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AEL501
A t
Automotive
ti Engines
E i
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M.S Ramaiah School of Advanced Studies - Bangalore
PEPM
AEL501
Session Objectives
• To understand the classification of
automotive engines.
• Study the constructional features and
arrangement of various parts of IC engines.
engines
• Discus the new developments to improve
th low-end
the l d performance
f off an engine
i
• Understand the lubrication system and
cooling system of an IC engine
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PEPM
AEL501
Topics
• Introduction to automotive engines
• 4S Petrol and Diesel engines
4S,
• Main engine components
• Cooling system
• Lubrication system
y
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AEL501
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PEPM
AEL501
Engine classification
Some engine classifications include:
• Cylinder arrangement • Type of aspiration
– In-line*, V engine, opposed – Naturally aspirated engine
ppiston / flat engine
g – Turbo
Turbo* / super charged engine
• Type of fuel burned • Number of valve / cylinder
– Diesel*
– 2 valves per cylinder*
– Petrol
– Multi
M lti valve
l engines
i
– CNG / LPG
• Valve location
– Dual fuel engine
– L – head engine
• Type of ignition
– Compression ignition* – I – head engine ( OHV)*
– Spark ignition
• Camshaft location
• Number of strokes / cycle – Overhead cam engine
– 4 – stroke cycle* – Cam in the block engine*
– 2 – stroke cycle • Combustion chamber design
• Cooling system type – Shapes: Pancake, wedge,
– Water cooled engine* hemispherical, pent roof, pre
pre-
combustion chamber
– Air cooled engine
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In-line Engines
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V- Engines
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Horizontallyy Opposed
pp
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AEL501
2. Compression stroke
• The inlet and exhaust valves are
closed.
closed
• The ppiston’s upward
p movement
compresses the air to the degree
determined by the compression
ratio (16:1 to 24:1).
• The
h air,
i in
i this
hi process, heats
h up to
9000C.
• Near the completion of the
compression
i stroke,
t k theth fuel-
f l
injection system injects the fuel at
high pressure (as much as 2000
bar in modern engines) in to hot
compressed air in the CC.
• When the cylinder reaches the
TDC the cylinder capacity is at its
TDC,
minimum.
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AEL501
3. Ignition stroke
• After the ignition lag (a few
degrees of C/s rotation) the
ignition stroke begins.
• Th finely
The fi l atomized
i d andd easily
il
combustible diesel fuel
spontaneously ignites and burns.
• As a result, the cylinder charge
heats up even more and pressure
in the cylinder
y rises.
• The mass of the fuel injected
(quality based control) determines
the amount of energy released.
released
• The pressure forces the piston
downwards. The C/s drive
translates the KE of the piston into
torque.
torque 12
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4. Exhaust stroke
• Just before the ppiston reaches
the BDC, the exhaust valve
opens.
opens
• The hot pressurized
press ri ed gases flow
flo
out of the cylinder.
• The upwards
p movement of the
piston forces the remaining
exhaust gas out of the cylinder.
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AEL501
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Piston Assembly
• The piston converts the potential
energy of the combustion gases, into
the kinetic energy that turns the
crankshaft.
• The
Th piston
i t isi a cylindrical
li d i l shaped
h d Diesel Engine Piston
hollow part that moves up and down
inside the engine's cylinder.
• It has g
grooves around its pperimeter
near the top where rings are placed.
• The wrist pin connects the piston to
the connecting rod. The connecting
rod comes up through the bottom of
the piston.
• The wrist pin is inserted into a hole
(about half way up) that goes through
the side of the piston
piston, where it is
attached to the connecting rod.
• Pistons are usually made of aluminum
alloy, because it is light and a good
h t conductor.
heat d t
Petrol Engine Piston
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AEL501
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Engine Block
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Engine Head
• The cylinder
Th li d head
h d is
i the
th metalt l partt off the
th
engine that encloses and covers the
cylinders.
• Bolted on to the top of the block, the
cylinder head contains combustion
chambers (petrol engine), water jackets
and valves (in overhead-valve engines).
• The head gasket seals the passages within
the head-block connection, and seals the Typical Diesel Engine Heads
cylinders as well.
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Typical School
M.S Ramaiah Petrol Engine HeadStudies - Bangalore
of Advanced
PEPM
AEL501
Indirect Injection:
• In indirect injection,
injection the fuel is injected into a separate chamber that is connected to the
main chamber above the piston by a narrow passage-way.
• When the piston rises toward top-dead-center, the air is forced through the connecting
passage at high velocity into the small chamber, called a swirl chamber.
• The high velocity air rotates at high velocity in the chamber as fuel is injected.
injected
• A glow plug inserted into the chamber helps during cold starting.
• This type of system relies on the high velocity air swirl to mix the air so the fuel
injection system can operate at lower pressures and be less expensive.
• After
Af the h ffuell ignites,
i i the
h combusting
b i mixturei pushes
h back
b k out through
h h the
h passage-way
where the rise in pressure does work on the piston.
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AEL501
Direct Injection:
• In the direct injection diesel engine, the
fuel is sprayed into the combustion
chamber directlyy above the piston.
p
• The piston usually has a recess or bowl
that is designed to confine the air into a
region that matches the fuel spray
trajectory.
trajectory
• This type of system relies primarily on
the momentum of the fuel spray to mix
the fuel and air.
• The indirect injection (IDI) engine is less
efficient than the direct injection (DI)
engine.
• This is because the high velocity air
motion in the combustion chamber causes
high heat transfer rates resulting in greater
loss of fuel energy.
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Valve Train
• The valve train consists of the valves
and a mechanism that opens and closes
them.
• The opening and closing system is
made up of a camshaft and rocker
arms.
arms
• The camshaft has lobes on it that move
the
h valves
l up andd down.
d Diesel Engine Cam shaft
Poppet valves
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(Advanced inlet gives more top end power at the expense of low end power, and vice-versa) 25
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Flywheels
• A flywheel is bolted to the
crankshaft flange
• The flywheel
y is also fitted
with a ring gear to which the
starter pinion meshes while
cranking the engine using
starter.
• The clutch cover with the
clutch disc are bolted to the
flywheel.
• In certain diesel engines used
on light vehicle, the flywheel
will be replaced with a DMF
for smoother, vibration free
operation.
operation 27
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Coolants
• Ethylene glycol based engine coolant concentrate
• 40 to 70 percent concentration in water
• Effective
Eff i during
d i bothb h winter
i andd summer in
i
automotive vehicle cooling systems to provide
protection against freezing, boiling and corrosion.
• A typical coolant fluid used in cooling system
consists essentially of:
– ethylene glycol
– corrosion inhibitors,
– a foam suppressor,
– sufficient
ffi i water to dissolve
di l theh additives
ddi i
• Can be poured at temperatures as low as zero
degrees
g -17.8 degrees
g C.
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AEL501
• Water pump:
– A centrifugal pump forces coolant through
the engine
g block,, cylinder
y head,, intake
manifold, hoses and radiator
– It is often driven by engine crankshaft
throughg belt
• Radiator
– Transfers coolant heat to the outside air
– N
Normally
ll mounted d iin the
h ffront off the
h engine
i
Scorpio water pump
– Consists:
• Radiator core
• Radiator tanks
• Radiator filler neck
• Transmission oil cooler
• Radiator drain cock
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Radiator Types
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Cl d system
Closed
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Thermostat
• Senses engine temperature and
controls the coolant flow through
the radiator.
• It reduces the coolant flow when Wax pellet type thermostat operation
engine is cold and increases as the
engines
g ggets warmer
• Wax pellet type is commonly used.
• When heated, the pellet expands and
ppushes the valve open.
p
• As the pellet and the thermostat cool,
the spring tension overcomes pellet
expansion and the valve closes
• Th
The rating
i off the
h thermostat
h is
i its
i
operating temperature which is
normally 82 – 91 degree Centigrade
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AEL501
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SAE Classification
• A higher viscosity oil is very thick and resists flow and
vise versa
• SAE has established an oil viscosity classification system.
system
• It is a numeric rating in which higher the number, higher
the viscosity.
• Single-viscosity oil:
– Rated and designated for a limited range of operating temperatures.
Its viscosity is not stable as multiviscosity oil
• Multiviscosity oil:
– Will exhibit operating characteristics of a thin oil light oil when
cold and a thicker, heavier oil when hot.
• Although single-
single-viscosity oils are available, most engine
oils are multiviscosity oils
oils.Ex: SAE 10W-30
• To specify engine oil,
oil both the API service designation and
the SAE viscosity grade are required.
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• Oil pump:
– Most commonly used oil pumps:
• Rotor type
• Gear type
– Both are positive displacement type
pumps.
– The output volume is proportional to
the speed of the pump.
– Pump is directly or indirectly driven by
the cam shaft or a gear at the front of
the crankshaft.
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PEPM
AEL501
• Engine oil galleries:
– The oil galleries consist of interconnecting passages
that have been drilled completely through the engine
block during manufacturing.
– The oil is routed through these passages to various parts
of the engine.
– The crankshaft also contains oil passages to route the
oil
il from
f the
h maini bearing
b i to the h connecting
i rodd bearing
b i
surfaces.
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AEL501
• Oil filters
– All the oil that leaves the pump is directed to the oil filter (Full-flow filter).
filter)
– This is to ensure that very small particles of dirt and metal carried by the oil
will not reach the close-fitting engine parts.
– From filter, oil flows into engine
engine’ss main oil gallery.
gallery
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M.S Ramaiah School of Advanced Studies - Bangalore
PEPM
AEL501
Example: Commercial vehicle engine
Specifications 6.12TCA 6.12TCE
Euro III, capability for Euro III, capability for
Emissions
Euro IV Euro IV
Configuration 6, Inline 6, Inline
Valves / Cylinder 4 4
Displacement – Lts 7.2 7.2
Bore x Stroke – mm 105 x 137 105 x 137
Combustion system
y Direct Injection
j Direct Injection
j
Injection system Mechanical Common Rail
• The combustion technology with 4 valve per 180 - 210 (132.5 - 260 - 315 (190 - 232)
cylinder and optimised fuel injection system Power Output hp (kW) @ rpm
154.5) @ 2200 @ 2200
helps in achieving the stringent BS III
emissions without any after treatment and
emissions without any after treatment and 97.8 - 112 ((960 -
P k Torque
Peak T k f
kgf-m (N ) @ rpm 89.7
(Nm) 89 7 (880) @ 1400
not even EGR system. 1100) @ 1250 - 1500
• The superior combustion technology Weight (Dry) – kg 540 570
enables to meet the futuristic emission
norms of BSIV also without any after‐ Dimensions – mm
treatment like SCR or Catalytic convertors. Length 1100 1100
Width 734 734
Height 985 985
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M.S Ramaiah School of Advanced Studies - Bangalore
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AEL501
Summary
• The classification of IC engines based on various
pparameters, and engine
g applications
pp have been
explained.
• The constructional details of the main parts of an
engine like – piston assembly, block, head and
valve mechanisms including the recent
d l
developmentst have
h been
b discussed.
di d
• The lubrication system and cooling systems of an
IC engine has been explained
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