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there given is types of ignition system in SI engines like battery ignition system,magneto coil ignition system.
also given details about electronic fuel pump and spark plug
there given is types of ignition system in SI engines like battery ignition system,magneto coil ignition system.
also given details about electronic fuel pump and spark plug
there given is types of ignition system in SI engines like battery ignition system,magneto coil ignition system.
also given details about electronic fuel pump and spark plug
engine. UNIT-2 EME-505 I.C.ENGINES B.TECH 5TH SEM MECHANICAL ENGINEERING 2011 batch BY VINOD KUMAR YADAV MECHANICAL ENGG. DEPTT G.L.B.I.T.M BASICS OF IGNITION SYSTEM SI engine low compression ratio and high self ignition temperature of fuel so for combustion ignition source is must.
Principle: A conventional ignition system should provide sufficiently large voltage across the spark plug electrodes to affect the spark discharge.
Air is poor conductor of electricity- an air gap in an electric circuit acts as a high resistance. But when a high voltage is applied across the electrodes of a spark plug, it produces a spark across the gap.
When such a spark is produced to ignite a homogeneous A/F mixture in the combustion chamber of an engine it is called the spark ignition engine (or SI Engine). BASIC REQUIREMENT OF IDEAL IGNITION SYSTEM Supply necessary energy within a small volume in a time sufficiently short to ensure that minimum energy is lost other than that needed to establish the flame under all conditions of operation. For A/F range 12-13:1 a spark under 10 millijoules is sufficient to initiate the combustion. The system must produce and distribute high voltage of the order of 20000 volts to 22000 volts for generating spark between the electrode gap The system must have a source of electrical energy (may be a battery or a generator or a magneto). Battery voltage is usually 6 to 12 volts. This low voltage is boosted by means of an induction coil, contact breaker and a condenser to a value sufficient to meet the breakdown voltage and to release sufficient energy for spark generation.
TYPES OF IGNITION SYSTEM 1. Battery Ignition system (conventional and transistor assisted)
2. Magneto ignition system
3. Electronic ignition system
BASICS OF BATTERY IGNITION SYSTEM Distributor form the secondary circuit COMPONENTS OF THE IGNITION SYSTEM 1- A Ballast resistor: In series with primary winding to regulate primary current. The objective of BR is to prevent injury to the spark coil by overheating if the engine should be operated for a long time at low speed, or stalled with breaker in closed position.
This coil is made of iron wire, and iron has the property that its electrical resistance increases very rapidly if a certain temperature is exceeded.
The coil is therefore made of wire of such size that if the primary current flows nearly continuously, the ballast coil reaches a temperature above that where this rapid increase in resistance occurs. This additional resistance in primary circuit holds the primary current down to safe value.
For starting this resistor is by passed so that more current can flow in the primary circuit. COMPONENTS OF THE IGNITION SYSTEM
2- A cam rotating at camshaft speed operates the contact breaker points and causes them to open and close. 3- Ignition coil to step up the 6 volts or 12 volts of the battery to a high tension voltage sufficient to promote and electric spark across the electrodes of the spark plug. 4- A distributor to distribute the high voltage to different spark plugs at correct time 5- A battery : 6 volts or 12 volts (Lead acid light duty commercial vehicles : Alkaline battery heavy duty commercial vehicles) 6- Contact breaker points (CB point) : Made of hard material (tungsten) with 3 mm diameter.
COMPONENTS OF BATTTERY IGNITION SYSTEM
CONSTRUCTION OF IGNITION COIL IGNITION COIL CONSTRUCTIONAL DETAILS
The Ignition coil consist of two insulated conducting coil- primary and secondary. The primary winding is connected to the battery through an ignition switch and the contact breaker. The secondary winding is connected to the spark plugs through the distributor In order to boost the voltage the primary windings has a few hundred turns (100-300) of relatively thick wire (20 gauge) while the secondary windings contain several thousand turns (20000-22000) of thin wire (38-40 gauge enameled copper wire sufficiently insulated to withstand high voltage). More heat is generated in primary than secondary and so primary winding is wounded over secondary to dissipate heat. The two wires are also interconnected allowing the secondary windings to be earthed through the primary circuit
Ignition coil contd. WORKING OF BATTERY IGNITION SYSTEM When ignition switch closed (switch on) primary winding is connected to positive terminal post of storage battery. If primary circuit is closed through the CB point, a current flows which is called primary current Primary current produces a magnetic field in core. A cam driven CB opening mechanism opens it when spark is required When CB points are open, the current which had been flowing now flows into the condenser. As the condenser becomes charged, the primary current falls and magnetic field collapses. The collapse of the field induces a voltage in the primary winding, which charge the condenser to a voltage much higher than the battery voltage. The condenser then discharges into the battery, reversing the direction of both the primary current and the magnetic field.
WORKING OF BATTERY IGNITION SYSTEM The rapid collapse and reversal of the magnetic field in the core induce a very high voltage in the secondary winding. The secondary winding consists of large number of turns of very fine wire wound on the same core with the primary. The high secondary voltage is led to the proper spark plug by means of rotating switch (distributor). 2-MAGNETO IGNITION SYSTEM 2-MAGNETO IGNITION SYSTEM WORKING Magneto- special type of electric generator
It is mounted on the engine and replaces all the components of the coil ignition system except the spark plug and cb point - A magneto when rotated by the engine, is capable of producing very high voltage and does not need a battery as a source of external energy - The high tension magneto incorporates in itself windings to generate as well as to step up the voltage and thus does not require a separate coil to boost up the voltage required to generate the spark. - Magneto can be rotating armature type or rotating magneto type - The operation of the magneto ignition system is exactly same as that of the battery coil ignition system. In MIS as the breaker points are opened and closed with the help of a cam, the primary circuit flux is charged and a high voltage is produced in the secondary circuit
Magneto Vs Battery Ignition system S.No Battery Ignition system Magneto Ignition system 1 Requires battery: Difficult to start the engine when battery is discharged No battery, no discharge 2 More maintenance problems due to battery Less maintenance 3 Current for primary circuit is obtained from battery Current is generated by magneto 4 A good spark is available at spark plug even at low engine speed. During starting quality of spark is poor due to low speed. 5 Efficiency of system decreases with reduction in spark intensity as engine speed rises. Efficiency of system increases with increase in engine speed due to high intensity spark 6 Occupies more space Occupies less space 7 Used in cars and LCVs Used in Racing cars and two wheelers
LIMITATIONS OF BREAKER SYSTEMS AND NEED OF MODERN IGNITION SYSTEMS Contact Breaker systems: Available voltage decreases as engine speed increases due to limitations in current switching capability of the breaker system and the decreasing time available to build up the stored energy in the primary coil. Due to high current load, the breaker points are subjected to electrical wear in addition to mechanical wear which requires frequent maintenance
So there is a need to develop advanced (Modern) ignition systems (like TCI and CDI) TRANSISTORISED IGNITION SYSTEM OR TRANSISTOR ASSISTED CONTACT SYSTEM (TAC) TRANSISTOR ASSISTED CONTACT SYSTEM (TAC) The inherent property of transistor is to interrupt a relatively high current carrying circuit, i.e its ability to control a much larger current in the collector circuit with a small current in the base circuit, makes it ideal replacement for the breaker points and condenser of a conventional ignition system. The emitter (E) of the transistor is connected to the ignition coil through a ballast resistor and the collector (C) to the battery. When the cam operated contact point opens the base current and , thereby, the primary circuit current is interrupted and the normal induction coil operation follows. The current through the contact breaker is reduced by a large amount due to the fact that the contact breaker has to switch only the base current TRANSISTOR ASSISTED CONTACT SYSTEM (TAC) disadvantages Source impedance: Opposition exhibited by output terminals to an AC of a particular frequency as a result of resistance, inductance and capacitance 4-HIGH VOLTAGE CAPACITIVE DISCHARGE IGNITION OR CAPACITIVE DISCHARGE IGNITION (CDI) In CDI ignition system, a capacitor is used as a means of energy storage. It is charged to a high voltage (about 500volts) by means of a transformer and at the moment of ignition, discharged by the thyristor through the primary circuit which generates a high voltage pulse in the secondary circuit to fire the spark plug CDI Trigger box contains Capacitor, thyristor power switch (SCR), charging device (to Convert battery voltage to the charging voltage of 300 to 500 V by means of pulse Via a voltage transformer Further explanation on Transistorized Ignition System Transistorized Ignition System In automotive applications, the transistorized coil ignition systems which provide a higher output voltage and use electronic triggering to maintain the required timing are fast replacing the conventional ignition systems. These systems are also called high energy electronic ignition systems. These have the following advantages:- 1. Reduced ignition system maintenance 2. Reduced wear of the components. 3. Increased reliability 4. Extended spark plug life 5. Improved ignition of lean mixtures An ignition system using a transistor as a power switch; available as breaker-triggered TI with contact breaker or as breakerless TI with magnetic pick-up or hall generator. This type of maintenance-free electronic ignition system constantly feeds electrical power to the high tension coil(s) [also known as ignition coil(s)]. The circuit is switched on and off by a transistor circuit in the ECU or igniter assembly. This system is commonly found on motorcycles using fuel injection. The longer spark duration, a feature of this system, makes it a good choice for improving the fuel combustion and thereby lowering the exhaust gas emissions. CDI SYSTEM WORKING
Capacitor discharge ignition (CDI) or thyristor ignition is a type of automotive electronic ignition system which is widely used in motorcycles, lawn mowers, chain saws, small engines, turbine powered aircraft, and some cars. It was originally developed to overcome the long charging times associated with high inductance coils used in inductive ignition systems, making the ignition system more suitable for high engine speeds (for small engines, racing engines and rotary piston engines). Capacitor discharge ignition uses capacitor discharge current output to fire the spark plugs. ADVANTAGES OF CDI SYSTEM OVER TCI SYSTEM Further explanation on C.D.I. (Capacitive Discharge Ignition System)
Capacitor discharge ignition (CDI) or thyristor ignition is a type of automotive electronic ignition system which is widely used in motorcycles, lawn mowers, chain saws, small engines, turbine powered aircraft, and some cars. It was originally developed to overcome the long charging times associated with high inductance coils used in inductive ignition systems, making the ignition system more suitable for high engine speeds (for small engines, racing engines and rotary piston engines). Capacitor discharge ignition uses capacitor discharge current output to fire the spark plugs. C.D.I. (Capacitive Discharge Ignition System)
Electronic capacitor discharge ignition (CDI) systems have been common on large industrial engines because the technology has been in use since the 1960's. An advantage of the capacitor discharge ignition system is that the energy storage and the voltage step up' functions are accomplished by separate circuit elements allowing each one to be optimised for its job.
Capacitive discharge ignition systems work by storing energy in an external capacitor, which is then discharged into the ignition coil primary winding when required. This rate of discharge is much higher than that found in inductive systems, and causes a corresponding increase in the rate of voltage rise in the secondary coil winding.
This faster voltage rise in the secondary winding creates a spark that can allow combustion in an engine that has excess oil or an over rich fuel air mixture in the combustion chamber. The high initial spark voltage avoids leakage across the spark plug insulator and electrodes caused by fouling, but leaves much less energy available for a sufficiently long spark duration; this may not be sufficient for complete combustion in a lean burn turbocharged engine resulting in misfiring and high exhaust emissions.
Ignition in lean fuel mixtures by capacitor discharge systems can sometimes only be accomplished by the use of multi-spark ignition, where the ignition system duplicates the prolonged spark of inductive spark systems by sparking a number of times during the cycle. This adds greater stress onto the high-tension leads and can cause considerable spark plug wear and possible failure. Basic principle Most ignition systems used in cars are inductive ignition systems, which are solely relying on the electric inductance at the coil to produce high-voltage electricity to the spark plugs as the magnetic field breaks down when the current to the primary coil winding is disconnected (disruptive discharge). In a CDI system, a charging circuit charges a high voltage capacitor, and during the ignition point the system stops charging the capacitor, allowing the capacitor to discharge its output to the ignition coil before reaching the spark plug.
A typical CDI module consists of a small transformer, a charging circuit, a triggering circuit and a main capacitor. First, the system voltage is raised up to 400-600 V by a transformer inside the CDI module. Then, the electric current flows to the charging circuit and charges the capacitor. The rectifier inside the charging circuit prevents capacitor discharge before the ignition point. When the triggering circuit receives triggering signals, the triggering circuit stops the operation of the charging circuit, allowing the capacitor to discharge its output rapidly to the low inductance ignition coil, which increase the 400-600 V capacitor discharge to up to 40 kV at the secondary winding at the spark plug. When there's no triggering signal, the charging circuit is re-connected to charge back the capacitor. AC-CDI - The AC-CDI module obtains its electricity source solely from the alternating current produced by the alternator. The AC-CDI system is the most basic CDI system which is widely used in small engines.
Note that not all small engine ignition systems are CDI. Some older engines use magneto ignition. The entire ignition system, coil and points, are under the magnetized flywheel.
If the engine was rotated while examining the wave-form output of the coil with an oscilloscope, it would appear to be AC. But you must consider that since the charge-time of the coil corresponds to much less than a full revolution of the crank, the coil really 'sees' only DC current for charging the external ignition coil.
There exist some electronic ignition systems that are not CDI. Some systems use a transistor to switch the charging current to the coil off and on at the appropriate times. This eliminated the problem of burned and worn points, and provided a hotter spark because of the faster voltage rise and collapse time in the ignition coil. Most CDI modules are generally of two types: DC-CDI - The DC-CDI module is powered by the battery, and therefore an additional DC/AC inverter circuit is included in the CDI module to raise the 12 V DC to 400-600 V DC, making the CDI module slightly larger. However, vehicles that use DC-CDI systems have more precise ignition timing and the engine can be started more easily when cold. Advantages and Disadvantages of CDI
A CDI system has a short charging time, a fast voltage rise (between 3 ~ 10 kV/s) compared to typical inductive systems (300 ~ 500 V/s) and a short spark duration limited to about 50-80 s. The fast voltage rise makes CDI systems insensitive to shunt resistance, but the limited spark duration can for some applications be too short to provide reliable ignition. The insensitivity to shunt resistance and the ability to fire multiple sparks can provide improved cold starting ability.
VACUUM ADVANCE The vacuum adavnce on spark timing is necessary because the lean mixtures require an earlier spark timing than the rich mixtures. Therefore as the throttle is closed the spark must be advanced for optimum performance Vacuum advance When an engine is at idle, it experiences high manifold vacuum. If you have ever popped a vacuum line off of an idling automobile engine, then you have heard the loud hiss that results. That is manifold vacuum suction. Because the fuel is traveling so slowly and the engine is under no load, the vacuum in the engine operates the advance on the distributor, which then advances the timing so the engine idles smoothly and the spark is happening at the correct time. When the accelerator is depressed hard or when the vehicle is under a good load, there is essentially zero manifold vacuum. Therefore, the advance mechanism on the distributor is not actuated at all, resulting in no timing advance.
VACUUM ADVANCE Vacuum advance mechanism
Vehicles equipped with vacuum advanced distributors (usually older models) have a "pod" on the side of the distributor, with a rubber hose attached to it. The hose connects directly to the intake manifold of the engine so that it receives the full vacuum, or lack there of.
At idle, when the manifold vacuum is high, the tube attached to the advance pod will suck in, causing the distributor to advance the timing. There are springs inside the distributor which hold the timing mechanism in place. They remain in that position until the manifold vacuum affects them.
Newer automobiles sometimes use a centrifugal system that uses weights instead of vacuum. The problem with them is that they are based only on engine RPM (revolutions per minute) and cannot detect whether or not the engine is under a load or not. Because of that, the vacuum advanced systems are much more efficient at advancing or retarding the timing to the engine's needs. CENTRIFUGAL SPARK ADVANCE centrifugal advance mechanism The centrifugal advance mechanism advances the ignition spark as engine speed increases. This is accomplished by two weights attached to the cam. As the engine's speed and that of the distributor shaft increase, the weights move outward by centrifugal force, thereby turning the cam and causing the ignition to advance. CENTRIFUGAL ADVANCE CENTRIFUGAL ADVANCE CONTD.. As speed increases, centrifugal force on the weights moves them outwards against spring tension.
This movement causes the distributor cam or trigger wheel to move ahead. With this design, the higher the engine speed, the faster the distributor shaft turns, the farther out the advance weights move, and the farther ahead the cam or trigger wheel is moved forward or advanced. At a preset engine speed, the lever strikes a stop and centrifugal advance reaches maximum.
The action of the centrifugal advance causes the contact points to open sooner, or the trigger wheel and pickup coil turn off the ECU sooner. This causes the ignition coil to fire with the engine pistons not as far up in the cylinders.
COMPUTERIZED ADVANCE COMPUTERIZED ADVANCE The computerized advance, also known as an electronic spark advance system, uses various engine sensors and a computer to control ignition timing. The engine sensors check various operating conditions and sends electrical data to the computer
The computer an change ignition timing for maximum engine efficiency. Ignition system engine sensors include the following:-
1. ENGINE SPEED SENSOR (reports engine speed to the computer) 2. CRANKSHAFT POSITION SENSOR (reports piston position) 3. THROTTLE POSITION SWITCH (notes the position of the throttle) 4. INLET AIR TEMPERATURE SENSOR (checks the temperature of the air entering the engine) 5. ENGINE COOLANT TEMPERATURE SENSOR (measures the operating temperature of the engine) 6. DETONATION SENSOR (allows the computer to retard timing when the engine knocks or pings) 7. INTAKE VACUUM SENSOR (measures engine vacuum, an indicator of load) The computer receives different current or voltage levels (input signals) from these sensors. It is programmed to adjust ignition timing based on engine conditions. The computer may be mounted on the air cleaner, under the dash, on a fender panel, or under a seat. The following is an example of the operation of a computerized advance. A vehicle is traveling down the road at 50 mph; the speed sensor detects moderate engine speed.
The throttle position sensor detects part throttle and the air inlet and coolant temperature sensors report normal operating temperatures. The intake vacuum sensor sends high vacuum signals to the computer. The computer receives all the data and calculates that the engine requires maximum spark advance. The timing would occur several degrees before TDC on the compression stroke. This action assures that high fuel economy is attained on the road.
If the operator began to pass another vehicle, intake vacuum sensor detects a vacuum drop to near zero and a signal is sent to the computer. The throttle position sensor detects a wide, open throttle and other sensor outputs say the same.
The computer receives and calculates the data, then, if required, retards ignition timing to prevent spark knock. Mechanical Fuel Pump Mechanical Fuel Pump A mechanical fuel pump is a device that delivers fuel to the engine. Due to the fact that mechanical fuel pumps generally work best on carbureted engines, they are typically found only on older vehicles. A carburetor squats over the engine on many older cars and delivers fuel into the combustion chambers via intake ports. Some older cars ran the fuel lines below the gas tank so that gravity does the work of carrying gasoline from the tank to the carburetor. However, many older models needed a little additional help to get the fuel from the tank to the carburetor. The mechanical fuel pump, which was usually located on the side of the engine, was therefore designed to run off of the engines momentum and provide the carburetor with a steady supply of fuel. FIGURE A mechanical fuel pump. A mechanical fuel pump mounts to the side of the engine. A lever or push rod on the pump passes through an opening in the side of the engine and lines up with a special lobe on the camshaft. As the camshaft turns, the lobe moves the lever up and down, raising and lowering a flexible diaphragm inside the pump. With the motion of the diaphragm, gasoline is drawn down the fuel lines and into the pump. From there, the gasoline is pushed into the carburetor, which uses the vacuum of the engine to pull fuel into the combustion chambers.
Because diaphragm fuel pumps run directly off of the engine, they will only work when the engine is running or being started. This prevents dangerous buildups of fuel from occurring in the lines. Mechanical fuel pumps also do not pressurize the system very highly:- Most carbureted fuel systems run as low as 4 pounds per square inch (psi), and rarely ever more than 15 psi. Since diaphragm fuel pumps are located right on the side of the engine, replacing this part is relatively easy and quick. However, despite the low pressure levels of carbureted fuel systems, if you disconnect the line that feeds into a mechanical fuel pump, it will drip fuel. The fuel line is below the gas tank, so gravity will continuously pull fuel down the line if you do not plug it. You will also need to be sure that you correctly line the lever or push rod up with the engines camshaft when installing the new fuel pump, so that you do not inadvertently damage the pump when you turn the engine over.
Eventually electronic fuel injection systems, which were favored for greater accuracy and control, replaced carburetors. When this happened, cars also began to require fuel systems that ran under high pressure, generally between 40 and 60 psi. Because a mechanical fuel pump cannot support a system under that much pressure, they were eventually cast aside in favor of the higher performing electronic fuel pump. Decline of mechanical pumps
As engines moved away from carburetors and towards fuel injection, mechanical fuel pumps were replaced with electric fuel pumps, because fuel injection systems operate more efficiently at higher fuel pressures (40-60psi) than mechanical pumps can generate. Electric fuel pumps are generally located in the fuel tank, in order to use the fuel in the tank to cool the pump and to ensure a steady supply of fuel.
Another benefit of an in-tank mounted fuel pump is that a suction pump at the engine could suck in air through a (difficult to diagnose) faulty hose connection, while a leaking connection in a pressure line will show itself immediately. A potential hazard of a tank- mounted fuel pump is that all of the fuel lines are under high pressure, from the tank to the engine. Any leak will be easily detected, but is also hazardous.
Electric fuel pumps will run whenever they are switched on, which can lead to extremely dangerous situations if there is a leak due to mechanical fault or an accident. Mechanical fuel pumps are much safer, due to their lower operating pressures and because they 'turn off' when the engine stops running. WARNING: A leaky fuel pump is dangerous because the fuel may ignite and start a fire! Another way to check the pump is to disconnect the fuel line at the carburetor and place the end of the line into a container. Crank the engine to see if the pump is pushing any fuel through the line. Strong steady spurts of fuel mean the pump is working. No fuel or a weak stream means a bad pump, a plugged fuel filter, fuel line blockage or no fuel in the tank.
WARNING: Do not smoke near gasoline, and do not allow any sparks near the carburetor or open fuel line as this may ignite the fuel causing a fire! Do not spill gasoline on a hot engine. Wait until the engine has cooled to work on the fuel system. Also, avoid skin contact with gasoline and do not breathe the vapors.
Electronic Fuel Pump The fuel pump is a submersible pump with a permanent magnet electric motor. Fuel enters the pump inlet tube after passing through a sock style filter and is pushed through the pump by the motor to the outlet. Electronic Fuel Pump It consists of a motor, a vane roller pump, a fuel damper, and a relief valve to prevent system damage from over pressure. The fuel pump shares its mounting cage with the fuel gauge sending unit. Long time back when the diesel engines had not much evolved like today, to extract best performance and long life adequate fuel pressure in the lines was necessary for diesel pump & nozzles to work at their optimum. Over a period of time, the pump used to get weak leading to drop in fuel pressure in lines and laborious working of the engine. This used to result in fuel pump calibration that was a costly affair. FIGURE A typical fuel pump model assembly, which includes the pickup strainer and fuel pump, as well as the fuel-pressure sensor and fuel level sensing unit. To ensure optimum performance, additional electric fuel pump, either in the tank or near diesel filter intake used to be installed; not in all but in some where the owners were knowledgeable or the mechanic suggested so. In addition to maintaining proper fuel pressure, one problem that was the bane of all diesel owners was of air interlock that was due to, no fuel, damaged fuel line, frayed 'o' ring of the filters etc., that resulted in stalling, misfiring etc. Electric fuel pump removed the air interlock problem.
FIGURE A roller cell-type electric fuel pump. SPARK PLUG CONSTRUCTION SPARK PLUG HEAT RANGE SPARK PLUG OPERATING TEMPERATURE