Patent Publication Number: US-9903326-B2

Title: Fuel injector having a magnetostrictive actuator device

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/993,403, filed May 15, 2014, and entitled “FUEL INJECTOR HAVING A MAGNETOSTRICTIVE ACTUATOR DEVICE,” the complete disclosure of which is expressly incorporated by reference herein. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to a fuel injector, and more particularly, to a fuel injector including a magnetostrictive actuator device. 
     BACKGROUND OF THE DISCLOSURE 
     Fuel injectors are provided to control fuel flow during a fuel injection event. Such control may be accomplished by controlling the movement of a needle or nozzle valve element, such as may be accomplished by actuation of a piezoelectric actuator. Improved systems and methods of controlling the actuation of piezoelectric actuators have been developed to better control a needle or nozzle valve element. More recently, magnetostrictive materials have been used in actuator mechanisms to cause the movement of needle or nozzle valve elements. 
     SUMMARY OF THE DISCLOSURE 
     This disclosure provides a fuel injector for an internal combustion engine, comprising a fuel injector body, a magnetostrictive actuator, and a nozzle valve element. The fuel injector body includes a longitudinal axis, an upper body portion, a fuel injector cavity, and a nozzle housing having at least one injector orifice positioned at a distal end thereof in communication with the fuel injector cavity. The magnetostrictive actuator extends along the longitudinal axis and is positioned in the fuel injector cavity. The magnetostrictive actuator includes at least one annular magnetostrictive element comprised of a material configured to elongate when under tension and a coil positioned to provide a magnetic field to the at least one annular magnetostrictive element. The nozzle valve element extends along the longitudinal axis and into a first end of the at least one annular magnetostrictive element and out from a second end of the at least one annular magnetostrictive element. The at least one annular magnetostrictive element is extendable, in the presence of the magnetic field generated by the coil, to move the nozzle valve element from a closed position, blocking a fuel flow into the at least one injector orifice from the fuel injector cavity, to an open position, permitting fuel flow into the at least one injector orifice from the fuel injector cavity. The at least one magnetostrictive element is contractable to permit the nozzle valve element to move from the open position to the closed position upon removal of the magnetic field. 
     This disclosure also provides a fuel injector for an internal combustion engine, comprising a fuel injector body, a magnetostrictive actuator, and a nozzle valve element. The fuel injector body includes a longitudinal axis, an upper body portion, a fuel injector cavity, and a nozzle housing having at least one injector orifice positioned at a nozzle housing distal end in communication with the fuel injector cavity. The magnetostrictive actuator includes a longitudinally extending passage that extends from a first, distal end of the magnetostrictive actuator. The nozzle valve element extends from the nozzle housing distal end into the longitudinally extending passage. The magnetostrictive actuator is operable through magnetostrictive displacement to move the nozzle valve element from a closed position, blocking a fuel flow into the at least one injector orifice from the fuel injector cavity, into an open position, permitting fuel flow into the at least one injector orifice from the fuel injector cavity, and the magnetostrictive actuator is configured to receive a control signal to increase the magnetostrictive displacement. 
     This disclosure also provides a fuel rate shaping system for an internal combustion engine, comprising a control system and a fuel injector. The control system is configured to generate a rate shaping signal. The fuel injector is configured to receive the rate shaping signal. The fuel injector includes a fuel injector body including a longitudinal axis, a nozzle housing having at least one injector orifice, and a fuel injector cavity. The fuel injector further includes a nozzle valve element positioned in the fuel injector cavity, and a magnetostrictive actuator positioned in the fuel injector cavity to transversely overlap at least a portion of the nozzle valve element along the longitudinal axis and operable to move the nozzle valve element from a closed position in response to the rate shaping signal, blocking a fuel flow into the at least one injector orifice from the fuel injector cavity, to a plurality of open positions, permitting a variable fuel flow rate into the at least one injector orifice from the fuel injector cavity. 
     This disclosure also provides a fuel injector for an internal combustion engine, comprising a fuel injector body, a first annular magnetostrictive element, a second annular magnetostrictive element, a first annular coupler, a coil, and a nozzle valve element. The fuel injector body includes a longitudinal axis, an upper body portion, a fuel injector cavity, and a nozzle housing having at least one injector orifice positioned at a nozzle housing distal end in communication with the fuel injector cavity. The first annular magnetostrictive element has a longitudinally extending central passage. The first annular coupler is positioned transversely between the first annular magnetostrictive element and the second annular magnetostrictive element. The first annular magnetostrictive element, the second annular magnetostrictive element and the coupler are positioned in the fuel injector cavity between the upper body portion and the at least one injector orifice, and the first annular magnetostrictive element, the second annular magnetostrictive element and the coupler extend along the longitudinal axis. The coil is positioned to provide a magnetic field to the first annular magnetostrictive element and the second annular magnetostrictive element. The nozzle valve element extends along the longitudinal axis and into the central passage. The first annular magnetostrictive element is expandable in the presence of the magnetic field to apply an actuating force to move the first coupler in a direction that is longitudinally away from the at least one injector orifice. The second annular magnetostrictive element is expandable in the presence of the magnetic field to move the nozzle valve element from a closed position, blocking a fuel flow into the at least one injector orifice from the fuel injector cavity, to an open position, permitting fuel flow into the at least one injector orifice from the fuel injector cavity. The first annular magnetostrictive element and the second annular magnetostrictive element are contractable upon removal of the magnetic field to permit the nozzle valve element to move from the open position to the closed position. 
     Advantages and features of the embodiments of this disclosure will become more apparent from the following detailed description of exemplary embodiments when viewed in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic of an internal combustion engine incorporating an exemplary embodiment of a fuel injector of the present disclosure. 
         FIG. 2  is an elevation view of a portion of the fuel injector of the internal combustion engine of  FIG. 1  in accordance with an exemplary embodiment of the present disclosure. 
         FIG. 3  is an exploded view of the fuel injector of  FIG. 2 . 
         FIG. 4  is a cross sectional view of the fuel injector of  FIG. 2 , taken along the line  4 - 4 , with a nozzle or needle valve element in a closed position. 
         FIG. 5  is a cross sectional view of the fuel injector of  FIG. 4  with the nozzle or needle valve element in an open position. 
         FIG. 6  is a graph showing an exemplary fuel injector flow rate profile enabled by the exemplary embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring to  FIG. 1 , a portion of an internal combustion engine in accordance with an exemplary embodiment of the present disclosure is shown as a simplified schematic and generally indicated at  10 . Engine  10  includes an engine body  12 , which includes an engine block  14  and a cylinder head  16  attached to engine block  14 , a fuel system  18 , and a control system  20 . Control system  20  receives signals from sensors located on engine  10  and transmits control signals to devices located on engine  10  to control the function of those devices, such as one or more fuel injectors. The present disclosure provides a fuel injector including a magnetostrictive actuator that is capable of precise control of a needle or nozzle valve element, which provides the ability to perform variable spray atomization and sophisticated rate-shaping of a fuel injection event, i.e., fuel delivery and fuel energy management. Examples of rate-shaping systems and methods are described in U.S. Pat. Nos. 5,619,969, 5,983,863, 6,199,533, and 7,334,741, the entire contents of which are hereby incorporated herein by reference in their entirety. 
     Engine body  12  includes a crank shaft  22 , a plurality of pistons  24 , and a plurality of connecting rods  26 . Pistons  24  are positioned for reciprocal movement in a plurality of engine cylinders  28 , with one piston positioned in each engine cylinder  28 . One connecting rod  26  connects each piston  24  to crank shaft  22 . As will be seen, the movement of pistons  24  under the action of a combustion process in engine  10  causes connecting rods  26  to move crankshaft  22 . A plurality of fuel injectors  30  are positioned within cylinder head  16 . Each fuel injector  30  is fluidly connected to a combustion chamber  32 , each of which is formed by one piston  24 , cylinder head  16 , and the portion of engine cylinder  28  that extends between a respective piston  24  and cylinder head  16 . Throughout this specification, “inwardly,” “distal,” and “near” are terms used to describe longitudinal movement in the direction of combustion chamber  32 . “Outwardly,” “proximate,” and “far” are terms used to describe longitudinal movement away from the direction of combustion chamber  32 . 
     Fuel system  18  provides fuel to injectors  30 , which is then injected into combustion chambers  32  by the action of fuel injectors  30 , forming one or more injection events. The injection event may be defined as the interval that begins with the movement of a nozzle or needle valve element, described in more detail hereinbelow, permitting fuel to flow from fuel injector  30  into an associated combustion chamber  32 , until the nozzle or needle valve element move to a closed position to block the flow of fuel from fuel injector  30  into combustion chamber  32 . Fuel system  18  includes a fuel circuit  34 , a fuel tank  36 , which contains a fuel, a high-pressure fuel pump  38  positioned along fuel circuit  34  downstream from fuel tank  36 , and a fuel accumulator or rail  40  positioned along fuel circuit  34  downstream from high-pressure fuel pump  38 . While fuel accumulator or rail  40  is shown as a single unit or element, accumulator  40  may be distributed over a plurality of elements that transmit or receive high-pressure fuel, such as fuel injector(s)  30 , high-pressure fuel pump  38 , and any lines, passages, tubes, hoses and the like that connect high-pressure fuel to the plurality of elements. Fuel system  18  may further include an inlet metering valve  44  positioned along fuel circuit  34  upstream from high-pressure fuel pump  38  and one or more outlet check valves  46  positioned along fuel circuit  34  downstream from high-pressure fuel pump  38  to permit one-way fuel flow from high-pressure fuel pump  38  to fuel accumulator  40 . Though not shown, additional elements may be positioned along fuel circuit  34 . For example, inlet check valves may be positioned downstream from inlet metering valve  44  and upstream from high-pressure fuel pump  38 , or inlet check valves may be incorporated in high-pressure fuel pump  38 . Inlet metering valve  44  has the ability to vary or shut off fuel flow to high-pressure fuel pump  38 , which thus shuts off fuel flow to fuel accumulator  40 . Fuel circuit  34  connects fuel accumulator  40  to fuel injectors  30 , which receive fuel from fuel accumulator  40  and then provide controlled amounts of fuel to combustion chambers  32 . Fuel system  18  may also include a low-pressure fuel pump  48  positioned along fuel circuit  34  between fuel tank  36  and high-pressure fuel pump  38 . Low-pressure fuel pump  48  increases the fuel pressure to a first pressure level prior to fuel flowing into high-pressure fuel pump  38 . 
     Control system  20  may include a controller or control module  50  and a wire harness  52 . Many aspects of the disclosure are described in terms of sequences of actions to be performed by elements of a computer system or other hardware capable of executing programmed instructions, for example, a general purpose computer, special purpose computer, workstation, or other programmable data processing apparatus. It will be recognized that in each of the embodiments, the various actions could be performed by specialized circuits (e.g., discrete logic gates interconnected to perform a specialized function), by program instructions (software), such as logical blocks, program modules etc. being executed by one or more processors (e.g., one or more microprocessors, a central processing unit (CPU), and/or application specific integrated circuit), or by a combination of both. For example, embodiments can be implemented in hardware, software, firmware, middleware, microcode, or any combination thereof. The instructions can be program code or code segments that perform necessary tasks and can be stored in a non-transitory, machine-readable medium such as a storage medium or other storage(s). A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. 
     The non-transitory machine-readable medium can additionally be considered to be embodied within any tangible form of computer readable carrier, such as solid-state memory, a magnetic disk, and an optical disk containing an appropriate set of computer instructions, such as program modules, and data structures that would cause a processor to carry out the techniques described herein. A computer-readable medium may include the following: an electrical connection having one or more wires, magnetic disk storage, magnetic cassettes, magnetic tape or other magnetic storage devices, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (e.g., EPROM, EEPROM, or Flash memory), or any other tangible medium capable of storing information. 
     It should be noted that the system of the present disclosure is illustrated and discussed herein as having various modules and units which perform particular functions. It should be understood that these modules and units are merely schematically illustrated based on their function for clarity purposes, and do not necessarily represent specific hardware or software. In this regard, these modules, units and other components may be hardware and/or software implemented to substantially perform their particular functions explained herein. The various functions of the different components can be combined or segregated as hardware and/or software modules in any manner, and can be useful separately or in combination. Input/output, or I/O, devices or user interfaces including but not limited to keyboards, displays, pointing devices, and the like can be coupled to the system either directly or through intervening I/O controllers. Thus, the various aspects of the disclosure may be embodied in many different forms, and all such forms are contemplated to be within the scope of the disclosure. 
     Control system  20  may also include an accumulator pressure sensor  54  and a crank angle sensor. While sensor  54  is described as being a pressure sensor, sensor  54  may be other devices that may be calibrated to provide a pressure signal that represents fuel pressure, such as a force transducer, strain gauge, or other device. The crank angle sensor may be a toothed wheel sensor  56 , a rotary Hall sensor  58 , or other type of device capable of measuring the rotational angle of crankshaft  22  and transmitting a signal representing the rotational angle of crankshaft  22  to control system  20 . Control system  20  uses signals received from accumulator pressure sensor  54  and the crank angle sensor to determine which combustion chamber  32  is receiving fuel, which is then used to analyze the signals received from accumulator pressure sensor  54 . 
     Control module  50  may be an electronic control unit or electronic control module (ECM) that may monitor conditions of engine  10  or an associated vehicle in which engine  10  may be located. Control module  50  may be a single processor, a distributed processor, an electronic equivalent of a processor, or any combination of the aforementioned elements, as well as software, electronic storage, fixed lookup tables and the like. Control module  50  may include a digital or analog circuit. Control module  50  may connect to certain components of engine  10  by wire harness  52 , though such connection may be by other means, including a wireless system. For example, control module  50  may connect to and provide control signals to inlet metering valve  44  and to fuel injectors  30 . 
     When engine  10  is operating, combustion in combustion chambers  32  causes the movement of pistons  24 . The movement of pistons  24  causes movement of connecting rods  26 , which are drivingly connected to crankshaft  22 , and movement of connecting rods  26  causes rotary movement of crankshaft  22 . The angle of rotation of crankshaft  22  is measured by engine  10  to aid in timing of combustion events in engine  10  and for other purposes. The angle of rotation of crankshaft  22  may be measured in a plurality of locations, including a main crank pulley (not shown), an engine flywheel (not shown), an engine camshaft (not shown), or on the camshaft itself. Measurement of crankshaft  22  rotation angle may be made with toothed wheel sensor  56 , rotary Hall sensor  58 , and by other sensors or techniques. A signal representing the angle of rotation of crankshaft  22 , also called the crank angle, is transmitted from toothed wheel sensor  56 , rotary Hall sensor  58 , or other device to control system  20 . 
     Crankshaft  22  drives high-pressure fuel pump  38  and low-pressure fuel pump  48 . The action of low-pressure fuel pump  48  pulls fuel from fuel tank  36  and moves the fuel along fuel circuit  34  toward inlet metering valve  44 . From inlet metering valve  44 , fuel flows downstream along fuel circuit  34  through inlet check valves (not shown) to high-pressure fuel pump  38 . High-pressure fuel pump  38  moves the fuel downstream along fuel circuit  34  through outlet check valves  46  toward fuel accumulator or rail  40 . Inlet metering valve  44  receives control signals from control system  20  and is operable to block fuel flow to high-pressure fuel pump  38 . Inlet metering valve  44  may be a proportional valve or may be an on-off valve that is capable of being rapidly modulated between an open and a closed position to adjust the amount of fuel flowing through the valve. 
     Fuel pressure sensor  54  is coupled to fuel accumulator  40  and is capable of detecting or measuring the fuel pressure in fuel accumulator  40 . Fuel pressure sensor  54  sends signals indicative of the fuel pressure in fuel accumulator  40  to control system  20 . Control system  20  provides control signals to fuel injectors  30  that determine operating parameters for each fuel injector  30 , such as the length of time fuel injectors  30  operate and the number of fueling pulses per a firing or injection event period, which determines the amount of fuel delivered by each fuel injector  30 . 
     Referring to  FIGS. 2-5 , fuel injector  30  includes a fuel injector body  60 , a magnetostrictive actuator or magnetostrictive actuator assembly  62  positioned in fuel injector body  60 , and a nozzle or needle valve element  64  positioned for reciprocal movement in fuel injector body  60 . The reciprocal movement of nozzle valve element  64  is caused by a magnetostrictive actuating force applied by magnetostrictive actuator  62 . Because magnetostrictive actuator  62  contacts nozzle valve element  64  and the movement of components in magnetostrictive actuator  62  applies the magnetostrictive actuating force on nozzle valve element  64 , thereby moving nozzle valve element  64 , magnetostrictive actuator  62  may be described as providing direct acting control over nozzle valve element  64 . Direct acting control contrasts to conventional fuel injector control designs that indirectly move nozzle valve element  64 , such as through a valve arrangement. Fuel injector body  60  includes an upper housing or barrel portion  66 , an actuator housing  68 , a nozzle element housing  70 , a longitudinal axis  72 , and a fuel injector cavity  82 . Nozzle element housing  70  includes one or more fuel injector orifices  92  positioned at a distal end thereof. Fuel injector cavity  82  includes an actuator cavity  84 , which receives or positions magnetostrictive actuator  62 , and a nozzle element cavity  86 , which is in fluid communication with fuel injector orifices  92 . Nozzle valve element  64  extends along longitudinal axis  72  from actuator cavity  84  into nozzle element cavity  86 . 
     Upper housing portion  66  and nozzle element housing  70  are fixedly connected or attached to actuator housing  68 . In the exemplary embodiment, upper housing portion  66  includes an upper housing thread  74  and actuator housing  68  includes a mating first actuator housing thread  76 , and upper housing portion  66  attaches to actuator housing  68  by engaging upper housing thread  74  with first actuator housing thread  76 . Also in the exemplary embodiment, nozzle element housing  70  includes a nozzle element housing thread  80  and actuator housing  68  includes a mating second actuator housing thread  78 , and nozzle element housing  70  attaches to actuator housing  68  by engaging nozzle housing thread  80  with second actuator housing thread  78 . When upper housing portion  66  and nozzle element housing  70  are attached to actuator housing  68 , nozzle valve element  64  is positioned longitudinally between upper housing portion  66  and nozzle element housing  70 . 
     Fuel injector  30  further includes a fuel delivery circuit  88  that connects fuel from fuel system  18  to combustion chambers  32 . Fuel delivery circuit  88  includes a longitudinally extending fuel delivery passage  90  that is formed in upper housing portion  66 , actuator cavity  84 , and nozzle element cavity  86 . During a fuel injection event, which occurs when nozzle valve element  64  moves along longitudinal axis  72  away from an inner surface  94  of nozzle element housing  70  to permit fuel flow through fuel injector orifices  92  until a time when nozzle valve element  64  moves longitudinally to block fuel flow through fuel injector orifices  92 , fuel flows from fuel system  18  into one or more longitudinally extending fuel delivery passages  90 . From longitudinally extending fuel delivery passage(s)  90 , the fuel flows into actuator cavity  84 , then into nozzle element cavity  86 , and, after travelling to a distal end of nozzle element cavity  86 , through fuel injector orifices  92  into combustion chamber  32 . 
     Movement of nozzle valve element  64  is effected or caused by the actuating force exerted on nozzle valve element  62  by magnetostrictive actuator  62 . Magnetostrictive actuator  62  includes a coil, which may be included as part of a coil assembly  96 , and a magnetostrictive element or component. In the exemplary embodiment, magnetostrictive actuator  62  includes coil assembly  96 , a first annular magnetostrictive component or element  98 , a first annular carrier component or element  100 , which is shown partially cutaway in  FIG. 3  to permit viewing of an interior portion of first annular carrier component  100 , a second annular magnetostrictive component or element  102 , a second annular carrier component or element  104 , and a third annular magnetostrictive component or element  106 . As described hereinabove, magnetostrictive actuator  62 , which includes the aforementioned components of magnetostrictive actuator  62 , is positioned in actuator cavity  84 , which is part of fuel injector cavity  82 . First annular carrier component or element  100  and second annular carrier component or element  104  are fabricated of steel in an exemplary embodiment. 
     Coil assembly  96  includes an annular non-magnetic spacer  108  and an annular coil  110  positioned within spacer  108 , each of which extend along longitudinal axis  72 . Annular coil  110  includes a pair of wires  124  that connect annular coil  110  to control system  20 . Annular non-magnetic spacer  108  may include a plurality of longitudinally extending grooves or passages  112  that permit fuel to flow from an upper or proximate end of actuator cavity  84  to a lower or distal end of actuator cavity  84 . Thus, fuel delivery circuit  88  may include longitudinally extending grooves or passages  112 . Actuator housing  68  may include a plurality of radially extending grooves  114  that permit fuel flow from longitudinally extending grooves or passages  112  along a distal end of magnetostrictive actuator  62  and then into nozzle element cavity  86 . 
     First annular magnetostrictive component  98  has a tube-like shape that extends along longitudinal axis  72 , and in the exemplary embodiment, first annular magnetostrictive component  98  is formed of the magnetostrictive material galfenol. Galfenol is beneficial as compared to commonly used terfenol in that galfenol is more physically robust than terfenol. For example, galfenol is a ductile material configured to longitudinally expand or elongate when under certain tensile forces, withstand certain compressive forces without plastic deformation, and may be annealed or machined. Illustrative magnetostrictive actuator  62  may include galfenol and is configured to move nozzle valve element  64  a longitudinal distance sufficient for the anticipated fueling needs of engine  10 . First annular magnetostrictive component  98  is slidingly positioned within the interior of annular coil  110  and contacts a radially extending interior surface  116  formed on actuator housing  68 . 
     First annular carrier component  100  includes a first longitudinally extending central or tube portion  118 , a first upper or proximate lip  120  that extends radially outwardly from first central or tube portion  118 , and a first lower or distal lip  122  that extends radially inwardly from first central or tube portion  118 . First annular carrier component  100  is slidably positioned within the interior of first annular magnetostrictive component  98  so that upper or proximate lip  120  contacts a proximate end of first annular magnetostrictive component  98 . 
     Second annular magnetostrictive component  102  has a tube-like shape that extends along longitudinal axis  72 , and in the exemplary embodiment, second annular magnetostrictive component  102  is formed of the magnetostrictive material galfenol. Second annular magnetostrictive component  98  is slidingly positioned within the interior of first annular carrier component  100  so that a distal end of second annular magnetostrictive component  102  contacts first lower distal lip  122  of first annular carrier component  100 . 
     Second annular carrier component  104  includes a second longitudinally extending central or tube portion  126 , a second upper or proximate lip  128  that extends radially outwardly from second central or tube portion  126 , and a second lower or distal lip  130  that extends radially inwardly from second central or tube portion  118 . Second annular carrier component  104  is slidably positioned within the interior of second annular magnetostrictive component  102  so that second upper or proximate lip  126  contacts a proximate end of second annular magnetostrictive component  102 . 
     Third annular magnetostrictive component  106  has a tube-like shape that extends along longitudinal axis  72 , and in the exemplary embodiment, third annular magnetostrictive component  106  is formed of the magnetostrictive material galfenol. Third annular magnetostrictive component  106  includes a first, distal opening  152 , a second, proximate opening  154 , and a central passage  142  extending from first, distal opening  152  to second, proximate opening  154 . Third annular magnetostrictive component  106  is slidingly positioned within the interior of second annular carrier component  104  so that a distal end of third annular magnetostrictive component  106  contacts second lower distal lip  130  of second annular carrier component  104 . 
     As should be apparent from the foregoing description and from the figures, coil assembly  96 , first annular magnetostrictive component  98 , first annular carrier component  100 , second annular magnetostrictive component  102 , second carrier component  104 , and third annular magnetostrictive component  106  are positioned transversely or radially adjacent to each other, beginning at the outermost radial distance or portion with coil assembly  96  and ending at the innermost radial distance or portion with third annular magnetostrictive component  106 , also thus making coil assembly  96 , first annular magnetostrictive component  98 , first annular carrier component  100 , second annular magnetostrictive component  102 , second annular carrier component  104 , and third annular magnetostrictive component  106  concentric. Furthermore, first annular magnetostrictive component  98 , first annular carrier component  100 , second annular magnetostrictive component  102 , second carrier component  104 , and third annular magnetostrictive component  106  are positioned transversely between coil assembly  96  and nozzle valve element  64 . 
     Nozzle valve element  64  includes a radially extending protrusion  132 . Radially extending protrusion  132  includes an upper or proximate surface  134 , a cylindrical guide  136  that extends longitudinally away from proximate surface  134 , and a distal surface  138 . A proximate end of third annular magnetostrictive component  106  contacts distal surface  138  of radially extending protrusion  132 . A bias spring  140  is positioned between upper housing  66  and a proximate end of nozzle valve element  64 . More specifically, bias spring  140  contacts proximate surface  134  of radially extending protrusion  132 . Bias spring  140  is kept in position by cylindrical guide  136 , which extends into an interior of bias spring  140 . Bias spring  140  assists in keeping nozzle valve element  64  in the closed position, and also keeps third annular magnetostrictive component  106 , and thus the other components of magnetostrictive actuator  62 , biased in a distal direction by applying a bias force to proximate surface  134  of nozzle valve element  64  in the absence of a magnetostrictive actuator control signal generated by controller  50  and applied to annular coil assembly  96 . Furthermore, bias spring  140  assists in moving nozzle valve element  64  from an open position toward the closed positioned when the magnetostrictive actuator control signal is removed from magnetostrictive actuator  62 , or when the amplitude of the magnetostrictive actuator control signal is decreased. 
     Magnetostrictive actuator  62  includes a first, distal end  144 , and a second, proximate end  146 . First, distal end  144  includes a first, distal end face  148  and second, proximate end  146  includes a second, proximate end face  150 . In the exemplary embodiment, distal end face  148  and proximate end face  150  are non-planar faces. As best seen in  FIGS. 4 and 5 , nozzle valve element  64  extends longitudinally into magnetostrictive actuator  62  from distal end  144  of magnetostrictive actuator  62 . More specifically, nozzle valve element  64  extends through first, distal end face  148  into central passage  142  formed in magnetostrictive actuator  62 , and more specifically, in third annular magnetostrictive component  106 . 
     In the exemplary embodiment nozzle valve element  64  extends longitudinally from nozzle element cavity  86  through first, distal end face  148  of magnetostrictive actuator  62 , through central passage  142  entirely through magnetostrictive actuator  62 , extending longitudinally away from second, proximate end face  150  of magnetostrictive actuator  62 . Thus, nozzle valve element extends from a first side of magnetostrictive actuator  62  and longitudinally beyond a second side of magnetostrictive actuator  62 . Thus, in the exemplary embodiment magnetostrictive actuator  62  is positioned longitudinally between a proximate end of nozzle valve element  64  and a distal end of nozzle valve element  64 . In an alternative embodiment, nozzle valve element  64  may extend into distal end  144  of magnetostrictive actuator  62  and terminate within an interior of magnetostrictive actuator  62 . In the alternative embodiment, bias spring  140  may interface with third annular magnetostrictive component  106  instead of with nozzle valve element  64 . In both the exemplary embodiment and the alternative embodiment, magnetostrictive actuator  62  and the components positioned within magnetostrictive actuator  62  transversely overlap nozzle valve element  64  as well as each other. The aforementioned arrangement of magnetostrictive actuator  62  and nozzle valve element  64 , in particular, the extension of nozzle valve element  64  into magnetostrictive actuator  62 , provides fuel injector  30  with a compact arrangement that makes fuel injector  30  significantly smaller than conventional fuel injectors having a piezoelectric actuator or other embodiments of a magnetostrictive actuator. 
     Magnetostrictive actuator  62  functions as follows. Magnetostrictive actuator  62  receives the magnetostrictive actuator control signal from control system  20  by way of coil wires  124 . The magnetostrictive actuator control signal causes annular coil  110  to generate a magnetic field that extends through first annular magnetostrictive component  98 , second annular magnetostrictive component  102 , and third annular magnetostrictive component  106 . The application of the magnetic field on, or presence of the magnetic field through, each magnetostrictive component causes each magnetostrictive component to extend or elongate longitudinally. The amount of extension of each magnetostrictive component is linear and proportional to the amplitude of the magnetostrictive actuator control signal received by magnetostrictive actuator  62 . In other words, the amount of extension, or magnetostrictive displacement, of each magnetostrictive component may be increased or decreased by the control signal. Because the longitudinal movement of nozzle valve element  64  controls the flow of fuel from fuel delivery circuit  88  into injector orifice(s)  92 , and because the amplitude of the control signal determines the amount of longitudinal movement, magnetostrictive actuator  62  is configured to provide rate shaping to the fuel flow into combustion chamber  32 . As first annular magnetostrictive component  98  extends, first annular magnetostrictive component  98  applies a force or pushes against first upper or proximate lip  120 , forcing first annular carrier component  100  to move longitudinally in a direction that is toward the proximate end of fuel injector  30 . The movement of first annular carrier component  100  causes first lower distal lip  122  to apply a force to move second annular magnetostrictive component  102 , which then applies a force to second upper lip  128  to move second annular carrier component  104 . Second lower distal lip  130  of second annular carrier component  104  then applies a force to third annular magnetostrictive component  106 , causing third annular magnetostrictive component  106  to move longitudinally, applying a force or pushing against protrusion distal surface  138 , forcing nozzle valve element  64  to move longitudinally. The longitudinal movement caused by the extension of first annular magnetostrictive component  98  is toward the proximate end of fuel injector  30 , which thus forces and moves nozzle valve element  64  away from fuel injector orifice(s)  92 , permitting fuel to flow from nozzle element cavity  86  into combustion chamber  32 . 
     Second annular magnetostrictive component  102  also extends longitudinally toward the proximate end of fuel injector  30  in the presence of the magnetic field generated by annular coil  110 , contacting second upper or proximate lip  128  of second annular carrier component  104 , applying a force to move second annular carrier component  104  longitudinally with respect to first annular magnetostrictive component  98  and first annular carrier component  100 . The expansion or extension of second annular magnetostrictive component  102  toward the proximate end of fuel injector  30  causes the proximate end of second annular magnetostrictive component  102  to extend longitudinally beyond the proximate end of first annular magnetostrictive component  98 . Thus, second annular magnetostrictive component  102  and second annular carrier component  104  appear to telescope with respect to first annular magnetostrictive component  98 . The longitudinal movement of second annular carrier component  104  applies a force to cause second lower distal lip  130  to push against third annular magnetostrictive component  106 , moving third annular magnetostrictive component  106  longitudinally toward the proximate end of fuel injector  30 . The longitudinal movement of third annular magnetostrictive component  106  by the extending action of second annular magnetostrictive component  102  is also relative to first annular magnetostrictive component  98  and first annular carrier component  100 , and the contact of third annular magnetostrictive component  106  with protrusion distal surface  138  moves nozzle valve element  64 , which is an additive movement to the movement caused by first annular magnetostrictive component  98 . 
     Third annular magnetostrictive component  106  also extends longitudinally toward the proximate end of fuel injector  30  by the application or presence of the magnetic field generated by annular coil  110 , contacting and applying a force to protrusion distal surface  138  and moving nozzle valve element  64  longitudinally toward the proximate end of fuel injector  30 . The movement caused by third annular magnetostrictive component  106  is additive to the movement caused by first annular magnetostrictive component  98  and second annular magnetostrictive component  102 , thus, nozzle valve element  64  is movable by an amount sufficient to provide all anticipated fueling rates required by engine  10 . In other words, the magnetostrictive displacement may be multiplied by adding the movement of third annular magnetostrictive component  106  to the movement of first and second annular magnetostrictive components  98 ,  102 . More particularly, the movement of third annular magnetostrictive component  106  causes the proximate end of third annular magnetostrictive component  106  to move longitudinally beyond the proximate end of first annular magnetostrictive component  98  and second annular magnetostrictive component  102  in a proximate direction, appearing to telescope with respect to first annular magnetostrictive component  98  and second annular magnetostrictive component  102 . As previously noted, when the magnetostrictive actuator control signal is removed from magnetostrictive actuator  62 , first annular magnetostrictive component  98 , second magnetostrictive component  102 , and third magnetostrictive component  104  each contract, or are contractable. As first annular magnetostrictive component  98 , second magnetostrictive component  102 , and third magnetostrictive component  104  each contract, nozzle valve element  64  is permitted to move toward the closed position, which is assisted by the bias force applied by bias spring  140 . 
     Because each annular magnetostrictive component extends longitudinally with respect to at least one adjacent component, for example, first annular magnetostrictive component  98  extends relative to coil assembly  96 , second annular magnetostrictive component  102  extends relative to first annular carrier component  100 , and third annular magnetostrictive component  106  extends relative to second annular carrier component  104 , magnetostrictive actuator  62  may be described as moving in a telescoping manner. The telescoping movement may be best seen by comparing  FIG. 5  to  FIG. 4 . It should also be understood that the force applied by each magnetostrictive element is part of the magnetostrictive actuating force. Thus, the magnetostrictive actuating force is the total force exerted by first annular magnetostrictive component  98 , second annular magnetostrictive component  102 , and third annular magnetostrictive component  106  as each magnetostrictive component expands under the influence, presence, or application of the magnetic field generated by annular coil  110 . 
     Referring to  FIG. 6 , an exemplary fuel flow rate profile  200  in accordance with an exemplary embodiment of the present disclosure is shown that is made possible by the exemplary embodiment magnetostrictive actuator  62  of the present disclosure. Control system  20  generates a rate shaping signal that is received by magnetostrictive actuator  62 , which moves nozzle valve element  64  in response to the rate shaping signal beginning with a start of fuel injection. The movement of nozzle valve element  64  in response to the rate shaping signal causes fuel flow into combustion chamber  32  to vary, creating a flow rate profile, such as flow rate profile  200 . Flow rate profile  200  includes a first flow rate peak  202  shortly after a start of injection, which is followed by a flow rate decrease  204 . Fuel flow rate profile  200  then includes a fuel rate increase ramp  206 , followed by a plateau  208 , which terminates with an end of injection. Fuel flow rate profile  200  describes an injection event. The overall shape of fuel flow rate profile  200  is similar to a boot-shape injection profile, though modified with features, e.g., first flow rate peak  202  and fuel rate increase ramp  206 , made possible by magnetostrictive actuator  62 . It should be understood that fuel flow rate profile  200  is but one of an infinite number of fuel flow rate profiles made possible by the ability to precisely control the movement of nozzle valve element  64  using magnetostrictive actuator  62 . First flow rate peak  202  represents an initial quantity of fuel flowing into combustion chamber  32 . The initial quantity of fuel expands across combustion chamber  32 , followed by fuel supplied during fuel rate increase ramp  206 , and fuel supplied during plateau  208 . The initial quantity of fuel may be advantageous in fuel flow around a periphery of combustion chamber  32 , with the fuel flow during fuel rate increase ramp  206  providing a uniform spread of fuel in combustion chamber  32 . Once the initial flow of fuel occurs, the fuel flow during plateau  208  fills combustion chamber  32  to optimize the fuel flow mixture throughout combustion chamber  32 . Thus, one benefit to the magnetostrictive actuator of the present disclosure is to provide precise fuel flow control throughout a fuel injection event. 
     While various embodiments of the disclosure have been shown and described, it is understood that these embodiments are not limited thereto. The embodiments may be changed, modified and further applied by those skilled in the art. Therefore, these embodiments are not limited to the detail shown and described previously, but also include all such changes and modifications.