valve is mounted for longitudinal movement between seated and unseated positions relative to said valve seat, said control fluid chamber being positioned adjacent the outer end of said guideway with pressurized control fluid therein providing a fluid seal between said valve and said guideway, and cushioning the movement of said valve to an unseated open position.

6 more elements

An improved fuel injector adapted for use with a fuel injection system for a multi-cylinder internal combustion engine including a control fluid pressure source and a pressurized fuel source;

said fuel injector comprising:
an elongate body having a bore therein;
a fuel nozzle at an inner end of said body for projecting within an associated cylinder combustion chamber for delivery of fuel therein, a fuel chamber adjacent the fuel nozzle and having pressurized fuel therein, and a valve seat between the fuel nozzle and fuel chamber;
a valve mounted within said bore on said valve seat and movable between open and closed positions relative to said valve seat and said nozzle, said valve being in fluid communication with pressurized fuel in said fuel chamber and urged toward an open unseated position by said pressurized fuel for providing fuel to said nozzle for discharge into an associated cylinder;
a control fluid chamber in said body adjacent said valve and having pressurized control fluid therein for urging said valve toward a closed seated position on said valve seat to block the flow of fuel to said nozzle under a primary fluid control mode of operation;
a mechanical mode spring in said body operable upon the decrease in pressure of said control fluid below a predetermined minimum amount for urging said valve toward a seated closed position on said valve seat, said mechanical mode spring comprising a compression spring acting against the outer end of said valve for urging said valve toward a seated position;
means to maintain said mechanical mode spring in an inoperable position during the primary fluid control mode of operation;
and
spring retaining means for holding said compression spring in an inoperable position during operation of said fuel injector in the fluid control mode, said spring retaining means and said compression spring being activated upon the reduction of said fluid control pressure to a predetermined amount to permit said compression spring to urge said valve toward seated position.

6 more elements

An improved fuel injection system for a cylinder of an internal combustion engine comprising:

a fuel injector having a fuel discharge nozzle adjacent an end thereof for discharge of fuel into the cylinder and adapted to be operated under the influence of a pressurized control fluid in a primary mode of operation and alternatively under the influence of a mechanical mode spring in a secondary mode of operation when the pressurized control fluid reaches a predetermined minimal amount, said fuel injector having an elongate body and a needle valve guide carrier adjacent the inner end of said body receiving a removable sleeve to define a guideway;
a valve in said injector movable between an open position to permit fuel flow to the nozzle and a closed position to block fuel flow through the nozzle, said valve comprising a needle valve mounted within said sleeve and defining an annular clearance between said needle valve and sleeve of a radial thickness around 2-5 microns;
means to supply pressurized fuel to said valve to urge said valve toward an open position for supply of fuel to said nozzle;
means to supply pressurized control fluid to said valve to urge said valve toward a closed position against the urging of said fuel, said valve moving to open position upon a reaching of a predetermined pressure differential between said pressurized fuel and said pressurized control fluid;
a mechanical mode spring mounted in said fuel injector for selectively acting against said valve for urging said valve to a closed position against the urging of said pressurized fuel;
and
means for maintaining said mechanical mode spring in an inoperable position during operation of said injector in the primary mode of operation when said fluid control pressure is above a predetermined minimum amount, said maintaining means being responsive to a decrease in control fluid pressure below a predetermined minimum to activate said mechanical mode spring for acting against said valve to urge said valve toward a closed position against the urging of said pressurized fuel.

4 more elements

An improved fuel injection system for a cylinder of an internal combustion engine comprising:

a fuel injector having a fuel discharge nozzle adjacent an end thereof for discharge of fuel into the cylinder and adapted to be operated under the influence of a pressurized control fluid in a primary mode of operation and alternatively under the influence of a mechanical mode spring in a secondary mode of operation when the pressurized control fluid reaches a predetermined minimal amount;
a valve in said injector movable between an open position to permit fuel flow to the nozzle and a closed position to block fuel flow to the nozzle;
means to supply pressurized fuel to said valve to urge said valve toward an open position for supply of fuel to said nozzle;
means to supply pressurized control fluid to said valve to urge said valve toward a closed position against the urging of said fuel, said valve moving to open position upon a reaching of a predetermined pressure differential between said pressurized fuel and said pressurized control fluid;
a mechanical mode spring mounted in said fuel injector for selectively acting against said valve for urging said valve to a closed position against the urging of said pressurized fuel;
and
means for maintaining said mechanical mode spring in an inoperable position during operation of said injector in the primary mode of operation when said fluid control pressure is above a predetermined minimum amount, said maintaining means being responsive to a decrease in control fluid pressure below a predetermined minimum to activate said mechanical mode spring for acting against said valve to urge said valve toward a closed position against the urging of said pressurized fuel;
said valve being mounted for sliding movement between open and closed positions relative to said nozzle and said fuel injector having an elongate guideway receiving said valve with pressurized fuel being supplied adjacent one end of said guideway and fluid control pressure being supplied adjacent the opposite end of said guideway, the control fluid pressure forming a seal between the valve and guideway.

5 more elements

An improved fuel injection system for a cylinder of an internal combustion engine comprising:

a fuel injector having an elongate body with a bore therein and a fuel discharge nozzle adjacent an end of the body for discharge of fuel into the cylinder, said fuel injector adapted to be operated under the influence of a pressurized control fluid in a primary mode of operation and alternatively under the influence of a mechanical mode spring in a secondary mode of operation when the pressurized control fluid reaches a predetermined minimal amount;
a valve in said injector movable between an open position to permit fuel flow to the nozzle and a closed position to block fuel flow to the nozzle;
means to supply pressurized fuel to said valve to urge said valve toward an open position for supply of fuel to said nozzle;
means to supply pressurized control fluid to said valve to urge said valve toward a close position against the urging of said fluid, said valve moving to open position upon a reaching of a predetermined pressure differential between said pressurized fuel and said pressurized control fluid;
a mechanical mode spring mounted in said fuel injector for selectively acting against said valve for urging said valve to a closed position against the urging of said pressurized fuel;
means for maintaining said mechanical mode spring in an inoperable position during operation of said injector in the primary mode of operation when said fluid control pressure is above a predetermined minimum amount, said maintaining means being responsive to a decrease in control fluid pressure below a predetermined minimum to activate said mechanical mode spring for acting against said valve to urge said valve toward a closed position against the urging of said pressurized fuel, said maintaining means including a mode control piston mounted within said bore of said injector body and responsive to said control fluid pressure;
a mode control rod extending from said mode control piston operatively connected to said mechanical mode spring;
and
a lost motion connection extending between said valve and said mechanical mode spring to permit opening and closing of said valve relative to said compression spring in the primary mode of operation under the influence of fluid control pressure.

6 more elements

An improved fuel injection system for a multi-cylinder internal combustion engine comprising:

a fuel injector having an elongate body with a bore therein defining a guideway, a fuel chamber adjacent the inner end of said guideway, and a pressurized control fluid chamber adjacent the outer end of said guideway;
a fuel discharge nozzle adjacent the inner end of said elongate body and in communication with said fuel chamber, a valve seat between the fuel chamber and said fuel discharge nozzle, and a valve mounted within said guideway for reciprocal movement between seated closed position and unseated open position relative to said valve seat;
a main pressurized control fluid supply line extending to said injector and said control fluid chamber;
a fuel pump in fluid communication with said fuel chamber for supplying pressurized fuel to said fuel chamber;
an engine driven control fluid pump in fluid communication with said main control fluid supply line for supplying pressurized control fluid to said control fluid chamber;
said valve having its inner end exposed to pressurized fuel in said fuel chamber and its outer end exposed to pressurized control fluid in said control fluid chamber for unseating of said valve upon the reaching of a predetermined fluid control pressure differential between said pressurized fuel and said pressurized control fluid for operation of said fuel injector under a primary fluid control mode;
a mechanical mode compression spring mounted within the bore of said fuel injector body for selectively acting against said valve for urging said valve to seated position on said valve seat;
means for selectively maintaining said mechanical mode spring in an operable position during operation of said injector under said primary fluid control mode, said maintaining means responsive to a decrease in control fluid pressure operating below a predetermined minimum to activate said mechanical mode spring for urging said valve toward a seated position on said valve seat against the urging of said pressurized fuel for providing a secondary mechanical mode of operation for said fuel injector;
a spindle mounted between the outer end of said valve and the inner end of said compression spring with said spring urging said spindle toward said valve;
a mode control piston responsive to control fluid pressure mounted within said body bore and having a mode control rod secured thereto and extending to said spindle;
and
a lost motion connection between the inner end of said mode control rod and the outer end of said spindle whereby upon a predetermined operating control fluid pressure being exerted against a side of said mode control piston, said spindle is maintained out of contact with said valve to permit independent operation of said valve under the primary control mode of operation.

9 more elements

In a fuel injection system for a multi-cylinder internal combustion engine;

an injector having an elongate body with a nozzle adjacent one end thereof for providing fuel to a cylinder of the internal combustion engine;
a needle valve mounted within said elongate body for sliding movement;
a fuel chamber at one end of said needle valve adjacent said nozzle;
a control fluid chamber at the other opposite end of said needle valve;
a fuel passage in said injector body for the supply of fuel to said fuel chamber;
a pressurized control fluid passage in said injector body for the supply of a pressurized control fluid to said control fluid chamber;
a valve seat in said fuel chamber adjacent said nozzle with said needle valve moving between seated and unseated positions relative to said valve seat in response to a predetermined pressure differential between the fuel in said fuel chamber and the control fluid in said control fluid chamber;
a pressure regulator for said control fluid;
a microprocessor providing an output signal for said pressure regulator for varying the pressure of said control fluid in response to operating conditions of the internal combustion engine;
a plurality of sensors for predetermined operating parameters of said engine providing input signals to said microprocessor whereby the pressure of said control fluid is varied according to predetermined operating parameters of said engine, said engine being a diesel engine and the operating parameters of said engine being sensed by said sensors include the air intake pressure, the air intake temperature, the exhaust gas temperature, the combustion chamber temperature, and the rotational speed of the crankshaft;
and
a separate removable guide sleeve mounted in said elongate body and receiving said needle valve therein for sliding movement, said needle valve and said sleeve defining an annular space therebetween in fluid communication with said control fluid chamber, said control fluid filling said annular space and contacting the opposed surfaces forming said annular space in a capillary action to provide a high fluid tension effect along said opposed surfaces thereby to center said needle valve and prevent the penetration of heavy diesel fuels within the annular space.

9 more elements

A fuel injector adapted for use with a fuel injector system for a multi-cylinder internal combustion engine having a pressurized fluid control and pressurized fuel supply comprising;

an elongate injector body having a fuel nozzle at an inner end thereof for projecting within an associated cylinder combustion chamber for delivery of fuel therein, a fuel chamber adjacent the fuel nozzle, a valve seat between the fuel chamber and the fuel nozzle, and a valve guideway having an inner end adjacent the fuel chamber;
a valve having a main body mounted within said guideway for sliding movement and an inner end for seating on said valve seat in a closed position, and a control fluid chamber adjacent the outer end of said guideway with said valve having its outer end in fluid communication with said fluid chamber;
a fuel passage in said injector body extending to said fuel chamber for providing pressurized fuel to the fuel chamber for urging said valve toward open position for opening of the valve to provide fuel to the fuel nozzle;
and
a fluid control passage in said injector body extending to said fluid chamber for providing control fluid to said control fluid chamber for normally urging said valve into seated closed position, said valve moving to open position upon the reaching of a predetermined fluid pressure differential between said fuel and said control fluid and reseating upon a predetermined reduction of said pressure differential;
said control fluid in said control fluid chamber providing a continuous fluid seal between said valve and said guideway and cushioning the movement of said valve to an open position.

3 more elements

An improved fuel injector adapted for use with a fuel injector system having a fluid control pressure source and a pressurized fuel source;

said fuel injector comprising;
an elongate body having a longitudinally extending bore therein and defining a longitudinally extending guideway;
a fuel nozzle at an inner end of said body for discharging fuel therefrom;
a fuel chamber positioned between the fuel nozzle and the inner end of said guideway;
a valve seat between the fuel nozzle and the fuel chamber;
a needle valve having a generally cylindrical main body mounted within said guideway for sliding movement between open and closed position on said valve seat and having an inner end exposed to pressurized fuel in said fuel chamber, said needle valve defining an annular clearance between the needle valve and the bore of said body;
a fluid control chamber adjacent the outer end of said guideway and having pressurized control fluid therein exposed to the outer end of said needle valve for urging said needle valve toward a closed seated position on said valve seat, said valve moving to an unseated position upon the reaching of a predetermined fluid pressure differential between said fuel and said control fluid and reseated upon a predetermined reduction of said pressure differential, said pressurized control fluid in said fluid chamber providing a continuous fluid seal between said valve and said guideway for cushioning the movement of said valve to an unseated open position and preventing the penetration of contaminated heavy fuels in the annular clearance between said needle valve and guideway.

4 more elements

An improved fuel injector adapted for use with a fuel injector system having a fluid control pressure source and a pressurized fuel source;

said fuel injector comprising:
an elongate body having a longitudinally extending bore therein and defining a longitudinally extending inserted guideway;
a fuel nozzle at an inner end of said body for discharging fuel therefrom;
a fuel chamber positioned between the fuel nozzle and the inner end of said inserted guideway;
a valve seat between the fuel nozzle and the fuel chamber;
a valve having a generally cylindrical main body mounted within said inserted guideway for sliding movement between open and closed position on said valve seat and having an inner end exposed to pressurized fuel in said fuel chamber;
a control fluid chamber adjacent the outer end of said guideway and having a control fluid pressure therein exposed to the outer end of said valve for urging said valve toward a closed seated position on said valve seat, said valve moving to an unseated position upon the reaching of a predetermined fluid pressure differential between said fuel and said control fluid and reseated upon a predetermined reduction of said pressure differential, said control fluid pressure in said fluid chamber providing a continuous fluid seal between said valve and said guideway and cushioning the movement of said valve to an unseated open position;
a mechanical compression spring in said body bore outwardly of said valve and guideway;
and
a lost motion connection between the valve and the inner end of the spring to permit movement of said valve between open and closed positions relative to said spring for a fluid control mode of operation of said valve.

7 more elements

A fuel injector adapted for use with a fuel injection system having a fluid control pressure source and a pressurized fuel source;

said fuel injector comprising;
an elongate body having a longitudinally extending bore therein and defining a longitudinally extending inserted guideway;
a fuel nozzle at an inner end of the body for discharging fuel therefrom;
a fuel chamber positioned between the fuel nozzle and the inner end of said guideway;
a valve seat between the fuel nozzle and the fuel chamber;
a valve having a generally cylindrical main body mounted within said guideway for sliding movement between open and closed positions on said valve seat and having an inner end exposed to pressurized fuel in said fuel chamber;
a mechanical compression spring in said body bore outwardly of said valve and said guideway;
a spindle between the outer end of said valve and the inner end of said compression spring and urged by said spring toward said valve member;
a piston responsive to fluid control pressure mounted within said body bore and having a mode control rod secured thereto and extending to said spindle;
and
a lost motion connection between the inner end of said mode control rod and said spindle, said piston and mode control rod being responsive to a fluid control pressure greater than a predetermined minimum amount to engage said spindle and hold said spindle and spring out of engagement with said valve to permit movement of said valve between open and closed positions relative to said compression spring, said piston and control rod upon a decrease in fluid control pressure below a predetermined minimum permitting said spindle to contact said valve under urging from such compression spring for operation of said valve under the influence of said mechanical spring.

8 more elements

A fuel injection system for operating a fuel injector for a multi-cylinder internal combustion engine in a primary fluid control mode and alternatively in a secondary mechanical spring mode in the event of a decrease in the operating fluid control pressure below a predetermined minimum;

said system comprising:
a high pressure fuel line connected to said fuel injector;
a fuel pump for supplying pressurized fuel to said fuel injector through said high pressure fuel line for delivery into an associated cylinder combustion chamber;
a main fluid supply line to said fuel injector:
a fluid reservoir and an associated pressure accumulator for maintaining the control fluid under a predetermined pressure;
an engine driven fluid control pump in fluid communication with said reservoir for supplying pressurized control fluid to said fuel injector through said main supply line for operation thereof in a primary fluid control mode;
an auxiliary air operated pump in fluid communication with said reservoir and said main fluid supply line;
a shuttle valve between said air operated pump and said engine driven fluid pump blocking supply of control fluid from said air operating pump when said engine driven fluid control pump is supplying control fluid at a predetermined minimal fluid pressure;
means for sensing the fluid control pressure in said main control fluid supply line;
and
means responsive to said sensing means when the control fluid supplied to said fuel injector reaches a predetermined minimal amount to stop the supply of control fluid to said fuel injector from said engine driven fluid control pump and from said auxiliary air operated pump.

8 more elements

An improved fuel injection system for a multi-cylinder internal combustion engine comprising:

a fuel injector having an elongate body with a bore therein defining a guideway, a fuel chamber adjacent the inner end of said guideway, and a control fluid chamber adjacent the outer end of said guideway;
a fuel discharge nozzle adjacent the inner end of said elongate body in fluid communication with said fuel chamber, a valve seat between the fuel chamber and said fuel discharge nozzle, and a valve mounted within said guideway for reciprocal movement between seated closed position and unseated open position relative to said valve seat;
a main control fluid supply line extending to said injector and said control fluid chamber;
a fuel pump in fluid communication with said fuel chamber for supplying pressurized fuel to said fuel chamber;
a primary engine driven fluid control pump in fluid communication with said main control fluid supply line for supplying pressurized control fluid to said control fluid chamber;
a secondary independent air operated pump in fluid communication with said control fluid chamber for supplying fluid control pressure to said control fluid chamber when said primary engine driven control fluid pump is inoperable;
and
shuttle valve means in said main control fluid supply line permitting supply of control fluid to said main supply line from said secondary air operated pump only when said primary engine driven control fluid pump is inoperable and not providing pressurized control fluid to said main supply line.

5 more elements

Dependencies are inferred from the claim text.

Fuel injection system for internal combustion engines

Life of this patent

Fuel injection system for internal combustion engines

Life of this patent

Abstract

Claims46