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Engine Principles 1 Chonan Technical Service Training Center Engine Principles Chapter 1. What is the Engine?. 2. Kinds of Engine. 3. Engine layout. 4. Expansive force and nertia!orce. ". #eciprocal Engine. $. Exhaust and nta%e &tro%e. +. Engine structure.,. -iesel Engine. 1. Nternal (o) ustion and / otor. 11. 0
Engine Principles 1 Chonan Technical Service Training Center Engine Principles Chapter 1. What is the Engine?. 2. Kinds of Engine. 3. Engine layout. 4. Expansive force and nertia!orce. ". #eciprocal Engine. $. Exhaust and nta%e &tro%e. +. Engine structure.,. -iesel Engine. 1. Nternal (o) ustion and / otor. 11. 0
Engine Principles 1 Chonan Technical Service Training Center Engine Principles Chapter 1. What is the Engine?. 2. Kinds of Engine. 3. Engine layout. 4. Expansive force and nertia!orce. ". #eciprocal Engine. $. Exhaust and nta%e &tro%e. +. Engine structure.,. -iesel Engine. 1. Nternal (o) ustion and / otor. 11. 0
Engine Principles Engine Principles Chapter 1. What is the Engine? 1. What is the Engine?............................... 2. Kinds of Engine..................................... 3. Engine layout........................................ 4. Expansive force & nertia !orce............... ". #eciprocal Engine.................................. $. Exhaust & nta%e &tro%e........................ '. (o)pression & (o)*ustion &tro%e........ +. Engine structure.................................... ,. -iesel Engine........................................ 1.. nternal (o)*ustion & /otor................ 11. 0ean 1urn Engine................................ Chapter 2. Cylinder block and Moving parts 1. (ylinder 1loc%....................................... 2. (ylinder 0iner........................................ 3. Water 2ac%et......................................... 4. Piston................................................... ". Piston #ing........................................... $. (onnecting #od..................................... '. (ran%shaft............................................ +. (ran% (ase........................................... ,. 2ournal 1earing..................................... 1.. !ly3heel.............................................. 11. 1alance shaft4 1alancer for secondary inertial force....................................... Chapter 3. Cylinder Head 1. (ylinder 5ead........................................ 2. (a) & (a)shaft................................... 3. -riving the (a)shaft............................. 4. nta%e & Exhaust 6alve.......................... ". 6alve -riving &yste)............................. $. 6alve 7i)ing.......................................... '. 6aria*le 6alve 7i)ing............................. +. /alfunction of 6alve.............................. ,. 8verrun & #ed 9one.............................. Chapter 4. Intake yste! 1. Enhance the 6olu)e Efficiency............... 2. nta%e nertia Effect & Pulsation Effect.... 3. 6aria*le nta%e &yste).......................... 4. nta%e &yste)....................................... ". 7hrottle 6alve & /anifold....................... Chapter ". E#ha$st yste! 1. Exhaust &yste).................................... 2. Exhaust nertia Effect & Pulsation Effect.. 3. (o)ponent of Exhaust :as.................... 4. ;ir<!uel #atio & Exhaust (o)ponent....... ". Exhaust Purification &yste)................... $. 1lo3<*y :as #ecirculation -evice............ Chapter %. Charger 1. 7he Kind of (harger............................... 2. 7ur*ocharger......................................... 3. 1oost Pressure & (o)pression #atio..... 4. 7ur*o 0ag............................................. ". &upercharging &yste) & 5eat................ $. &upercharger........................................ Chapter &. '$brication yste! 1. #ole of Engine 8il.................................. 2. 0u*rication /ethod................................ 3. Parts of 0u*rication &yste).................... 4. Engine 8il............................................. Chapter (. Cooling yste! 1. (ooling &yste)..................................... 2. #adiator................................................ 3. (ooling of the (ylinder 5ead.................. 4. 8ver 5eat............................................. Chapter ). *$el yste! 1. (ar*uretor............................................ 2. /echanical !uel n=ection &yste)........... 3. Electrical !uel n=ection &yste).............. 4. !uel &upplying &yste)........................... Chapter 1+. Ignition yste! 1. Point type gnition.................................. 2. !ull 7ransistor type gnition..................... 3. -istri*utor<less gnition.......................... 2 Chonan Technical Service Training Center Engine Principles 4. &par% Plug............................................ Chapter 11. Co!b$stion and Co!b$stion Cha!ber 1. (o)*ustion Process.............................. 2. ;>! ratio & !la)e 6elocity...................... 3. gnition 7i)ing....................................... 4. &3irl Effect........................................... ". Knoc%ing............................................... $. ;*nor)al (o)*ustion............................ '. &hape of (o)*ustion (ha)*er.............. +. nta%e<Exhaust 6alve & (o)*ustion (ha)*er................................................... ,. Piston & (o)*ustion (ha)*er............... Chapter 12. ,er-or!ance. *$el cons$!ption. /oise. and 0ibration 1. #e?uired Perfor)ance.......................... 2. What is 8utput?................................... 3. #epresenting /ethod for Po3er.............. 4. What is 7or?ue?.................................... ". 7o enhance Po3er................................. $. &>1 ratio & 8utput................................ '. (o)pression #atio & 8utput.................. +. Enhancing 8utput *y 5igh rp)................ ,. 7ransient (haracteristic & #esponse...... 1.. (ylinder ;rray & Perfor)ance............... 11. !uel (onsu)ption #atio....................... 12. 8utput & !uel Efficiency....................... 13. !uel Efficiency of 6ehicle...................... 14. 6i*ration of the Engine......................... 1". @oise of the Engine....................................... 3 Chonan Technical Service Training Center Engine Principles Chapter 1. What is the engine? 1. What is the engine? 7his *oo% introduces a*out the auto)o*ile engine especially the gasoline engine. 5o3ever4 it is very co)plicated to define a*out the engine4 so called4 3hat the engine is. n general concept4 the engine is the devices driving so)ething *y changing the energy in the natural source such as fire4 3ind or electric )aterial to the )echanical energy continuously. 7here are )any types of the engine and they are driven in different 3ays. 7herefore4 3e can define the gasoline engine4 as a %ind of co)*ustion device in other 3ord4 the device changing the heat ac?uired *y co)*usting the gasoline to the )echanical force for driving the vehicles. 5o3 is the heat energy changed into the )echanical energy? !or exa)ple4 the *ottle or pot. ;s they are heated4 the covers )ove 3ith a noise. 7he heat ac?uired fro) the gas or electric energy *oils the 3ater so as to )a%e the 3ater vapor pushing up the cover of the *ottle or pot. 7here is an i)portant thing. 7he )oving force is not co)e fro) the heat energy4 *ut the hot air or vapor *y the heat 3or%s. 7hat is4 the )edia is need for changing the energy for). 7his )edia is the 3or%ing fluid in the technical ter)inology. 7he 3or%ing fluid for 4 Chonan Technical Service Training Center Engine Principles the gasoline engine is the air in<ta%en 3ith the gasoline into the engine and then co)*usted and exhausted. !uel (o)*ustion 5eat :eneration ;ir Expansion Pressure :eneration Piston /ove)ent 7he procedure for trans)itting the fuel to the )echanical energy in the vehicle engine 3ill *e explained in the follo3ing sections. n this process4 the 3or%ing fluid is the air. f there is no 3or%ing fluid4 the energy transfor)ation shall not *e perfor)ed. n contrary4 thin% a*out the transfor)ing the )echanical energy to the heat energy. n the vehicle4 the *ra%e is the represented exa)ple. 7he principle is the friction heat co)ing fro) the ru**ing or stri%ing the t3o )aterials. We can 3ar) our hands *y ru**ing each other4 that is4 the )oving forceAru**ingB can easily transfor) to the heat energyA3ar)ing handsB. ;t this ti)e4 there is no 3or%ing fluid. 7he force is changed into heat directly. 5o3ever4 3hen the heat energy is transfor)ed into the )echanical energy4 there )ust *e a 3or%ing fluid. 1eing the )edia for the transfor)ing the energy4 there should *e a lot of loss of energy4 at any case. 7herefore4 ho3 )uch energy of the heat can *e transfor)ed into the )echanical energy4 the efficiency4 is an i)portant factor in the engine. 2. 1inds o- engine 7here are )any %inds of the engines. 7he engines can *e classified *y the nu)*er of cylinder4 the array style of the cylinder or the e?uipped )ethod at the vehicle4 and so on. ;s you %no34 the engine )a%es the driving force *y the reciprocal )ove)ent of the piston in the cylinder so that the po3er is decided *y the nu)*er of the cylinder. 7herefore4 the engine is )ainly classified *y the nu)*er of the cylinder. 7he co))ercial vehicles are classified into the 24 34 44 "4 $4 +4 and 12 cylinders. /ore displace)ent volu)e has the )ore cylinders. ;ccording to the array of the cylinder4 there are three types including the n<line type 3ith serial arraying of the cylinder4 the 6 type 3ith 6< shaped arraying of the cylinder and the opposed type in 3hich the cylinders are arrayed facing each other. ;ccording to the engine installation type4 there are t3o typesC the one is the length3ise type and the *readth3ise type. When the engines are arrayed in length direction of the vehicle is called as the length3ise type4 3hen the engines are arrayed in 3idth direction of the 5 Chonan Technical Service Training Center Engine Principles vehicle is called as the *readth3ise type. 0ength3ise type 1readth3ise type !or exa)ple4 the !# type car having the engine at front and driving the rear 3heels has the length3ise type engine. 7he reason is that the propeller shaft trans)itting the driving force to the rear 3heels shall *e run underneath the floor. n the case of !! type car4 the )ost s)all car4 having the engine at front and driving the front 3heels4 the engine is *readth3ise type *ecause that the rotation axis of the engine and the driving axis rotating the 3heels should *e are parallel. 5o3ever4 3hen the !! type car has the $<cylinder engine4 if the serial engine is installed in 3idth direction4 then the 3idth of the car is too 3ide. 7herefore4 in that case4 the engine rather is the 6<type. n this )anner4 considered 3ith the displace)ent volu)e and vehicle type4 the engine array type and the installation type are selected for the *est co)*ination in design. 3. Engine layo$t !! D !ront Engine !ront -rive !# D !ront Engine #ear -rive /# D /idship Engine #ear -rive ## D #ear Engine #ear -rive t is possi*le to assu)e that the engine 3ill *e installed at the front of the car. 5o3ever4 the all vehicles do not have their engine at front side. n 1''.4 the origin of the car4 the engine of the stea) car of (ugnot 3as located at the front ends of the *ody. n 1++"4 the first car e?uipped the gasoline engine4 the engine of the -ai)lerEs car is located at the under the seat and the front of the rear 3heel axis. n the history4 )any researches had *een perfor)ed to find the *est condition 3here the engine 3as installed. n 1+,14 the !# Afront engine rear driveB car 3as in !rance. 7he !# type is that the engine 3as installed at the front side and the rear 3heels 3ere driven. ;fter that4 this type 3ould *e the set as the standard layout of the engine. Fntil no34 the )ost large passenger cars and the sports cars accept this type. 7he typical characteristics of the !# type car is that the ca*in space is located to rear side4 the steering is controlling the front 3heels and the driving is contri*uted to the rear 3heels so that the operation and 3eight load are evenly divided to the front side and rear side and the )ove)ent perfor)ance and passenger convenience are *alanced as 3ell as the vi*ration and noise are less than other types. 6 Chonan Technical Service Training Center Engine Principles n the layout of the relatively s)all pu*lic car4 there had *een t3o *ig develop)ents for a*out hundred years. 7he first one is the 6ol%s3agen in 1,3$ having the engine at the rear side for driving the rear 3heel. ;fter the World War 4 this type 3as leading the 3orld3ide design of the )ainstrea) the passenger car of rear engine and rear drive A##B type. 7he second one is the /ini of England in 1,",. 7he /ini accepted the front engine and front drive A!!B type having the *readth3ise type engine at front side for driving the front 3heels. @o3adays4 this type is applied to the s)all cars as 3ell as the )iddle siGed sedans. 7he !! type car has the engine and driving devices at the front side so that it should not applied to the car of 3hich 3eight is concentrated to the front side. 7he defect of this type is that it is not easy to steer the car. 5o3ever4 it has the relatively large space of indoor and trun%4 and the safety is *etter than other types. 7herefore4 it is the *est design for the layout of the utility cars. 7he )idship engine and rear drive A/#B type is focused on the perfor)ance rather than the convenience of the passenger so that it is )ainly applied to the sports cars. When the )ain parts of the engine are located at front side than the rear 3heel type4 it is called the )idship type. When the )ain parts are located at rear side4 it is called the rear engine type. 4. E#pansive *orce and Inertia *orce ;l)ost of the co))ercial gasoline engines for the vehicles are the #ecipro<engines except for the rotary engine of 3hich 3or%ing principle is different. 7he 3ord H#eciproI co)es fro) the H#eciprocatingI. 7he reciprocation is the )echanical )ove)ent of go and *ac% so that the #ecipro<engine is the device transfor)ing the reciprocal )ove)ent to the rotational )ove)ent using the cran% 3hich is the device having the pro)inence and depression shape. 7 Chonan Technical Service Training Center Engine 0ayout & 6ehicle !eatures Engine Principles 7he cross sectional vie3 of the #ecipro<engine sho3s that there is a piston reciprocal )oving in the cylinder at the upper side and there is a cran%shaft at the lo3er side and the piston and the cran%shaft are connected *y the connecting rod. 7he gasoline engine uses the air as the )edia of 3or%ing fluid for transfor)ing the heat energy to the )echanical energy. 7he air is )ixed 3ith the )ist of gasoline in the cylinder. When the )ixture of air and gasoline are co)pressed using the piston and co)*usted4 then the expansive gas 3ill press the piston. 7he expansive force pressing the piston shall drive the car. ;t this ti)e4 except for the expansive force4 there is an inertia force 3hich 3e are considering. 7his force is so)e3hat strange *ecause it is not generated intentionallyC ho3ever4 this force is follo3ed in the )oving part of the engine naturally. 7herefore4 it can affect to the perfor)ance of engine or is the source of the vi*ration or noise. (onsidering the reciprocal )ove)ent of the piston4 the piston starts )oving fro) the halt state at the highest position of the stro%e4 has the )axi)u) speed at the )iddle of the stro%e4 ;fter that4 the speed is reduced and stops to the lo3est position of the stro%e4 and then goes *ac% to the highest position again. -uring perfor)ing these )ove)ents4 the inertia forces shall *e generated 3hen the speed of )ove)ents are changed. !or exa)ple4 fro) the highest position of the piston to the )iddle of the stro%e4 there is an ascending inertia force. ;fter that there is a descending inertia force fro) the )iddle of the stro%e to the lo3est position of the piston. When this inertia force is resonated 3ith the other inertia forces fro) the other pistons4 there )ay *e vi*rations or noises. ". 2eciprocal Engine 8 Chonan Technical Service Training Center Engine Principles 7he #ecipro<Engines are classified into t3o types4 the 2<cycle type and the 4<cycle type. ;fter developed *y -ai)ler of :er)any in 1++34 the 4<cycle type 3hich had *een co)pleted its standard syste) until 1,.. is the )ainly used in the )ost of vehicles. 7he principle of the reciprocal engine is that the )ixture of the air and the gasoline are in=ected into the cylinder4 the )ixture is co)*usted using the electric spar% to explode4 the co)*ustion force drives the piston in reciprocal )ove)ent4 and the reciprocal )ove)ent is changed to the rotational )ove)ent *y the cran%shaft. 3he operation o- the 44cycle engine is li%e that. When the piston is at the highest position4 the inta%e valve is opened. 1eing do3n the piston4 the )ixtures of fuel gas is in=ected into the cylinder and then the inta%e valve is closed Jnta%e &tro%eK. @ext4 the piston 3ill go to up3ard to co)press the )ixtures of gas J(o)pression &tro%eK. 7hen4 the co)pressed )ixtures of gas 3ill *e *urnt *y an electrical ignition J(o)*ustion &tro%eK. 7he *urnt gas having the high pressure and te)perature 3ill press the piston do3n3ard. ;t this ti)e4 the exhaust valve shall *e open to ta%e out the *urnt gas JExhaust &tro%eK. 7hese stro%es are repeated. ;)ong these 4 stro%es4 only at the co)*ustion stro%e4 the engine )a%es the po3er for 3or%. 7herefore4 there are needed the additional forces4 for inta%e and exhausting the gas at the inta%e and exhaust stro%e4 and for co)pressing the )ixture at the co)pression stro%e. 7o do so4 a fly3heel is installed to the cran%shaft to )a%e these additional forces using the inertia force to ensure the continuous rotational )ove)ent.
3he 24cycle engine co)prises of the t3o stro%es. 7he operation of this engine co)prises the four co)ponents such as the inta%e4 the co)pression4 the co)*ustion4 and the exhaust as the 4<cycle engine. (o)pression and Expansion 9 Chonan Technical Service Training Center Engine Principles Exhaust and nta%e 5o3ever4 *efore and ;fter the piston is located at the highest position4 the co)pression and co)*ustion operations are perfor)ed4 and *efore and ;fter the piston is located at the lo3est position4 the exhaust and inta%e operation at the sa)e ti)e. &o4 through the t3o stro%es4 the one cycle of engine operation is co)pleted. 7he 4<cycle engine perfor)s the co)*ustion stro%e at one ti)e per t3o cycles of the cran%shaft4 *ut4 the 2<cycle engine perfor)s the co)*ustion stro%e at every cycle of cran%shaft. 7herefore4 the 2<cycle has higher efficiency. &cavenging ;dditionally4 it has no inta%e and exhaust valves so that it has si)ple structure and lo3 cost. 5o3ever4 this )erit can *e a defect. 7he exhaust gas is exhausted *y the entering ne3 )ixtures of gas 3hen the piston is located at the lo3est position. 7herefore4 so)e ne3 )ixtures 3ill *e )ixed the co)*usted gas and un*urned gases 3ill *e exhausted. t )a%es the air pollutions and the large fuel consu)ptions. %. E#ha$st 5 Intake troke 7his content 3ill explain a*out the engine on focusing the 4<cycle gasoline engine4 the )ost used type. 7o understand the 4 stro%es4 the inta%e4 the co)pression4 the co)*ustion4 and the exhaust4 it is helpful to refer the figures4 the indicator diagra) AP<6 diagra)B4 sho3ing the process of the engine operations. t loo%s so)e3hat co)plicated4 *ut it is easy to understand =ust follo3ing the figures. 10 Chonan Technical Service Training Center Engine Principles 7he indicator diagra) is the graph consisting of the horiGontal axis representing the pressure of the cha)*er and the vertical axis representing the volu)e of the cha)*er. ;t the left ends of the graph4 ( and !4 the piston is located at the highest position of the cylinder4 and at the right ends of the graph4 : and 54 the piston is located at the lo3est position of the cylinder. 1y co)paring the lines of the graph to the 4 stro%es4 the line of ;<1 is the inta%e stro%e4 the line of 1<( is the co)pression stro%e4 the line of (<- is the co)*ustion stro%e and the line of -<E is the exhaust stro%e. n act4 the cycle of the stro%es is starting fro) the inta%e stro%e. 7o understand the engine operation4 it is easy to start fro) the exhaust stro%e. 7o inhale )ore air as possi*le4 the engine uses also the force fro) the exhausted gas outgoing to the outside of the engine through the exhaust port. 7he exhaust stro%e is for pushing the co)*usted gas to outside of the cha)*er *y )oving the piston fro) the lo3est position to the highest position 3ith *eing opened exhaust valve. n principle4 it is thin% that the exhaust valve 3ill *e opened 3hen the piston is reaching at the lo3est position. Exhaust stro%e 5o3ever4 actually4 the exhaust valve prefers to *e opened *efore the piston reaches to the lo3est position4 that is4 at the position of - in the dra3ing. #e)aining the pressing force of the *urent gas4 the exhausting the used gas is )ore effective *y opening the exhaust valve in advance. ;fter that4 the piston 3ill push out the re)ained used gas thoroughly to finish the exhaust stro%e. ;t the inta%e stro%e4 the inta%e valve is opened4 and the piston goes do3n fro) the highest position to the lo3est position so that the )ixtures of fuel gas and the air are inhaled into the cylinder fro) the inta%e port. ;t that ti)e4 the inta%e valve shall *e opened =ust *efore the piston reaches the highest position4 that is4 the E in the dra3ing. -oing so4 the inta%e operation is enhanced so)e3hat *ecause of the exhausting force of the used gas 3ill pull the inta%e gases. nta%e stro%e 11 Chonan Technical Service Training Center Engine Principles With the sa)e )anner4 the inta%e valve shall *e closed 3hen the piston is at the 1. -oing so4 )ore )ixtures of gas shall *e inhaled into the cylinder *y the inertia force of the inta%e gas. 7o inhale air into the engine is perfor)ed *y the difference of air pressure. When the piston goes do3n4 the air pressure in the cylinder is lo3er than that of the outside of the cylinder4 so that the air around the inta%e valve shall *e inhaled to the cylinder. 7he opening ti)ing of the valve is different fro) the stro%e position is to use this force to inhale )ore air as possi*le &. Co!pression and Co!b$stion troke ;t the co)pression stro%e4 the )ixtures of gas are co)pressed *y the piston4 so that the pressure is increased and the te)perature is high *y adia*atic co)pression. 7herefore4 the gasoline is vaporiGed *y the co)pressive heat of the air4 ready to *e co)*usted. 7he in=ected gasoline in the cylinder li%e the )isty 3ith the air is vaporiGed to *e gas state *y the heat fro) the adia*atic co)pression. 7hen it is ready to *e co)*usted easily. 7his space for co)*ustion is called the co)*ustion cha)*er. 7he reason of that it is hard to start the engine in 3inter is that it is hard for the gasoline to *e vaporiGed. 7o solve this pro*le)4 one )ethod is to )ix )ore gasoline 3ith the air. ;nother pro*le) is thatC 3hen the gasoline is vaporiGed4 the a)*ient heat is used to the vaporiGation4 so the te)perature of the cha)*er is lo3ered so)e3hat. t )ay decrease the fuel efficiency of the engine. 7o prevent fro) lo3ering the fuel efficiency4 the a)ount of the gasoline is reduced. 5o3ever4 to do so4 the te)perature of the cha)*er is so high that the co)*ustion )ay *e perfor)ed prior to the ignition4 so called the a*nor)al co)*ustion. 7he )ost i)portant fact fro) the inta%e stro%e to the co)pression stro%e is the flo3 of the )ixtures of the gasoline and the air. t is not proper that the flo3 is too strong to *e ignited. 7he little particles of gasoline should *e )ixed 3ith air to *e the )ixtures. 7herefore4 )any )anufacturers research and develop the shape of the inta%e port and flo3 pattern of the )ixtures so that the strength and the pattern of the )ixture flo3 are )aintained until the co)*ustion stro%e for the *est efficiency of the engine. (o)pression stro%e ;s processing the co)pression stro%e4 the piston reaches the highest position. When the piston is at the ( of the dra3ing4 the ignition 3ill *e perfor)ed *y the electric spar% generated fro) the spar% plug. 7he ti)ing to )a%e the spar% is very i)portant. 7he )ixture 12 Chonan Technical Service Training Center Engine Principles is not fully co)*usted at the ignition ti)e4 *ut the co)*ustion is started fro) the ignition. t is needed so)e ti)e interval *et3een the ti)e of the ignition and the ti)e to *e )axi)u) pressure of the cha)*er. (o)*ustion stro%e 7he ignition ti)ing is deter)ined *y considering that the co)*ustion shall *e co)pleted *et3een the highest position and the al)ost half position of the co)*ustion cha)*er. ;dditionally4 this co)*ustion speed is proportion to the rotational speed of the engine so that the ignition ti)ing should *e ad=usted 3ith the engine speed. 1eginning the co)*ustion4 the vaporiGed )ixtures are co)*usted in a short ti)e so that the pressure and the te)perature are increased. ;t this ti)e the expanded gas *y the co)*ustion shall press the piston. 7his pressing force should *e stronger as possi*le. 7he ti)e period of co)*ustion is prefera*le to *e short to strength the force. f the ti)e period for co)*ustion is longer4 then the co)*ustion force is not leading the pressing the piston *ut follo3ing the piston. 7herefore4 the engine efficient is 3orst. 7he co)*ustion ti)e period is affected *y flo3 of the )ixtures defined *y the siGe and shape of the co)*ustion cha)*er and the co)ponent of the )ixture and so on. (. Engine str$ct$re 7he gasoline engine is a co)plicated )achine having co)prising of parts. 0oo% into ho3 the engine is structured. 7he engine is si)ilar 3ith the 3 floors *uilding. 7he first floor is the cran% case including the cran%shaft transfor)ing the reciprocal )ove)ent to the rotational )ove)ent. 7he second floor is the cylinder *loc% including the cylinder of 3hich a piston is )oving 3ith reciprocal )ove)ent. 7he third layer is the cylinder head. n this structure4 the )oving parts of the first layer and the second layer are called as the !ain !oving part. t includes the piston4 the cran%shaft and the connecting rod. n the third layer4 there are the valves controlling the inta%e and exhaust of the )ixtures gas and the used gas and the ca)shaft operating the valves. 7hese are called the cylinder head syste!. 8n the cylinder head4 there are inta%e )anifold sending the gasoline and the air to the cylinder and the exhaust )anifold ta%ing out the *urnt 13 Chonan Technical Service Training Center Engine Principles gas. 7hese are called the intake4e#ha$st syste!. 7he )anifold consists the H)anyI and the HfoldI4 that is4 )any )aterials are co)*ined. n actual4 they are )any *ranched pipes distri*uting the air and gasoline to each cylinder or )erging the exhausted gases in one place. 7here is the -$el syste! including the fuel pu)p ta%ing the gasoline fro) the fuel tan% and the car*uretor or fuel in=ector to )a%e a air fuel )ixture. 7here is the l$brication syste! including the oil pu)p supplying the oil for reducing the frictions and the oil filter for filtering the oil. ;lso there is the cooling syste! including the radiator and 3ater pu)p for )aintaining the te)perature of the engine properly. 7o drive the engine4 the electric po3er is needed. 7here are electric devices including igniting spar% plug4 the alternator generating the electric po3er and the start )otor supplying the initial )ove)ent to the engine. ;dditionally4 there are the a$#iliaries such as the oil pu)p for the po3er steering the air<con co)pressor and so on. ,. 6iesel Engine 7he diesel engine has si)ilar shape and structure 3ith those of the gasoline engine. 7he different point is the ignition )ethod. 7he gasoline engine ignites the )ixture of fuel 3ith the electric spar%. (ontrary4 in diesel engine4 the fuel is in=ected into the co)pressed air having the high te)perature. When the air is co)pressed4 the te)perature of co)pressed air is increased. 7he gasoline engine co)presses the )ixture of fuel gas up to 1>1. of the initial volu)e. 14 Chonan Technical Service Training Center Engine Principles 7he diesel engine co)presses the air a*out 1>2. of the initial volu)e to increase the te)perature of the air over $..L4 and in=ects the fuel co)pressed 3ith over 1.. at) at the in=ection pu)p during 1>1...M2>1... seconds. 7he output shall *e controlled *y the a)ount of in=ected )ixtures of fuel and air for the gasoline engine. 8n the other hand4 the output of the diesel engine can *e controlled *y the a)ount of the in=ected fuel 3ithout controlling the air Athe fixed a)ount of the airB. 7o co)*ust the fuel perfectly *y increasing the te)perature of the air4 the co)pression ratio shall *e increased. 5o3ever4 doing so4 the expansion po3er 3ill *e increased also. 7herefore4 the engine should *e stronger to endure the increased force. ;dditionally4 the high ?uality of fuel in=ecting pu)p )ay *e needed. 7hen the engine is heavier and the cost is expensive. &o diesel engine is not proper to apply to the passengerEs car. n the diesel engine4 *ecause al)ost constant a)ount of the air a*out the volu)e of the cylinder is inhaled4 the load applying to the engine is relatively light. When the fuel a)ount is s)all at the lo3 speed4 the fuel shall *e al)ost perfectly co)*usted. 5o3ever4 3ith the full load4 the diesel engine needs )ore a)ount of fuel so that the air a)ount is respectively s)all. 7herefore4 it )ay exhaust a lot of *lac% s)o%e. n the gasoline engine4 the ignition is perfor)ed *y the electric spar% to the )ixture so the co)*ustion ti)e period is very short. 5o3ever4 in the diesel engine4 the fuel diesel is sprayed into the co)pressed air4 so it needs so)e ti)e period to *e vaporiGed. 7herefore4 the )axi)u) speed of engine is li)ited relatively lo3er and the output shall *e lo3er than the gasoline engine. (o)pared 3ith the gasoline engine4 the expansion force and the inertia force of the )oving part are *igger so it )a%es *igger noise and )ore vi*ration. t has )erits of easy )aintenance resulted fro) not having the delicate parts such as the ignition syste) and of good fuel efficiency so that it is used for co))ercial or *usiness purpose rather than passengerEs car. 1.. Internal Co!b$stion 5 Motor 7he force of the 4<cycle gasoline engine4 as one of the internal co)*ustion4 is changed according to the #P/ A#evolutions Per /inuteB of the engine co)pared *y the electric )otor or the stea) engine. &o4 it is i)possi*le to drive 3ith the lo3er revolutions than certain #P/ value. 7herefore4 the clutch and the trans)ission should *e e?uipped 3hen the gasoline engine is used for vehicles. !or the 4<cycle engine4 using the four stro%es4 it )a%es )oving force *y co)*usting the )ixture of fuel and air in the cylinder. t is very different 3ith the electric )otor used in electric vehicles 3hich can start =ust *y applying the electric po3er. f the )ixtures are not supplied into the cylinder at idle condition4 the engine can not continue to run. n order that the engine should *e operating continuously 3hen the vehicle is stopped4 the device for connecting or disconnecting the )oving force of the engine to 15 Chonan Technical Service Training Center Engine Principles the 3heels such as clutch should *e e?uipped. n general4 the vehicles needs larger po3er 3hen it is started or accelerated4 *ut 3hen it is driven in constant speed4 it does not need larger po3er. !or the )otor4 it outputs larger force 3hen it rotates 3ith lo3er #P/4 and 3hen the #P/ is increased4 the output 3ill *e lo3er. 7herefore4 the electric )otor can *e applied to the engine of the vehicles 3ithout any trans)itting device. 5o3ever4 for the gasoline engine4 the po3er is deter)ined according to the #P/ of the engine. 7he range of the #P/ is li)ited 3ithin certain ranges. !or exa)ple4 the #P/ of the gasoline engine is a*out '..M'... revolutions per )inute4 and the #P/ for getting the )axi)u) po3er Ator?ueB is a*out 4... revolutions. 7herefore4 3hen the vehicles are running 3ith various speeds4 it is necessary to control the speed and po3er of the vehicle *y inserting a trans)ission *et3een the engine and the 3heels. ;t si)ple sight4 the )otor )ay *e the *est engine for the vehicles. 7he i)portant thing is the fuel4 the source of po3er. 7he gasoline is easy to store during operating the engine4 *ut it is hard for the )otor to store the electric po3er effectively. 7o develop the electric vehicles4 it is essential to develop the *atteries having the high efficiency for charging and )aintaining the rechargea*le *atteries in e?uivalent state. /any co)panies are trying developing the )ethod for )aintaining the rechargea*le *atteries. Even though the *asic perfor)ance has *een developed in field test4 the )anufacturing cost is very high. 5o3ever there are *eing suggested so)e patents and technologies for utiliGing. 11. 'ean 7$rn Engine 7he exhaust purification syste) using the 33ay catalysts has the characteristics of )aintaining the actual air<fuel ratio to the ideal valve to perfor) the oxidation and reduction of the har)ful co)pounds si)ultaneously. 7o do so4 the purification of the exhausted gas 3ill *e li)ited4 and the fuel a)ount used for the engine is decided *y the engine driving status. 7herefore4 the engine shall not *e developed no )ore to get higher driving force 3ith less a)ount of the fuel.
7he lean *urn syste) is developed for enhancing the fuel efficiency 3ith the good purification of exhaust gas. 7o enhance the fuel efficiency is )ost i)portant point for future. 7he lean *urn engine is one of the )ost attracted pu*lic attention technologies. With the high ;>! ratio *y reducing the gasoline in the )ixture4 ho3 are the three )a=or har)ful )aterials4 car*on )onoxide4 hydrogen car*on4 and nitrogen oxide. 7he oxygen is )ore plentiful than fuel4 so the a)ount of car*on )onoxide 3ill *e less or the )ost car*on )onoxide 3ill *e changed into car*on dioxide4 har)less gas. 7he hydro car*on 3ill also *e co)pletely co)*usted and changed into car*on dioxide and 3ater. @o3 3e 3ill concern only the last one4 nitrogen oxide. f the ;>! ratio is higher4 then the te)perature 3ill *e increase *y the plentiful of the oxygen and the a)ount of the nitrogen oxide 3ill *e 16 Chonan Technical Service Training Center Engine Principles increased. ;t a*out 1$ of ;>! ratio4 the nitrogen oxide 3ill *e )axi)iGed. f the ;>! ratio is higher than 1$4 then the co)*ustion te)perature 3ill *e do3n so the tor?ue is also do3n. f the ;>! ratio is higher and higher4 the co)*ustion is not sta*le4 and tor?ue is very unsta*le4 finally co)*ustion 3ill not *e perfor)ed. ; )anufacturer focused on the tor?ue variations according to the lean *urn. 1y adapting the co)*ustion pressure sensor detecting the co)*ustion pressure in the cylinder4 the engine is operated 3ith the ;>! ratio =ust *efore the tor?ue variation is occurred. 7herefore4 they can )a%e next generation lean *urn engine having the lo3 fuel consu)ption and the less a)ount of nitrogen oxide. n that syste)4 the lean *urn is perfor)ed at the condition in 3hich the driving is not hindered *y the lo3 tor?ue at lo3 load. When the vehicle in accelerating or high load4 the co)*ustion is perfor)ed 3ith the theoretical ;>! ratio and the exhaust gas is purified *y 33ay catalyst. /any )anufacturers continue to research for enhancing the fuel consu)ption *y focusing on the inta%e syste) and co)*ustion cha)*er 3ith 1$M2. of ;>! ratio. /any ne3 engines satisfying this co)*ustion re?uire)ent and having less exhaust gas pro*le) are sho3n )ore and )ore. 17 Chonan Technical Service Training Center Engine Principles Chapter 2. Cylinder 7lock 5 Moving parts 1. Cylinder block 7he cylinder *loc% is the *asic part of the engine. t is )ade of cast iron or alu)inu). t co)prises of the cylinder in 3hich the piston shall *e )oving reciprocally4 the 3ater =ac%et for circulating the cooling 3ater )aintaining the te)perature of the cylinder4 and the cran%shaft installed underneath. 7he role of cylinder is for guiding the reciprocal )ove)ent of the piston accepting the force and high te)perature fro) the co)*ustion of the )ixtures4 for cooling the cylinder properly4 and for supporting the cran%shaft. ;s the *asis of the engine4 it should have enough strength for enduring the supporting the attached all parts of engine. !or these purposes4 the cylinder is generally )ade of cast iron *ecause that the iron is easy to *e processed )echanically and has the characteristics of good resistance against the 3are and corrosion. #ecently4 instead of the cast iron4 the alu)inu) alloy is )ore popular. 7he alu)inu) is lighter and trans)itting the heat easier than steel so that it is dee)ed as the ideal )aterial for engine. t is not easy to apply the alu)inu) to the engine *ecause it has different heat expansion coefficient 3ith the steel4 the )ain )aterial of other parts and it is co)plicated to design the engine structures4 as 3ell as it is )ore expansive than steel. !or the passengerEs car4 the 3eight of the engine is a*out 1.M1"N of the total 3eight of the car. 7he 1"M2.N of the engine 3eight is co)e fro) the cylinder *loc%. t is very i)portant to *e light )aintaining the strength of it as possi*le. 7herefore4 the s%eleton structure of the cylinder *loc% has different thic%ness such that the thic%ness is thic%er of the portion applied heavy force or having possi*ility of defor)ation and the thic%ness is thinner of the other portions. 7o design the cylinder *loc% regarding these factors4 the structure analysis is perfor)ed *y the finite ele)ent )ethod in 3hich the engine is divided into triangular or rectangular cells and the each ele)ent is esta*lished in si)ultaneous e?uations to calculate *y nu)erical analysis using co)puter. n side of the *loc%4 there should *e the 3ater =ac%et for circulating the cooling 3ater so it should *e precisely )anufactured for the co)plicate structure. 7o prevent fro) crac%ing at the *ottle nec% point of different thic%ness or to enhance the resistance against 3ear4 it should *e heat treated. 2. Cylinder 'iner 7he inside 3all of the cylinder *loc% is the frictional face 3ith the piston 3ith a lu*ricant oil there<*et3een. 7herefore4 it satisfies the strict re?uire)ents that it endures at the high te)perature and 3ear4 that its changes of the di)ension *y the heat expansion coefficient shall *e 3ithin the tolerance4 and that it should 18 Chonan Technical Service Training Center Engine Principles not *e adhesive 3ith each other *y the high te)perature. :enerally4 3hen the *loc% )aterial is the steel4 this part is )ade *y polishing the cast iron cylinder4 so called as the linerless type. When the *loc% )aterial is the alu)inu) alloy4 the inside 3all of the cylinder having a cylinder liner )ade of cast ion for preventing the 3are of the side 3all. 7he liner is the thing 3hich is attached the inside of the cylinder. 7he cylinder liner )ay *e )ade 3ith the cylinder *loc% or separately and =oined after that 3ith the cylinder. !or the alu)inu) cylinder *loc%4 the cast iron is used. t is heavier than the alu)inu) alloy as 3ell as it has the lo3er heat trans)ission ratio than the alu)inu). 7herefore4 for the engine of racing car or high efficiencies4 the special liner )ade of the silicon alloy *ased on the alu)inu) or having special treat)ent on the alu)inu) surfaces are utiliGed. 7hese special liners are so expensive and hard to )anufacture. ;lso4 there are so)e tries to develop the linerless cylinder 3ith alu)inu) alloy cylinder *loc%. Even though the linerless cylinder is )ore expensive4 the engine can *e lighter and co)pacted so that it is )ainly accepted to the high perfor)ance engines. 7he gap *et3een the cylinder liner and the piston is depended on the )aterial. When the liner is the cast iron and the piston is the alu)inu) alloy4 considering that the heat expansion ratio of the alu)inu) is al)ost t3ice than that of the steel so that the gap 3ill *e reduce at the high te)perature of the engine4 the gap shall *e 3.M4. )icrons A...3M...4))B at the roo) te)perature. f the liner and the piston are all the alu)inu)4 then the gap shall *e 1. )icrons *ecause there is no difference of the heat expansion *et3een the). 7he around of the cylinder liner is for)ed as a shape of path for cooling 3ater4 the 3ater =ac%et4 to )aintain the te)perature of the engine to certain value *y a*sor*ing the heat energy co)e fro) the re)ained energy of the co)*ustion. 3. Water 8acket When casting the cylinder *loc%4 the cylinder is surrounded *y the core )ade of sand to for) vacant spaces. 7hese spaces are the 3ater =ac%et for circulating the cooling 3ater to ta%e do3n the te)perature of the cylinder head and cylinder to the proper te)perature for operating. 7he 3ater circulating inside the 3ater =ac%et goes into the engine fro) the lo3er outlet port of the radiator cooling the heated 3ater. 7he 3ater flo3s fro) the lo3er part of the engine to the upper part of the engine. ;fter cooling the cylinder head4 the heated 3ater is ta%en out fro) the engine and goes into the upper inlet port of the radiator. -uring circulating inside the 3ater =ac%et4 it is i)portant to cool do3n the each cylinder e?uivalently. 7he design of the 3ater =ac%et is focused on the flo3 )ethod to spread the 3ater s)oothly over the all parts 3ith s)aller volu)e of the 3ater as possi*le. 7he heated 3ater is cooled in the radiator and then return to the 3ater =ac%et again. n 3inter4 the heated 3ater selectively flo3 into the another radiator for heating the ca*in. 19 Chonan Technical Service Training Center Engine Principles :enerally4 the 3ater =ac%et is surrounding the cylinder thoroughly. n order to reduce the path length along to the cylinder array4 the 3ater =ac%et is surrounding the out side of the cylinder so that the 3ater does not flo3 into the ad=acent space the cylinders. 7his type is called the &ia)ese type. 0i%e the &ia)ese t3ins4 so)e portions of the =ac%et surrounding the each cylinder are )erged into one *ody. 7he conventional =ac%et is called the full =ac%et type. !or the engine having the liner4 the type is divided into t3o %inds *y 3hether the 3ater is contacting 3ith the liner or not. When the cylinder liner is surrounded *y the 3all of the cylinder *loc% so that the outside of the liner can not contact 3ith the cooling 3ater4 it is called the dry type liner. When the )ost portions of the liner contact 3ith the cooling 3ater directly4 it is called the 9et type liner. 7he 3et liner has *etter cooling efficiency. t should *e sealed 3ith an 8<ring *et3een the liner and *loc% to prevent lea%ing the cooling 3ater. n K;4 the )ost engines having the liner are e?uipped 3ith the dry type liner *ecause K; have not any pro*le) co)e fro) the heat adhesive of the engine yet and 3e 3orry a*out the lea%ing the cooing 3ater. 4. ,iston 7he piston )oving inside the cylinder reciprocally trans)its the 3eight force of 3O4 tons A" tons for diesel engineB according to the co)*ustion of the fuel )ixture gas having over te)perature of 2...L at the co)*ustion stro%e to the connecting rod. 7he first thing to *e considered in design of the piston is that the piston should *e )ade of light )aterials to reduce the inertia force of the reciprocal )ove)ent. 7he next point is that its )aterial should have the strength enough to endure the co)*ustion force. ;nd then4 the )aterial of the piston shall have the good heat<trance and not *e distorted or defor)ed *y the high te)perature. ;t first4 the alu)inu) or alu)inu) alloy can *e considered for lightening and strengthening. 7hen4 for enhancing the heat resistance to prevent fro) changing in di)ension4 the heat treat)ent shall *e perfor)ed. 20 Chonan Technical Service Training Center Engine Principles 7he upper part of the piston is called as the piston head or the piston cro3n. t is very i)portant part for)ing the co)*ustion cha)*er *et3een the cylinder head. 7o enhance the co)*ustion efficiency *y co)*usting the fuel )ixture instantly4 the shape of piston head prefer to *e flat. 7o enhance the co)pression ratio4 the )iddle portion )ay *e upraised or there are so)e recessed positions4 the valve recess4 to ta%e the inta%e and exhaust valves not to touch 3ith the piston. 7he under portion of the piston is the piston s%irt sta*iliGing the reciprocal )ove)ent of the piston. 7he so)e front portions of the s%irt loo%s li%e *eing cut out *ecause that the *alance 3eight is passing these areas 3hen the piston goes do3n. 7here is a gap *et3een the piston and the cylinder. 7his gap shall *e sealed 3ith the piston ring. When the piston is )oving in reciprocal4 so)e portions of the s%irt )ay *e touching the cylinder 3all. 7o reduce this touch4 the shape of the s%irt shall *e changed. 7he shorter length of the s%irt has fe3er noises fro) the friction 3ith the piston and lighter 3eight. 5o3ever4 it is prefera*le for designing the s%irt to *e *alanced 3ith the siGe of the piston. 7he piston is connected 3ith the connecting rod *y a piston pin. &o4 the )ost forces of co)*ustion are applied to this pin. ;s the piston pin is the shape of hollo3 cylindrical structure4 the larger of outer dia)eter4 in a sa)e 3eight4 is the )ore strength against the *ending force. 5o3ever4 3hen the dia)eter of the piston pin is enlarged4 the piston pin *oss shall *e also enlarged. 7herefore4 the co)pression height4 the length fro) the pin to the piston head4 is also longed so the 3eight of the engine is heavier. &o4 the dia)eter should *e designed *y considering the *alance 3ith the piston siGe. ". ,iston 2ing 7he )ain roles of the piston ring4 the 3heel shaped steel surrounding the head part of the piston4 are to prevent fro) lea%ing the gas *y sealing *et3een the piston and the cylinder4 to prevent fro) re)aining the lu*ricant oil in the co)*ustion cha)*er *y gathering the oil do3n fro) the cylinder 3all and to prevent fro) trans)itting the heat fro) the piston to the cylinder. :enerally4 the piston ring co)prises of three rings. 7he t3o rings near to the piston head are called the co)pression rings4 and the one ring near to the s%irt is the oil ring. 7he top ring of the co)pression rings is used for sealing the gas4 the oil ring is used for re)oving the lu*ricant oil4 and the second ring of the co)pression rings is used for helping the sealing and for controlling the thic%ness of the lu*ricant oil fil). &o)e piston co)prises of the t3o rings4 the co)pression ring and the oil ring. n this case4 the roles of rings are so)e3hat loss4 *ut the fuel efficiency can *e enhanced *y reducing the loss of force fro) the friction *et3een the piston ring and cylinder 3all. &o)e racing cars accept the t3o ring syste) for shortening the piston height to reduce the engine 3eight. 21 Chonan Technical Service Training Center Engine Principles 7he co)pression ring is )ade of the spring steel *y casting iron4 and the surface should *e heat treated to reduce the friction and to enhance the lu*ricant of the piston. 7o insert the ring into the grooved portion of the piston and to ensure the tensile force for co)pressing to the cylinder4 one portion of the ring shall *e opened. 7his open portion is called the end gap. 7he co)*usted gas is lea%ed out through this end gap a little. 7his *lo3<*y gas is returned to the co)*ustion cha)*er *y the returning device not to lea% out. 7he grooved portion of piston for the co)pression ring has slightly lager then the 3idth of the rings. When the piston is )oving up and do3n4 the rings are rotating to prevent the end gap of the three rings fro) *eing aligned each other. f the rings have not enough strength4 the rings are fluttering 3ithin the grooves at the high speed of the engine so it cannot seal the gas properly. 7he cross section of the oil ring has the shape of reversed H(I. 7he gathered oils *y the rings are returned to the inside of the piston through the hole located at the lo3er portion of the (< shaped ring. When the engine has high speed4 the ring can not gather the oil only 3ith the its tensile force4 so an additional spring4 the expander4 shall *e attached to enforce the co)pressing force of the ring to the cylinder. %. Connecting 2od 7he connecting rod is the rod for connecting the piston and the cran%shaft. t transfers the reciprocal )ove)ent to the rotation )ove)ent. 7he connecting rod )oves very co)plicatedly 3ith s3ing )ove)ent a*out the piston pin and the linear )ove)ent up and do3n. &o4 there is a *alance 3eight to control the inertia force generated *y the co)plicating )ove)ents. 7he contri*ution ratio of the connecting rod 3eight to the inertia force is a*out 2 to the one reciprocal )ove)ent. 7o lightening the load to the *earing and the vi*ration *y reducing the inertia force4 the connecting rod should *e light as possi*le. 5o3ever4 it has enough strength to trans)it the co)*ustion force to the cran%shaft. 7he connecting rod is )ade of the special steel *y casting or forging. 7he forging is prefera*ly used for ensuring the strength. !or the racing cars4 the expensive *ut very light and strong )aterial4 titaniu) alloy4 is used also. 7he types of the rod can *e divided into t3o types according to the cross sectional shape of 22 Chonan Technical Service Training Center Engine Principles the rod4 type and 5 type. f the strength is sa)e4 then the <type is lighter than 5<type. 7herefore4 general cars accept the <type rod. 7he 5<type has stronger structure against the *ending force to the direction of the pin axis. ;s the (onnecting rod is longer4 the lateral vi*ration is s)aller. 7he reason is that4 considering the force applied to the piston at the rotation of the cran% *y divided into lateral direction and longitudinal direction4 the longer connecting rod can reduce the ratio of the force to the lateral direction than the shorter connecting rod so that the vi*ration and friction also shall *e reduced. 5o3ever4 if the connecting rod is so long4 the engine 3eight is heavier so it is not prefera*le. :enerally4 the length fro) the center of the piston pin to the cran% pin4 is a*out t3ice than the length of the stro%e. 7he end portion of the connecting rod to the piston side is called as the s)all end4 and the end portion to the cran% pin side is called as the *ig end. 7he s)all end is connected to the piston 3ith the piston pin4 and the *ig end is attached to the cran% pin *y inserting a *earing. &. Cranksha-t 7he cran% )eans the *ended handle as the transfer fro) the reciprocal )ove)ent to the rotational )ove)ent as have )entioned until no3. ;t the early ti)e of the vehicles history4 the engine is started 3ith the cran%. ;fter the electric )otor 3as used for the starting the engine4 until 1,".s4 &o)e cars had have a cran% at the front of the engine for e)ergency device at the )alfunction of the )otor. 7he cran%shaft connects the cran%s of each cylinder. 7he )ain shaft is called the cran% =ournal and the attaching part to the *ig end of the connecting rod 3ith the cran% is called the cran% pin. 7he other side4 the attaching part to the s)all end of the connecting rod 3ith the piston is called the piston pin. 7he connector connecting the cran% =ournal and the cran% pin is called the cran% ar). 7he sector for)ed pendulu) at the front of the cran% ar) is called the counter 3eight or the *alancing 3eight. 23 Chonan Technical Service Training Center Engine Principles 7he reason of the shape of the counter 3eight *eing spreading fro) the center ArootB to the circu)ferential portion Aouter portionB is that it can have larger inertial force 3hen it rotates a*out the root partC even the counter 3eight has the sa)e 3eight density. n the reciprocal engine4 the piston is press the cran% =ournal 3ith the connecting rod at every co)*ustion stro%e. 7he cran%shaft affected *y the co)plicated *ending and distorting force. 7herefore4 the cran% =ournal shall have strength enough to endure these forces so it is )ade of the casting or forging steel. !or the high perfor)ance engine or the racing car engine4 the forging steel is )ost used for ensuring the strength. !or the co))ercial or general purpose vehicle4 the casting steel is used *ecause the forging process is )ore expensive. Even though the casting steel has less strength than forging steel4 it is not so critical point *ecause that it is possi*le to )anufacture the counter 3eight precisely. 7he counter 3eight *alances the 3eights force *et3een fro) the reciprocal )ove)ent of the piston and fro) the rotational )ove)ent of the cran%shaft. &i)ply thin%4 to *alance the 3eight is to )atch the inertia forces fro) the piston and the counter 3eight as the ratio of 1D1. 7he counter 3eight should *e s)all as possi*le 3ithin the re?uire)ent load range of the =ournal in order to reduce the 3eight of the cran%shaft. (. Crank Case 7he cran%case is the part covering fro) the cylinder of the cylinder *loc% to the cran%shaft. n the cran%case4 there are so)e auxiliary devices such as the alternator Athe alternative current generatorB4 generating the electric po3er4 the co)pressor of the air conditioner and the oil pu)p for the po3er steering. ;nd the engine )ount *rac%ets installing the engine to the vehicle *ody are also attached to the cran%case. ;s the cran%case is one part of the cylinder *loc%4 it is al3ays vi*rated *y the reciprocal )ove)ent of the piston and the rotational )ove)ent of the cran%shaft. 7herefore4 the )aterial of the cran%shaft should satisfy the re?uire)ent of the resistant against the shoc%ing force and vi*ration. 7he types of the cran%case are divided into t3o types according to the covering range over the cran%shaft4 the half s%irt type and the deep s%irt type. n the half s%irt type4 the front portion of the cran%case is covering to the center of the cran%shaft. n the deep s%irt type4 the cran%case is covering over the *earing cap. 24 Chonan Technical Service Training Center Engine Principles 1ecause the half s%irt type has the short length4 it is possi*le for the *loc% to )a%e *e light. 5o3ever4 the =oint strength shall *e 3ea%er than the deep s%irt type4 *ecause the =oining area is s)all 3hen the trans)ission is attached to the engine. t is easy to )a%e so)e vi*rations so that it is necessary to *e assisted *y supporters. ;dditionally4 the space for attaching the auxiliary devices shall *e s)aller. 7o secure the cran%shaft to the cylinder *loc% and to reinforce the strength of the *loc%4 a supporting device )ight *e for)ed 3ith the *earing of the cran%shaft at the lo3er part of the cran%case. ;ccording to the type of this supporting device4 there are the ladder fra)e style and *earing *ea) style. ;t the lo3er part of the cylinder *loc%4 an oil pan is attached also. 7his is for gathering the oil co)pleting the lu*ricating and cooling role. t is )ade of a pressed steel sheet and attached *y ru**er pac%ing li%e the head cover. 7he oil pan is easy to )a%e a noise so that it is )ade of the vi*ration resistance steel plate. 7he vi*ration steel plate is )anufactured *y inserting a resin plate *et3een the t3o steel plates to prevent fro) vi*rating. ). 8o$rnal 7earing 7he *earing is for helping the s)ooth rotation of the rotating axis and supporting the rotation axis. 7here are various types of the *earing including the plain *earing supporting the axis 3ith the flat and 3ide side4 and the *earing supporting the axis and the around of the axis 3ith *alls or rollers. :enerally4 for the cran%shaft of the engine4 the plain *earing is )ore used. 7he reason that the roller *earing type is not applied to the cran%shaft is that the load can *e concentrated at the contacting portions of the *all or roller in a point or linear type. n the plain *earing the load is applied on the lu*ricated side4 the larger contacting area than the *all or roller *earing so that the plain *earing can support large force. ;s the plain *earing is also called as a sliding *earing4 the shaft is sliding on the *earing 3ith the lu*ricant oil. Even if the surface of the solid )etal *ody is applied the s)oothing surface treat)ent precisely and carefully4 it should have roughness so)e3hat. 7herefore4 3hen the t3o solid *odies are directly contacted4 they 25 Chonan Technical Service Training Center Engine Principles should *e 3orn. 7he lu*ricant oil inserting *et3een the plain *earing and the axis can )a%e the rough surface of these t3o solid *odies to *e s)oothly. 7he t3o solid *odies are not contacted directly even they are so closed. 7he thic%ness of the oil fil)4 that is the gap 3ith the *earing4 is changed *y the load or heat expansion. When it is so s)all4 it )ay *e adhered *y friction heat4 other3ise4 3hen it is so *ig4 it )ay )a%e vi*rations and noise. 7he *earing is )ade *y 3elding the *earing alloy having light 3eight and good fatigue resistance such as the copper or alu)inu). 8n the surface4 a special )etal *asis on the lead is coated. 7he *earing has the oil hole and oil groove for supply the lu*ricant oil to lu*ricate the contact portion *et3een the connecting rod and the cran% pin and *et3een the cran%shaft and the cran%case. 7he cran% =ournal4 the rotational axis of the cran%shaft4 is attached at the lo3er part of the cylinder *loc% *y the *earing cap 3ith the plain *earing. !or the serial engine4 this *earing should *e attached at the front side and rear side of the cylinder. f it is the 4<cylinder4 it has " *earings and if it is the $<cylinder4 it has ' *earings4 that is4 it called as "<*earing and the '<*earing4 respectively. (ertain old style engine of 4<cylinder )ight have 3<*earing structure. 7his type is not used *ecause the cran%shaft is easy to *e *ent and )a%e vi*rations. 1+. *ly9heel 7he fly3heel is e?uipped to the trans)ission side of the cran%shaft to )aintain the s)ooth rotation using inertia force and to reduce the irregularity of the rotational force. 7he cran%shaft is rotated t3ice per one of the co)*ustion. ;t the other stro%es4 the reversed directional force shall *e needed for the co)pression4 the inta%e and exhaust. f there is no fly3heel4 then the rotational force of the cran%shaft shall *e reduced at these stro%es. 7herefore4 3hen the intervals of the each co)*ustion stro%e are long li%e in the idling state4 the engine )ay *e stopped. ;round the fly3heel4 a ring gear is attached to 26 Chonan Technical Service Training Center Engine Principles rotate the cran%shaft *y *eing teethed 3ith the pinion gear. 7he clutch dis% can attach to the flat side of the fly3heel *y the spring to trans)it the driving force to the trans)ission. 7he )agnitude of the tor?ue is calculated *y )ultiple the )agnitude of the force to the distance *et3een the center of the axis to the point at 3hich the force is applied. 7he )agnitude of the force is proportional to the inertia )ass so that if the fly 3heel is heavy and the outer dia)eter is large4 or if the outer portion is heavy4 then the force of the fly3heel )ight *e large. n general engine4 the half of the total inertia )ass is distri*uted at the fly3heel. 7herefore4 3hen the rotation of the engine is lo3 or 3hen the engine is in the idling state4 the inertia )ass of the fly3heel should *e large to rotate the engine regularly. 5o3ever4 3ith the large inertia )ass of the fly3heel4 the rotation of the engine can not *e changed easily. t is hard to increase the engine rotation *y pressing the accelerator4 or to ta%e the engine *ra%e *y releasing the accelerator. 7hat is4 the engine response 3ill *e 3orse. &o4 the fuel efficiency shall *e 3orst too. &o)e engines use the 3.N of the tor?ue generated fro) the engine to increase the rotation of engine itself 3hen the accelerating is perfor)ed 3ith the lo3er speed shift. 7he siGe and the 3eight of the fly3heel are decided *y the purpose of the vehicles. !or exa)ple4 the engine for the racing car uses s)all siGe one4 and that of the fa)ily car uses large siGe one. !or the general purpose4 the fly3heel is )ade of the cast iron4 and for the special purpose such as the racing car4 it is )ade *y cutting the steel )aterial having high strength. 11. 7alance sha-t. 7alancer -or the secondary inertial -orce 7he piston4 the (onnecting rod and the cran% )a%e inertia force according to the reciprocal and rotational )ove)ent. !or this reason4 if the one<cylinder engine has not the counter 3eight for *alancing *et3een the inertial force and the 3eight of the piston4 the connecting rod and the cran%4 then the engine )ay *e severely vi*rated *y the un*alancing. !or the serial 4<cylinder engine4 the four pistons are connected to the cran%shaft 3ith *eing paired the first4 forth and the second 4 third4 in facing each other. When the cran%shaft is rotating4 the inertial forces are offset so that the counter 3eight )ight *e not needed. n actual )ove)ent structure of the piston< cran% syste) of the 4<cylinder engine4 the inertia force shall not *e offset. 7his is co)e for) the structure in 3hich the piston in 27 Chonan Technical Service Training Center Engine Principles reciprocal )ove)ent is connected to the cran% in rotational )ove)ent 3ith the connecting rod. !or exa)ple4 in the half rotation of the cran%shaft 3hen the piston )oves fro) the highest point A7-(4 7op -ead (enterB to the lo3est point A1-(4 1otto) -ead (enterB4 the piston has the )axi)u) speed at the near of the highest point of the stro%e rather than at the )iddle of the stro%e. 7he rotation of the cran% is regular so that the inertia force of the cran% of each cylinder Athe first inertia forceB is easily offset. 5o3ever4 the inertial force of the piston is not. !or exa)ple4 the upper inertia force generated 3hen the first and forth pistons are )oving fro) the highest point to the lo3est point is larger than the lo3er inertia force generated 3hen the second and third pistons are )oving fro) the lo3est point to the highest point. 1y representing these relationship on the graph 3ith the inertia force at the vertical axis and the rotation angle of the cran%shaft at the horiGontal axis4 3hen the upper inertia force of the first and fourth pistons is )axi)u) value4 the lo3er inertia force of the second and third pistons is )ini)u) value4 and vice versa after the cran%shaft 3ith 1+.P. !ro) this relationship4 3e %no3 that the inertia force is generated 3ith the ratio of 2 ti)es per one rotation of the cran%shaft. 7his inertia force is called as the secondary inertia force. t is easy to *e generated 3hen the engine is in the idling state. 7he four<cylinder engine is e?uipped in the s)all passenger car generally. !or the convenience of the passengers4 a *alance shaft having the half circle shape in the cross sectional vie3 shall *e attached at the *oth side of the engine to reduce the vi*ration fro) the secondary inertia force. 7his *alance shaft is designed to rotate 3ith t3o ti)es of speed in reverse direction against the cran%shaft. 7he additional inertia force generated fro) the *alance shaft 3ill offset the vi*ration fro) the secondary inertia force. 28 Chonan Technical Service Training Center Engine Principles Chapter 3. Cylinder Head 1. Cylinder Head 7he cylinder head is attached on the cylinder *loc% 3ith *eing inserting a gas%et to prevent fro) lea%ing the co)*usted gas. 7he *otto) of the cylinder head is also the roof of the co)*ustion cha)*er. 7herefore4 the shape of the cylinder head is very co)plicated. 7he rectangular *ox shaped portion located upper position has the valve driving syste) inhalation the )ixture of fuel to the engine and exhausting the co)*usted gas4 and the ignition plug so that the shape and operation of this part can decide the engine perfor)ance such as the co)*ustion of the )ixture of fuel. 7he structure of the cylinder head is various according to the type of engine. 7he )ost cylinder head has the co))on structure as this. ;t the upper part4 there is the valve driving syste) in 3hich the intake port inhaling the )ixture of fuel into the co)*ustion cha)*er and e#ha$st port ta%ing out the co)*usted gas in the longitudinal direction. nside the cylinder head4 there is a 3ater =ac%et circulating the cooling 3ater fro) the cylinder *loc%. 7he co)*ustion cha)*er is very i)portant part to decide the engine perfor)ance. &o the shape and the siGe are the i)portant factors. f the co)*ustion cha)*er is *ig4 the ti)e interval for co)*usting the )ixture of fuel is long even the )ixture can *e co)pressed enough. &o the *igger po3er cannot *e ensured. 7herefore4 it is prefer for the siGed of the co)*ustion cha)*er to *e co)pact. ;dditionally4 the shape of the co)*ustion cha)*er has less uneven surfaces as possi*le to enhance the co)*ustion of the )ixtures. f the shape of the co)*ustion cha)*er is co)plicated4 then the heat fro) the co)*ustion shall *e easily lost *ecause the surface of the cha)*er is too large a*out the volu)e of it. &o4 the force pressing the piston shall *e lo3ered. 7he inta%e port is also i)portant part *ecause that the flo3 of the )ixture is defined *y the siGe and the shape of it. (onsidering =ust a*out the flo34 the s)oother inner surface is *etter for reducing the resistance against the flo3 and the straight shape of port is the *etter. 5o3ever4 the shape of the port is helpful for the inhaling )ixture into the cylinder to *e for) the s3irled flo3 in order to *e co)*usted at the co)*ustion stro%e as 3ell as possi*le. 7he 3ater =ac%et 3ill a*sor* the re)ained heat after the co)*ustion until finishing the exhaust stro%e as fast as possi*le to prevent fro) increasing the te)perature of the next inhalation )ixtures. Especially4 the around portions having the high possi*ility of increasing the te)perature such as the exhaust valve and spar% plug should *e cooled )ainly to prevent fro) )a%ing a trou*le *y the over heat. ;t the cylinder head4 there is *earing for 29 Chonan Technical Service Training Center Engine Principles supporting the valve driving syste) including the ca) shaft. 7he *earing is lu*ricated and cooled *y the engine oil. 2. Ca! and Ca!sha-t 7he ca) drives the valves operation opening and closing the inta%e port for inhaling the )ixture of fuel into the co)*ustion cha)*er and the exhaust port for ta%ing out the co)*usted gas. !or the 85( or -85( engine4 the ca) is attached at the ca)shaft installed at the )iddle part of the cylinder head. 7he ca)shaft has the ca)s 3ith the sa)e nu)*er of the valves for inta%e and exhaust 3hich are arranged 3ith angles according to the ti)ing of the opening and closing. !or the 4< cycle engine4 the opening ratio of the inta%e and exhaust valves is one a*out the t3o revolutions of the cran%shaft. 7herefore4 the ca)shaft revolves 3ith the ratio of one turn a*out the t3o revolutions of the cran%shaft. 7he extrusion portion of the ca) is called as the ca! nose or the ca! robe. 7he height is called ca! li-t. 7he HliftI )eans that the ca)s lift the valve so that the opening status is deter)ined *y the ca! pro-ile. 7he opening and closing ti)ing of the valves are deter)ined *y the operation angle4 the angle fro) the start point to the end point of the nose.
When the valve is closed to the valve seat4 it is preferred that the i)pact shall *e little as possi*le4 so that the cross sectional shape of the ca) is the egg shape. 7he valve is al3ays applied a force in the closing direction *y the valve spring. 1y pressing the spring 3ith the ca) nose4 the valves 3ill *e opened. f the ca) velocity *eco)es fast to enlarge the inertia force of the valve4 the reciprocal )ove)ent of the valve is not *alanced 3ith the rotational )ove)ent of the ca). 7he engine speed generated *y this li)ited speed of the valve opening and closing is the )axi)u) speed of the engine. &o the ca) profile is very i)portant. 7he ca) nose should *e treated special surface treat)ent to ensure the strength for enduring fro) the frictions 3ith the valve lift and roc%er ar) installed at the valve. 7o do so4 the ca)shaft is )ade of cast iron and the ca) nose should *e treated 3ith a cooling treat)ent such as the chilling )ethod to strength the textures of the surface4 3hen it is cast. 30 Chonan Technical Service Training Center Engine Principles &)all ca) lift 1ig ca) lift 7here are t3o )ethods for supplying the lu*ricant oil to the ca) =ournal supporting the ca) nose and the ca)shaft4 fro) outside and fro) inside. n the outside supplying )ethod4 the oil 3ill *e supplied fro) the =ournal. n the inside supplying )ethod4 the ca)shaft has a hole for supplying the lu*ricant oil fro) the )iddle portion of the =ournal. n addition4 the ca)shaft is )ade *y hollo3 tu*e type and the lu*ricant oil )ay *e supplied through the hollo3 tu*e. 3. 6riving the Ca!sha-t !or the 85( engine4 the cran%shaft is located under the cylinder *loc% and the ca)shaft is located on the cylinder head4 so there should *e a chain or *elt for transfor)ing the rotational )ove)ent of the cran%shaft to the ca)shaft. ;s the driving for the inta%e and exhaust valves should *e exactly ti)ed 3ith the rotation of the cran%shaft4 for so)e case such as racing car4 a gear is used for transfor)ing the rotational )ove)ent exactly. n the chain syste) for transfor)ing4 the tooth 3heel for the chain is called the sprocket. 7he one attached at the cran%shaft is the cranksha-t sprocket4 and the other attached at the ca)shaft is the ca!sha-t sprocket. n the syste) in 3hich the ca)shaft is driven *y the chain4 the ratio the teeth nu)*ers *et3een the cran%shaft sproc%et and the ca)shaft sproc%et is 1D2. n order to )aintain the tension of the chain4 a chain tensioner is attached4 and the chain g$ide prevents fro) sha%ing the chain during rotating. f this )ethod is applied to the -85( engine4 the sproc%et shall have the large dia)eter according to the nu)*er of teeth ratio. 7herefore4 the gap of ca)shaft and gap of valves of inta%e and exhaust 3ill *e enlarged. (onse?uently4 this )ethod is not applied to the co)pact type engines. 7o solve this pro*le)4 an additional sproc%et is inserted there *et3een to trans)it the rotational )ove)ent to the ca)shaft sproc%et. 7he ti!ing belt type uses belt having toothed surface and pulley instead of the chain and the sproc%et4 respectively. n this type4 the 31 Chonan Technical Service Training Center Engine Principles sproc%et and pulley attached at the end of the ca)shaft have the ti)ing )ar% indicating the opening and closing ti)ing of the valve. &o 3e use the ter) of Hti)ingI to the na)e of the parts. 7he pulley attached at the cran%shaft is the cranksha-t ti!ing p$lley and the one attached at the ca)shaft is the ca!sha-t ti!ing p$lley. ;s 3ell as the chain type4 in this type4 there are direct reduction type and dou*le reduction type. Even though the 85( engine can accept the long chain to drive the ca)shaft4 the *elt driving )ethod is )ainly used. 7he reason is that the long chain can )a%e )is)atching the ti)ing and *ig noises4 and the chain syste) needs the lu*ricating e?uip)ent. 5o3ever4 the *elt is )ade of fi*er and ru**er so it can *e easily *ro%en *y the heat or oil. t is prefer that it should *e exchanged at every ,.4...%) running. 4. Intake and E#ha$st 0alve 7he cylinder head includes the inta%e port inhaling the )ixture of fuel to the cylinder and the exhaust port ta%ing out the *urnt gas. 7he valves at the ports are the inta%e valve and the exhaust valve4 respectively. ;ccording to the valve shape of )ushroo)4 3e call poppet valve. 7he poppet valves consist of the valve head and the valve ste). 7he valve ste) supports the valve guide and the valve spring. 7he valve is opened *y the pressing operation of the ca) nose4 and closed *y the elastic force of the valve spring. 7he co)*ustion te)perature is over 2...L4 and the te)perature of the *urnt gas passing through the valve is over 1...L. 7herefore4 the te)perature of the exhaust valve is over +..L and that of the inta%e valve is over 3..L. &o the )aterial of the valve should *e heat resistance steel. 7he valve siGe is represented *y the dia)eter of the head portion. 7he inta%e valve is larger than the exhaust valve. #epresenting *y the area of the head portion4 3hen the inta%e valve is 1..4 the exhaust valve is a*out '"M+". 7his difference in their siGes is for *alancing of the gas flo3. 7he inta%e is perfor)ed *y the decreased pressure resulting fro) the do3ning 32 Chonan Technical Service Training Center Engine Principles of the piston4 on the other hand4 the exhaust is perfor)ed *y the high pressure resulting fro) the co)*ustion. 7o *alance the flo3 of the inta%e and exhaust4 the inta%e valve siGe )ay *e larger than exhaust valve. 7he valve ste) is designed4 considering the flo34 such as that of the inta%e valve is thinner as possi*le to reduce the flo3 resistance and that of the exhaust valve is thic%er as possi*le to trans)it the heat fro) the extrude portion to the ste). 7he heat is transferred through the path of the valve ste) Q the valve guide Q the cylinder head Q the cooling 3ater. &o)e high perfor)ance engine uses the hollo3 ste) securing sodiu) for enhancing the valve cooling. 7he portion of the port contacting 3ith the valve face is called as the valve seat. f the cylinder head is casting iron4 then the valve seat has dou*le structure. f the cylinder head is )ade of alu)inu) alloy4 then the seat is )ade of heat resistance steel. 3he valve spring al3ays press the valve to attach to the ca) so that the valve spring is prefera*le to *e soft to reduce the frictional resistance generated 3hen the ca) nose presses the valve. ;dditionally4 in order to enlarge the a)ount of inta%e and exhaust gas4 the valve )ay *e enlarged and the lift of the ca) )ay *e extended as 3ell as the valve spring )ay *e softened to operate faster. 7hen4 it )ay )a%e the surging pro*le) and it is hard to *e *alanced. ". 0alve 6riving yste! ;s the valve controls the gases for inhaling into and the ta%ing out fro) the cylinder4 its driving )ethod can give an i)portant affects on the engine perfor)ances. 7here are various type of valve driving syste). t has *een developed fro) the side valve type4 8564 85( to the -85( type. &ide valve type In the side valve type. the ca)shaft installed near the ca)shaft presses the long valve syste) to open and close the valve. 7he co)*ustion cha)*er is large and it has long ti)e interval for co)*usting the )ixture of fuel so that it can not )a%e high output po3er. @o3adays this type is not used. 856 A8ver head valveB type In the :ver Head 0alve ;:H0< type. the valve li%e in the side valve type is attached on the cylinder to open and close the valve using a long rod4 the push rod. 7he shape and structure is si)ilar 3ith that of engines used no3 to enhance the perfor)ance. 33 Chonan Technical Service Training Center Engine Principles 856 A8ver 5ead (a)shaftB type ;fter that4 the :HC ;:ver Head Ca!sha-t< type is developed. ;s %no3 fro) the na)e4 the ca)shaft is located over the head4 exactly to say4 in the )iddle of the cylinder head. n the 85( type4 there are t3o types4 the one is the in4line type in 3hich the inta%e valve and the exhaust valve are alternatively arrayed along the linear direction4 and the other is the 04 shaped arrange type in 3hich the inta%e valve and the exhaust valve are faced each other in opposite side to for) the 6<shape. 7he later has )ore enhanced efficiencies and higher perfor)ance. -85( A-ou*le 8ver 5ead (a)shaftB type -eveloping this 6<shaped arrange type )ore and )ore4 the 6:HC ;6o$ble :ver Head Ca!sha-t< type. in 3hich the inta%e valve and the exhaust valve are independently driven *y the different ca)shaft4 is )ainly used no3adays for the high perfor)ance engine. ;s 3e see fro) the na)e4 there are t3o ca)shafts so 3e call it as the t9in ca! syste) also. ;dditionally4 in the 6<type engine4 it has t3o cylinder head so the ca)shaft shall *e four. -irect type &3ing ar) type #oc%er ar) type 7he driving )ethod for the inta%e and exhaust valves is divided into the direct type4 in 3hich the ca) directly drives the valves4 and the roc%er ar) type4 in 3hich the ca) drives the valve using a lever. 7he roc%er ar) )eans the lever connecting the leverage point and the ca). Fsing the lever4 it can drive the valve faster than the ca) lift. 7he direct type has less co)ponents and high strength. Fsing the oil pressure for the hydraulic tappet4 the valve can trace the ca) profile al3ays. %. 0alve 3i!ing 7he valve ti)ing is the ti)e at the opening and closing the inta%e and exhaust valve. Each ti)e indicating 3hen the valve starts opening and 3hen the valve finishes closing is represented *y the rotational angle of the cran%shaft a*out the highest point or the lo3est point of the piston as the standard ti)e. 34 Chonan Technical Service Training Center Engine Principles ;s si)ply saying a*out the opening and closing the valves4 the exhaust valve 3ill open 3hen the piston is at the lo3est point. ;fter ta%ing out the gas4 3hen the piston is at the highest point4 the exhaust valve 3ill *e closed. ;t the sa)e ti)e4 the inta%e valve 3ill *e opened to ta%e in the )ixture of fuel. When the piston is at the lo3est point4 the inta%e valve 3ill *e closed. 5o3ever4 this is =ust concept for the operation of valves. 7he )ixture of fuel and the used gas have )ass so the flo3 of the )ixture or gas is not co)pleted at a )o)ent *ut need so)e ti)e intervals. !urther)ore4 the valves can not open and close at an instant )o)ent4 too. !or exa)ple4 the inta%e valve need so)e ti)e interval to open fully4 and the )ixture is not inhaled at a )o)ent into the cylinder *ut inhaled during so)e ti)e interval *y the inertia of flo3. 7herefore4 the inta%e valve shall open prior that the piston is reached at the highest point. When the piston starts to go do3n4 then the valve is already little opened to ta%e into the )ixture of fuel into the cylinder. 1y that the inta%e open little early4 the valve 3ill *e fully opened 3hen the piston is reached at the lo3est point4 so that the )ixture of fuel can *e inhaled enough. nta%e valve ti)ing When the piston is passed the lo3est point4 the inta%e valve is not closed thoroughly. 7o do so4 the )ixture 3ill *e )ore inhaled into the cylinder *y the inertia of the flo3 of the )ixture. ;t the end of the co)*ustion stro%e4 the exhaust valve 3ill *e open =ust *efore the piston is reached at the lo3est pointA1-(B. Exhaust valve ti)ing t is for exhausting the co)*usted gas as fast as possi*le *y the re)ained expansion force in the cylinder. n the sa)e )anner of the inta%e valve4 even the piston is passed the highest pointA7-(B4 the valve is still opened to exhaust the *urnt gas fully using the inertial of exhausting flo3. 35 Chonan Technical Service Training Center Engine Principles ;ccording to these operating process of the valves4 there is so)e period in 3hich the inta%e valve and the exhaust valve are opened at the sa)e ti)e4 *ecause the exhaust valve is closed after passing through the highest pointA7-(B and the inta%e valve is opened *efore reaching to the highest pointA7-(B. ;t this ti)e4 the vacuu) inertia force generated fro) the exhausted gas can accelerate the inhalation of the fuel )ixtures. 7his period is called the valve overlap. &. 0ariable 0alve 3i!ing 6aria*le ca)shaft angle type 1eing overlapped in the opening ti)e of inta%e and exhaust valve4 the enhanced inta%e efficiency of the )ixtures is as high as the enhanced exhaust efficiency of the used gas4 that is4 the rotation of the engine. 8n the other hand4 3hen the engine is in the rotating state 3ith lo3 speed such as the idling state4 the engine efficiency )ay *e lo3ered *y the lo3ered gas flo3. Especially4 for so)e high perfor)ance engine having large overlap4 in the lo3 speed4 the inta%e valve 3ill open 3ith large a)ount of *urnt gas so that the *urnt gas 3ill *e adhered to the inta%e port. 7herefore4 the co)*ustion 3ill *e unsta*le or inco)pletely co)*usted. n the 4<valve engine4 if the valve overlap is too large4 then the engine 3ill *e easily unsta*le at the idling state. &o4 the overlap ti)e for the 4< valve engine shall *e very short4 or so)e cases have the Gero overlap ti)e4 that is4 the inta%e valve is opened according that the exhaust valve is closed. 36 Chonan Technical Service Training Center Engine Principles &elective ca)shaft<lo*e type ;s 3e )entioned4 the valve ti)ing is different according to the rotation speed of the engine. 7hat is4 the inta%e valve should *e opened 3ith little lately at the lo3er rotation4 and 3ith little early at the higher rotation. &o4 an additional s3itch operated *y oil pressure is installed at the inta%e ca) sproc%et in order that the ca)shaft can *e rotated so)e3hat 3hen the engine is rotating over certain #P/ so that the ca) presses the inta%e valve early. 7his is the variable valve ti!ing syste!. n the varia*le valve ti)ing syste)4 the ca) shape is not changed4 so the valve shall *e also closed early 3hen it is opened early. Early closing the valve4 the a)ount of the inhaled )ixture is reduced. 7herefore4 the choice of the valve ti)ing is decided *y not only the rotation speed of the engine *ut also the load of the engine. (onse?uently4 the ca) syste) 3ill include the t3o %inds of ca)s4 the one for the lo3 speed of the engine and the other for the high speed of the engine. !or the lo3 speed ca)4 the valve 3ill *e opened lately and closed early4 and the lift 3ill *e s)all and then the inhaled )ixture of fuel 3ill *e reduced so that the fuel efficiency can *e enhanced. !or the high speed ca)4 the valve 3ill *e opened early and closed lately and the lift 3ill *e large to inhaled )ore )ixtures so that the engine output shall *e enlarged. 7his syste) also called varia*le valve ti)ing syste) *ut this syste) controls the valve lift also. t is )ore advanced syste). (. Mal-$nction o- the 0alve 7he valve is opened *y the ca) *ut closed *y the spring. ;ctually4 the valve attached *y the spring to the valve seat is opened 3ith the pressing *y the ca) nose. ;t that ti)e4 the force rotating the ca)shaft is rather s)all as possi*le. &o the soft spring is )ore proper. 5o3ever4 for so)e high perfor)ance engine having large siGe of valve or lift4 the spring shall *e harder and the *alance of the spring strength is i)portant factor. Even not occurring in the nor)al driving situation4 the hardness of the spring 3ith the 3eight and the strength of the valve can )a%e an a*nor)al operation such as the valve =u)p4 the valve *ounce or the valve surge4 3hen the engine is rotating over the li)itation rp). 3he valve =$!p is that the inertial force of the valve is too large so that the ca) can not press the spring and then the valve is =u)ped up fro) the ca) nose 3hen the ca)shaft is rotating 3ith high speed. 7he valve can return *ac% to the original position *ut the other dyna)ic co)ponents including ca)4 roc%er ar)4 valve lifter4 etc are da)aged *y friction each other. 37 Chonan Technical Service Training Center Engine Principles 3he valve bo$nce is that the valve face is not contacted to the valve seat Acontacted portion 3ith the valveB *ut *ounced fro) the valve seat 3hen the valve is closed *y the spring. 7he dyna)ic co)ponents shall *e da)aged *y this *ouncing. ;s increasing the rotation of the engine4 the *ouncing is occurred over than li)ited rp). 7his li)ited rp) is called as the crush speed or li)it rp) of the engine. 3he valve s$rge is the a*nor)al vi*ration of the spring. ;s the natural fre?uency of the spring is corresponding 3ith to the elastic ti)ing *y the ca)4 the spring can )a%e a high )ove)ent *y the self<excited vi*ration. When the engine is rotated in force. f it is continued then the spring shall *e *ro%en. 7hese a*nor)al operations of valve can *e easily )ade 3hen the valve is heavy and the lift is large. When the )ost used engine 3as the 2< valve 85( engine4 they 3ere )ain pro*le)s in engine. ;fter the 4<valve -85( engine is )ainly used4 these pro*le)s are scarcely occurred. ;s the 2<valve syste) *eca)e to the 4<valve syste)4 the valve area 3ould *e enlarged so the inta%e and exhaust flo3 3ould *e s)oother. 7herefore4 the lift has not to *e enlarged. !urther)ore4 the valve is to *e lightened so that the spring has not to *e strengthened even if the rp) is increased. ). :verr$n and 2ed >one n the tacho)eter of the engine4 there is certain rp) range colored in red called as the red Gone. &o)e )eter has the yello3 Gone =ust *efore the red Gone. 7he rp) at the *eginning of the red Gone is the )axi)u) allo3a*le rp) decided *y the characteristics and endurance re?uire)ent of the dyna)ic co)ponents including valve and valve spring and the )ain syste) co)ponents including piston and connecting rod 3hen the engine is operated 3ith the )axi)u) speed having the )axi)u) output. 7o operate the engine over the )axi)u) allo3a*le rp) is called as the overrun or over< revo )eans the revolution. 7he over<revo )ay occur 3hen the shift is do3n to the lo3er speed gear at the driving 3ith high speed. When the engine is in the idling state4 if the rp) is increased in force4 then the engine 3ill *e overrun state. When the engine is overrun4 the valve shall *e a*nor)ally operated such as the valve surge4 =u)p or *ounce. n this case4 the valve and spring )ay *e da)aged or in so)e cases4 the piston )ay *e da)aged *y *u)ping 3ith the head of the piston and the valve. n order to prevent *u)ping *et3een the piston and valve4 a recessed portion is )ade at the piston. 5o3ever4 if the piston is =u)ped up over the recessed portion4 then the piston 3ill *e *u)ped to the valve. f the average speed of piston )ove)ent is a*nor)ally fasted *y the overrun4 the gap *et3een the piston ring and the cylinder 3ill *e 38 Chonan Technical Service Training Center Engine Principles da)aged and the oil fil) of the *earing at the piston pin and the cran%shaft 3ill *e *ro%en so that the te)perature 3ill *e increased or so)e parts 3ill *e adhered *y this heat. When the engine is operating 3ith high speed4 the co)*ustion speed is also fast and the around te)perature of the co)*ustion cha)*er 3ill *e increased. &o4 these pro*le)s )ight *e easily occurred4 so it needs to *e careful. ;dditionally4 *y the overrun4 the engine has the increased inertia force *eing results of the a*nor)al vi*ration. 7he parts shall *e *ro%en or crac%ed. 7he )axi)u) allo3a*le rp) is set 3ith 3..O13.. rp) higher than the )axi)u) output rp). n so)e engine4 in the red Gone the fuel in=ection 3ill *e cut to prevent the rp) fro) increasing over the )axi)u) rp) and to prevent fro) )a%ing pro*le)s *y the overrun. 39 Chonan Technical Service Training Center Engine Principles Chapter 4. Intake yste! 1. Enhance the 0ol$!e E--iciency 7he pressure of the fuel )ixture at the end of the inta%e stro%e is lo3er than the a)*ient pressure *ecause of the resistance against the flo3 of the air cleaner and duct. ;nd the te)perature of the fuel )ixture is high *ecause that it contacts 3ith the hot valve and cylinder 3all 3hen it is inhaled. ;s the density of the air *eco)es lo3 3hen the pressure *eco)es lo3er or the te)perature *eco)es higher. 7he vol$!etric e--iciency is used for indicating the inta%e a*ility of the )ixture. ;s indicating the a)ount of the inhaled air in rate a*out the engine displace)ent4 the volu)etric efficiency is calculated fro) dividing the 3eight of the inhaled air *y the 3eight of the air a)ount 3ith the displace)ent at the sa)e te)perature and the sa)e pressure. n another )ethod for indicating the efficiency of the inta%e stro%e4 the charging e--iciency can *e used also. 7his is the volu)e efficiency 3hen the te)perature and the pressure is in the standard condition A2"L4 ,,%PaB. n order to enlarge the )axi)u) output of the engine4 this volu)e efficiency should *e as high as possi*le. 7he )ethod for enhancing the volu)e efficiency is li%e the follo3ings. R 7he a)*ient air shall *e inhaled into the )anifold 3ith not high te)perature as possi*le. !or the engine having the tur*ocharger4 it should *e e?uipped 3ith the intercooler to prevent fro) increasing the te)perature of the inhaled air. S #educe the flo3 resistance of the inhaled gas *y increasing the nu)*er of valves4 and enlarging the siGe and the *ending radius of the duct and )anifold. T Enlarge the dia)eter of the valve and the height of the ca) lift4 and *alance the valve ti)ing properly. 40 Chonan Technical Service Training Center Engine Principles U (hoose a long inta%e )anifold at the lo3er speed 4 and choose a short one at the higher speed to use the inertia and pulsation effect of the air. V Enlarge the inta%e gas pressure *y installing the tur*ocharger. Fntil no34 3e )entioned a*out the enhancing )ethod for volu)e efficiency related to the inta%e stro%e. t is i)portant to exhaust perfectly the *urnt gas at the exhaust stro%e as possi*le in order to enhance the volu)e efficiency. t is possi*le to apply the A2B O A4B of a*ove )entioned )ethods applied to the inta%e syste) except A1B and A"B to the exhaust syste). !or exa)ple4 the Hflo3 resistance of the inhaled gasI of A2B is too% place 3ith the Hflo3 resistance of the exhausted gasI4 and the Hinertia energy of airI of A3B is too% place 3ith the Hexhausting inertiaI. !urther)ore4 the exhaust interference shall *e )ini)iGed as possi*le. ;dditionally4 a tur*ocharger shall increase the inta%e resistance. 1y tuning up the engine4 it can *e effective for increasing output even it is very difficult to tune up the engine. 2. Intake Inertia E--ect and ,$lsation E--ect n order to inhaling air having high density to the engine4 to use the inertia of the air flo3 is called the inertia e--ect4 and to use the characteristics of the longitudinal 3ave such as sound 3ave according to the density of the air is called the p$lsation e--ect. n the inertia effect4 as the high density air is inhaled into the engine using a inertia energy of air. t is called as the inertia s$percharging. 7he air into the engine has the flo3 inertia as a gas and is a )edia for trans)itting the pressure 3ave. 7he air flo3 in the inta%e )anifold is periodically intercepted *y the valve4 so the )anifold pressure has variations fro) the difference of pressures *et3een high density portion and lo3 density portion. 6alve open Anhaled airB 41 Chonan Technical Service Training Center Engine Principles 6alve close A5igh density air at valveB 6alve open Anhaled high density airB 7herefore4 the inta%e inertia effect and the pulsation effect could *e )ade. When this pressure variation affects to the inta%e stro%e at the cycle generating the 3ave directly4 it is called as the inertia effect. When the pressure variation is not reduced and then affects to the next cycle4 it is called as the pulsation effect. 5o3ever4 it is not distinguished *et3een the) exactly. We4 here4 3ill call as the inertia effect 3hen the air flo3 inertia is )ainly governed and as the pulsation effect 3hen the pressure 3ave is )ainly governed. ;s the first exa)ple4 assu)e that the inta%e valve is closed during the fuel )ixture is inhaled into the cylinder. ;s the fuel )ixture has the flo3 inertia4 the )ixture flo3 in the inta%e )anifold can not stop instantly =ust at the closing the valve4 *ut pretends to flo3 continuously. 7herefore4 the air =ust *efore the valve 3ill *e pressed *y inertia energy of inta%e air. (onse?uently4 the air density at the port portion 3ill *e increased. ;t that ti)e4 if the valve is opened in ti)e4 then the air of high density can *e inhaled into the cylinder. 7his is the inertia effect. 6alve close A5igh density air at valveB -ensity of follo3ing air is lo3 & pressure 3ave are reflected *y surge tan% 5igh density air *y reflection of pressure 3ave is inhaled When the air density near the port is increased4 the density of the follo3ing air is lo3 respectively. &o4 the *oundary portion )a%es the pressure variations4 that is4 noise. 7his air density variation passes through the )anifold 3ith the speed of sound. t reflects to the end of the )anifold4 and then it returns to the port. When the high density air is *ac% to the port4 if the port is opened4 then the high density air can *e in=ected into the cylinder. 7his is the pulsation effect. ;s these effects are co)*ined4 it is hard to separate fro) each other. 5o3ever4 in order to )axi)iGe the effect4 it is prefer to )a%e the pressure 3ave in the )anifold to )a%e high air density near the port 3hen the valve is opened. 42 Chonan Technical Service Training Center Engine Principles 7o do so4 the dia)eter and length the inta%e )anifold and the shape of the inta%e port shall *e controlled. 3. 0ariable Intake yste! ;t lo3 speed ;t high speed 7he air flo3 in the inta%e )anifold is not unifor)ed *ut varia*le according to the engine speed. When the high density air flo3 reaches at the port4 if4 ideally4 the inta%e speed is )axi)u) =ust *efore the closing the valve4 then the inta%e inertia effect 3ill *e )axi)iGed. 7he air pulsation fre?uency is decided *y the dia)eter and the length of the )anifold. When the dia)eter is sa)e4 the fre?uency of the long length )anifold is s)all. t is the sa)e that the sound has the lo3er fre?uency 3hen the distance *et3een the hole and the )outh piece of the recorder is larger. :enerally4 the length of the )anifold is already decided4 so if the engine is running 3ith certain velocity4 the inta%e inertia is effective. 5o3ever4 if it is rotating 3ith varia*le speed4 then the lo3er density air can reach at the port 3hen the valve is opened so4 the charging of air )ay *e 3orst. (onse?uently4 the )ethod for varying the length of )anifold is developed according to the rp) of the engine. When the engine has high rp) in 3hich the valve is fre?uently opened and closed 3ithin the sa)e ti)e interval4 the short length )anifold is chosen to )a%e the cycle *e short. (ontrarily4 3hen the rp) is lo34 the long )anifold is chosen to )a%e the cycle *e long. &o4 it is possi*le to get the inta%e inertia effect 43 Chonan Technical Service Training Center Engine Principles in 3ide range of rp). ;s *eing the varia*le inta%e syste)4 it is called as the variable inertia charging syste! or the variable intake control syste!. 7here are )any types to control the length of the inta%e )anifold. /ainly4 the t3o types are used. 7he one type is that the separated t3o )anifold groups are connected together. When the engine is high speed4 the path is divided each other4 and 3hen the engine is lo3 speed4 the t3o )anifold groups are lin%ed each other to elongate the length of the total )anifold. 7he other is to attach a *ypass at the )anifold syste) in 3hich the air pass through the *ypass 3hen the engine is lo3 speed4 and the path to the *ypass is closed to reduce the length of )anifold at the high speed. n case of lin%ing so)e )anifolds4 the resonance )ay *e occurred *et3een the )anifolds. 7his co)es fro) the pressure vi*ration having the sa)e fre?uency in the separated )anifold. n this case4 the inertia charging effect can not *e expected even at the high speed. 7his pheno)enon can *e inhi*ited *y enlarging the volu)e of the inta%e collector connecting to the )anifold. When the resonance is occurred4 at the )iddle and lo3 speed4 the inertia supercharging effect *eco)es high so the charging efficiency 3ill *e increased. 7his is called as the resonance s$percharging e--ect. 4. Intake yste! 7he inta%e syste) ta%es the air to )ix 3ith the gasoline and inhales the )ixtures into the cylinder. :enerally4 the inta%e syste) co)prises the air cleaner filtering the dust in the inhaled air4 the carb$retor )ixing the air and the gasoline4 and the intake !ani-old Aor inlet !ani-oldB inhaling the )ixture into the cylinder4 at the head portion of the cylinder. @o3adays4 the electrical controlled unit for fuel in=ecting to the inta%e )anifold directly is 3idely used4 so the design of the inta%e syste) is changed very )uch. (ar*uretor inta%e syste) 44 Chonan Technical Service Training Center Engine Principles /P inta%e syste) ;t first4 the air inlet port 3hich 3as near the cylinder head is )oved to the front grill to inta%e the a)*ient air having lo3er te)perature than the air around the engine roo). ;s *eing lo3 te)perature air4 the air has high density4 therefore4 the )uch a)ount of oxygen 3ill *e contained into the inlet air. With the sa)e volu)e of the inlet air4 the lo3er te)perature of the air is the )ore prefer. !or exa)ple4 in su))er of 3.L te)perature4 3hen the air conditioner is 3or%ing at the lo3 speed such as at the rush hour in the city4 the te)perature of the engine roo) could *e over +.L. n this case4 *y calculation4 the a)ount of the oxygen in the air around engine roo) is 1"N less than that of the a)*ient air. 7he inlet air to the front grill is inhaled into the inta%e )anifold through the long duct via the air cleaner4 resonance cha)*er and throttle *ody. n the car*uretor syste)4 the dish type air cleaner 3as loo%ing on the car*uretor4 *ut no3adays4 the *ox type air cleaner is installed at one corner of engine roo). 7he air cleaner not only cleans the air going into the cylinder *ut also reduces the noise fro) the inta%e operating. 7he air cleaner ele)ent should *e )aintained periodically. 3he resonance cha!ber is a s)all *ox *ranched fro) the duct as the device for reducing the inta%e noise4 and it is called as the regenerator cha)*er or the side *ranch. ;ccording to the opening and closing the inta%e valve4 the vi*ration of the air inside the air cleaner *ox or the duct can )a%e a large inta%e noise or hinder the inta%e operation. Fsing the resonance effect *y installing a resonance device4 this vi*ration 3ill *e ter)inated. ". 3hrottle 0alve and Mani-old
1utterfly type4 slide type throttle valve 7o rise up the engine rp)4 3e press the accelerator pedal4 and to lo3er do3n the rp)4 3e release the accelerator pedal. ;s the accelerator pedal is lin%ed to the throttle valve *y the 3ire and lin%age4 3hen the pedal is pressed the throttle valve 3ill *e opened to inta%e the air into the cylinder. 7hat is4 the 45 Chonan Technical Service Training Center Engine Principles car*uretor or the electronic control syste) for fuel in=ection auto)atically chec%s the a)ount of the air to supply the a)ount of gasoline proper to the driving situation. n the car*uretor syste)4 the throttle valve is e?uipped 3ith the car*uretor. n the electronic control syste)4 it is installed at the )iddle of the throttle *ody Athrottle cha)*erB separately installed in the inta%e syste) and *eing 3ith the air flo3 sensor detecting the air flo3 a)ount and the throttle position sensor chec%ing the status of the throttle valve opening. n the throttle valve type4 there are a *utterfly valve in 3hich dis% plate having the shape of the *utterfly 3ing is attached at the axis inside the pipe to control the air a)ount *y rotating the axis4 and a slide type in 3hich an alu)inu) plate controls the a)ount the air 3ithout any hindrance at opening the throttle valve4 especially for racing engine. 7he air passing through the throttle *ody and the )ixture )ixed 3ith gasoline at the car*uretor are distri*uted into the cylinder *y the inta%e )anifold. 7he fuel in=ection is perfor)ed *efore distri*uting the air at the )anifold4 or at each cylinder as the )ixture. 7he i)portant thing is that the inta%e )anifold should inhale the )ixture into the cylinder as s)oothly as possi*le4 so that the )anifold should have less *ent portions and s)ooth inside faces. 7he )ixed gasoline in the car*uretor is inhaled into the cylinder as the foggy state in the air. When the te)perature is lo3 such as =ust *efore starting the engine4 this foggy particle of the fuel can attach to the )anifold 3all during *eing inhaled. 7herefore4 the )ixture is leaned so the co)*ustion is not enough. 7o solve this pro*le)4 using the heat fro) the exhaust )anifold or fro) the cooling 3ater for the engine4 the inta%e )anifold should *e heated up. 7he )ethod for heating the inta%e syste) using the exhaust te)perature is only used for the counter flo3 type engine in 3hich *oth the inta%e and the exhaust )anifolds are installed at the sa)e side of the engine. 7he )ethod for heating the inta%e syste) using the cooling 3ater is accepted in the cross flo3 type engine in 3hich the )anifolds are installed at the opposite side of engine each other. 46 Chonan Technical Service Training Center Engine Principles Chapter ". E#ha$st yste! 1. E#ha$st yste! 1y opening exhaust port of the cylinder head4 the co)*usted gas is exhausted through the exhaust )anifold4 the exhaust pipe gathering the co)*usted gas fro) each cylinder4 the catalyst converter purifying the used gas and the silencer A)ufflerB reducing co)*ustion noise. 7he )ost i)portant thing in the exhaust syste) is the s)ooth path also. 7he exhausted gases fro) each cylinder are *u)ped at the exhaust pipe gathering the each exhaust )anifolds. &o4 it is i)portant to prevent fro) hindering each flo3 or to increase the exhaust efficiency using the exhaust inertia effect having the sa)e principle in the inta%e inertia effect. 5o3ever4 it is hard to *alance *et3een the increasing the exhaust efficiency and the enhancing the engine perfor)ance4 *ecause there are )any 3ea% points fro) the engine to the )uffler. 7he exhaust )anifold is )ade of the casting iron having high heat resistance4 or the alu)inu) alloy. ;lso the exhaust gas te)perature is high. &o4 it is need to )a%e the exhaust syste) 3ith the )aterial having *etter heat resistance or to cool the exhaust syste) 3ith the 3ind. 3he catalyst converter is used for purification of the exhausted gases. 7here are a )anifold catalyst installed near the )anifold and a under catalyst installed under the floor. 7he )anifold catalyst is )ore effective *ecause the exhaust te)perature is higher than the other syste). 5o3ever4 it can *e easily aged *y the high te)perature so usually t3o pieces are used. 7he under catalyst is not easily degraded4 ho3ever it has high perfor)ance of purification. 3he !$--ler is e?uipped for reducing the te)perature and pressure of the exhausted gas as 3ell as the co)*ustion and exhausting sound. :enerally4 the )uffler has )any sector 3alls to )a%e the inside space into )aGe path for flo3ing the exhaust gas4 so it called as the !a?e type. 7here is also a straight !$--ler type in 3hich a tu*e having )any holes on the surface and silencer such as glass 3ool inside the tu*e. 7he )aGe type )uffler has )ore effective sound a*sorption a*ility *ut has larger 47 Chonan Technical Service Training Center Engine Principles flo3 resistance. 7he straight )uffler has )ore enhanced output *ut has louder sound. n so)e cases4 these t3o )uffler types are si)ultaneously e?uipped using separated t3o pipes so that the )aGe type )uffler is only used 3hen the engine is 3or%ing in lo3 speed4 and the straight type )uffler 3ill *e additionally used 3hen the engine is 3or%ing in high speed and load. 2. E#ha$st Inertia E--ect and ,$lsation E--ect 7he )ost i)portant thing deter)ining the perfor)ance of the exhaust )anifold is the s)oothness in the exhausting. 7he exhaust interference is the )ain pro*le) hindering the s)oothing exhaust. !ro) the each cylinder4 the co)*usted gas is exhausted according to the order of ignition. ;s they are )erged into the )anifold4 if the exhaust syste) is not 3ell arranged and co)*ined4 then one exhausted gas passing through the )anifold can *e collided 3ith another exhausted gas fro) another cylinder or the pressure in the )anifold 3ill *e increased4 so that the exhaust gas can not *e exhausted 3ell. 7he exhaust interference can *e overco)e *y elongating the distance *et3een the exhaust valves to the collection portion of each cylinder gas or *e )a%ing the angle of collecting portion into an o*tuse angle to ensure the 3ell flo3. ;s increasing the nu)*er of cylinder4 it is hard to ensure the 3ell exhaust flo3 *y co)*ining the increased )anifolds. n the serial $<cylinder tur*o engine4 3ith not *eing fully closed the first exhaust valve4 the fifth exhaust valve is opened4 and 3ith not *eing fully closed the fifth exhaust valve4 the third valve is opened. &o4 if the all $ exhaust )anifolds are gathered into one collecting pipe4 then the se?uentially exhausted gases can *e collided each other. 7herefore4 the )anifolds are divided into t3o groupsC the one includes the first4 the second and the third )anifolds and the other includes the fourth4 the fifth and the sixth )anifolds. Each group has o3n tur*o charger to eli)inate the exhaust interference and to enhance the engine output. 7he inertia effect and pulsation effect are utiliGed to exhaust the re)ained co)*ustion gases in the co)*ustion cha)*er. ;s *eing the sa)e 3ith the inta%e syste)4 3hen the exhaust valve is closed4 the gas density around the valve shall *e reduced to accelerate the exhausting gases fro) the cha)*er effectively. When the exhaust valve is open4 the co)*usted gas having the high pressure is exhausted through the exhaust valve and the 48 Chonan Technical Service Training Center Engine Principles re)ained gases 3ill *e exhausted *y the follo3ing co)pressing pressure of the piston at the exhaust stro%e and then the exhaust valve is closed. 7herefore4 the exhausted gas flo3 has high density portion and lo3 density portion in the )anifold. ;s 3e )entioned in a*ove chapter4 3hen a gas flo3 has a difference in density4 then pressure 3ave is generated. 7herefore4 this difference is trans)itted during the )anifold 3ith sound velocity. 7his is called the exhaust pulsation. 2ust *efore the exhaust valve is closed4 if it is possi*le that the density around the valve is lo3er than other portions4 then it is accelerated that the re)ained gas in the cha)*er shall *e too% out as 3ell as the fuel )ixture shall *e inhaled fro) the inta%e valve. 3. Co!ponent o- the E#ha$st @as 7he exhaust gas fro) engine and fuel syste) to at)osphere co)prises of the *urnt gas fro) the exhaust pipe4 the *lo3 *y gas fro) the cran% roo)4 and the vapor gas fro) the fuel tan% *y the hot 3eather and hot te)perature of the 3or%ing engine. ;s these gases include har)ful )aterials conta)inating the at)osphere4 a purification syste) should *e e?uipped. Especially4 the exhaust gas is the )ost i)portant gas. f the fuel is co)*usted perfectly4 then any har)ful )aterial is not included in the exhaust gases. 7he fuel4 gasoline4 consists of hydrocar*on4 the co)pound of the car*on and the hydrogen. n the cha)*er4 the fuel is changed into the car*on dioxide A(8 2 B and 3ater A5 2 8B 3ith )a%ing heat energy. n actual che)ical reaction4 the hydrocar*on and the oxygen are not changed at a )o)ent into the car*on gas and 3ater vapor. 7his che)ical reaction is very co)plicated. !or exa)ple4 the hydrocar*on 3ould *e divided into a s)all unsta*le )aterial *y the heat and reacts 3ith the oxygen4 or the results particles are reacting each other4 and so on. ;)ong the gases generated during this co)plicated reaction4 the car*on )onoxide4 hydrocar*on gas and the nitrogen oxide are the )a=or har)ful )aterials. 3he carbon !ono#ide A(8B is the unsta*le )aterial having one car*on and one oxygen so that it can *e easily changed into the car*on dioxide4 the sta*le and har)less )aterial4 if additional oxygen and heat are supplied. f 3e *reath the car*on )onoxide4 then it 3ill catch the oxygen delivered *y the he)oglo*in in the *lood to *e car*on dioxide4 )ore sta*le )aterial. &o4 our *ody is lag of oxygen. 49 Chonan Technical Service Training Center Engine Principles 3he hydrocarbon gas A5) (n D here )4 n are integer nu)*erB is co)e fro) the fuel not co)*usted or the inter)ediated )aterial during the che)ical process of co)*ustion. t is co)e fro) the *lo3 *y gas or the vaporiGed fuel fro) the fuel tan%. f this gas is revealed at the at)osphere4 then it 3ill react 3ith the oxygen and hydrogen and change into the aldehyde4 the har)ful )aterial having strong sti)ulus. 3he nitrogen o#ide A@8xB is co)e fro) the reaction *et3een the nitrogen A'+N of the airB and the oxygen in the air *y the high te)perature of 2...L in the cha)*er. ;s the nitrogen oxide is )ade *y the difference )echanis) 3ith the car*on )onoxide or hydrocar*on gas4 it 3ill *e increased 3hen the car*on )onoxide and hydrocar*on are reduced *y al)ost perfect co)*ustion. When the co)*ustion te)perature is lo34 the nitrogen oxide 3ill *e lessC ho3ever4 the co)*ustion efficiency 3ill *e 3orse. &o4 the nitrogen oxide shall *e treated at the exhaust syste). 4. Air4*$el 2atio and E#ha$st Co!position ;s the har)ful )aterial in the exhaust gas is the product fro) the co)*ustion4 one of che)ical reactions4 the a)ount of it is decided *y the air<fuel ratio4 e.g. the ratio *et3een the a)ount of air and the gasoline4 the co)*usting te)perature and the gas flo3 status. When the air<fuel ratio is lo3er than theoretical value A&toichio)etricB4 that is rich fuel4 the co)*ustion is not co)pletely perfor)ed4 so that )ore hydrocar*on gas and car*on are )ade. (ontrarily4 if the air<fuel ratio is higher than the theoretical value A&toichio)etricB4 that is lean fuel4 then the gasoline shall *e co)*usted co)pletely. &o4 the a)ount of the car*on )onoxide and the hydrocar*on gas 3ill *e less4 ho3ever4 the a)ount of the nitrogen oxide 3ill *e increase *ecause the co)*ustion te)perature is high. Especially4 3hen the te)perature is over 2...L4 the nitrogen oxide 3ill *e a*ruptly increase. Even the nitrogen and the oxygen are not react in the roo) te)perature4 in the high te)perature4 they are changed into the nitrogen )onoxide and then changed into nitrogen dioxide ;fter exited fro) the exhaust syste). 50 Chonan Technical Service Training Center Engine Principles 7he a)ount of the nitrogen oxide 3ill *e )axi)iGed at a*out 1$ air<fuel ratio higher than the theoretical ratio A14.'B. With lo3er ratios than 1$4 the nitrogen oxide a)ount 3ill *e reduced *ecause the co)*ustion te)perature is lo3ered. When the air<fuel ratio is over 1+ 3ith less fuel4 the fuel can not co)*usted properly so that the hydrocar*on 3ill *e increased. 7o reduce the har)ful )aterial4 it is i)portant ho3 to decide the air<fuel ratio. n so)e cases4 the air<fuel ratio can *e controlled *y inhaling the co)*usted gas into the )ixturesC it is called the exhaust gas recirculation device AE:#B. 3he e#ha$st gas recirc$lation device is called as E:# as an a**reviation. t is the device for returning so)e a)ount of the exhaust gas *ac% to the cylinder. -oing so4 the actual a)ount of fuel is reduced and the co)*ustion speed is slo34 and then the )axi)u) te)perature of the co)*usting cha)*er 3ill *e lo3ered and the a)ount of the nitrogen oxide 3ill *e also reduced. 1ut4 if the a)ount of the re<circulated exhaust gas is too )uch4 then the engine output and fuel efficiency 3ill *e 3orse4 so it is i)portant to control the a)ount of E:#. n the car*uretor syste)4 the a)ount of the re< circulated exhaust gas is controlled *y the reverse pressure of the inta%e )anifold. n the E(/ syste)4 the a)ount 3ill *e deter)ined in opti)iGing the vehicle status *y the sensing and calculating 3ith the te)perature of )ixture and cooling 3ater4 the vehicle speed4 and the load. ". E#ha$st ,$ri-ication yste! -evices for reducing the har)ful )aterial fro) the exhaust gas are the exhaust oxidation device co)*usting the car*on )onoxide and car*on and the 33ay catalysts device treating the exhaust gas using oxidation and de< oxidation reaction *y the three catalysts for car*on )onoxide4 hydrocar*on4 and nitrogen oxide. ;s the car*on )onoxide and the hydrocar*on gas are co)e fro) the inco)plete co)*ustion of the hydrocar*on and oxygen4 the oxidation device supply additional air to the exhaust port to )a%e oxidation the inco)plete co)*usted gas included in the exhaust gas. &o it is called as the secondary air device. n so)e syste)4 in the )iddle of the exhaust pipe4 a oxidation catalyst coveter4 the vessel including the oxidation catalyst )ay *e e?uipped for converting the car*on )onoxide and the hydrocar*on into the car*on dioxide and 3ater4 respectively. 51 Chonan Technical Service Training Center Engine Principles 7he electronic control engine uses the 33ay catalysts device4 generally. n the nitrogen oxidation4 there are nitrogen )onoxide consisting of one nitrogen and one oxygen4 and nitrogen dioxide consisting of one )ore oxygen. f the oxygen is re)oved fro) the nitrogen oxidation4 e.g. de<oxidation reaction4 then it *eco)es nitrogen gas. f the ac?uired oxygen fro) de<oxidation reaction of the nitrogen oxidation is supplied to the car*on )onoxide and hydrocar*on to oxide the)4 then the three har)ful gases can *e si)ultaneously purified. !ro) this idea4 the cha)ical action is perfor)ed the de<oxidation reaction on the nitrogen oxide and the oxidation reaction on the car*on )onoxide and the hydrocar*on *y controlling air<fuel ratio to eli)inate the oxygen in the co)*usted gas co)pletely. 7he catalyst is the )aterial accelerating certain che)ical reaction. 7he catalyst used in this purification is called the 39ay catalysts. 7here are the pellet type covering a fil) of platinu) and rhodiu) on the particle alu)ina and the honey co)* type. ;s the theoretical air<fuel ratio4 the ratio of co)plete co)*ustion is 14.'. 1ecause the 33ay catalyst is not 3or% properly 3hen the oxygen is re)ained4 it is necessary to )aintain the air<fuel ratio 3ith the theoretical value. 7o do so4 an o#ygen sensor is used for detecting the oxygen. f oxygen is detected in the exhaust gas4 then the co)puter 3ill calculate the a)ount of inta%e air and E:# gas to )aintain the fuel ratio to the theoretical value. $. 7lo94by @as 2ecirc$lation 6evice 7he *lo3<*y gas is the lea%ed gas to the cran%case through the end gap of piston ring at the co)*ustion stro%e. t includes vaporiGed engine oil4 too. 7he old type engine or so)e racing engine exhausts this gas into the at)osphere. When you stand near the racing car4 you can s)ell li%e so)e oil *urning result fro) the *lo3<*y gas. 7he co)ponents of this gas are the fla))a*le gas of '"M+.N and the co)*usted gas of 2.M2"N. ;s they are the )ain causes of air pollution4 the perfect co)*ustion syste) *y recirculation of this gas should *e e?uipped *y la3. 7his device is called as the *lo3<*y gas recirculation device or the positive cran%case ventilation4 P(6 in a**reviation. n the 1W of *lo3<*y gas4 ...4M..."g of the 52 Chonan Technical Service Training Center Engine Principles strong acid )oistures are included4 so that the inside of the engine can *e easily corroded and the engine oil can *e easily oxidiGed. 7herefore4 it is i)portant to treat the *lo3<*y gas for )aintenance the engine. 7he *lo3<*y gas a)ount 3ill *e increased as the pressure difference *et3een the cylinder and the cran%case is large. 7he pressure inside the cran%case is not changed so )uch even the engine is running 3ith high speed. &o4 3hen the engine speed and load is increased4 the *lo3<*y gas 3ill *e increased. 7he *lo3<*y gas treating should *e perfor)ed in t3o steps according to the engine load. 7he *lo3<*y gas recirculation device co)prise of hoses4 one is connected *et3een the roc%er cover and the surge tan%4 the other is connected *et3een the roc%er cover and the inta%e duct *efore throttle *ody for fresh air. ;lso there is an air passage *et3een the cran%case and the roc%er cover. When the engine is 3or%ing4 the pressure in the inta%e )anifold is al3ays negative pressure so that the *lo3<*y gas 3ill *e flo3 fro) the cran%case to the )anifold. 7he *lo3<*y gas in the inta%e )anifold is inhaled into the cylinder. 7he *lo3<*y gas 3ill *e treated *y these )ethods. 53 Chonan Technical Service Training Center Engine Principles Chapter %. Charger 1. 1inds o- charger 7he *asic of increasing the engine po3er and tor?ue is 5o3 )ore oxygen can *e inhaled into the engine. !or exa)ple4 if the density and a)ount of inlet air is high4 then the po3er and tor?ue shall *e high. ;dditionally4 *y developing the inta%e syste) and co)*ustion cha)*er4 it is possi*le to inta%e )ore air. 8ne of possi*le )ethods is to co)press the air and to inhale4 that is4 to use auxiliary device4 the charger. 7here are so)e types in the chargers. 7ypically4 there are a 3$rbocharger type in 3hich the charger is driven *y the exhaust tur*ine4 and a $percharger type in 3hich the supercharger is driven in )echanically using driving force of so)e part Asuch as cran%shaft rotationB. 7ur*ocharger &upercharger 7he 7ur*ocharger is4 as the H7ur*ine driving chargerI4 a syste) co)pressing air *y the co)pressor rotating a tur*ine using the exhaust gas flo3. t is possi*le to get high po3er output using a s)all device. 5o3ever4 3hen the engine is rotating 3ith lo3 speed4 the tur*ine can not rotate 3ith high speed4 so the co)pressing po3er is not enough and the acceleration 3ill *e delayed. 7herefore4 even the accelerator is pressed the engine rotation )ay not *e response 54 Chonan Technical Service Training Center Engine Principles i))ediately4 that is 3$rbo 'ag. 7he lag )eans the ti)e delay. ;s driven *y the interloc%ing )echanis) 3ith the cran%shaft4 the &upercharger4 the )echanical supercharger4 has the 3ell response. 5o3ever4 in the lo3 engine speed4 the engine efficiency 3ill *e 3orse *y increasing lea% air through the gap *et3een the rotor and the housing. n the high engine speed4 the driven force loss )ay *e increased. 7o recover these defects4 the structure of supercharger syste) )ay *e changed or a the 7ur*ocharger and the &upercharger )ay *e co)*ined to ne3 syste). 7he engine 3ithout such supercharger is called as the naturally aspirate engine or @; engine. 2. 3$rbocharger ;s the tur*ocharger is a co)*ined 3ord of tur*o Atur*ineB and charger4 it co)prises of a tur*ine and a co)pressor directly lin%ed4 so that the tur*ine 3heel is rotated *y the exhaust gas energy and the inlet air 3ill *e co)pressed *y the rotation of the tur*ine 3heel. 7he *ody of tur*ocharger co)prises of tur*ine 3heel4 co)pressor 3heel and axis4 and attached near the exhaust )anifolds. 7he heated air *y the co)pressing is cooled *y the intercooler and supplied into the engine via the throttle valve. 7he exhaust gas passes to the tur*o charger to rotate the tur*ine 3heel. n order to prevent the over *oosting at high speed4 3hen the *oost pressure is over the predeter)ined pressure4 a 3aste gate valve Aexhaust *ypass valveB of the W:7 A3aste gate tur*ochargerB 3ill *e opened. 7he tur*ine 3heel is rotated 1..4... rp) O 1$.4... rp) 3ith hot exhaust gas a*out ,..L at high speed4 the tur*ine 3heel is )ade of light )aterial having high heat resistance such as cera)ics. 7he s)aller and lighter tur*ocharger is *etter for the engine response such as acceleration and deceleration *ut 3orse po3er at high speed. 8n the contrary4 the *igger tur*o charger has a high po3er at high speed *ut 55 Chonan Technical Service Training Center Engine Principles slo3 response. 7herefore4 it is i)portant to select the siGe of tur*o 3heel according to the displace)ent volu)e of the engine. :enerally4 the co)pressor 3heel is )ade of alu)inu) to )a%e lighter tur*ocharger. !or the supporting of the high speed rotor shaft4 lots of the engine oil is supplied to the shaft for the lu*rication and the cooling. f the engine is stopped fro) the high speed a*ruptly4 the tur*ocharger is rotated 3ithout the oil *y inertia force of tur*ocharger until self stopping. &o4 the rotor shaft )ay *e adhered. !or this reason4 the tur*o engine should *e stopped after idling. 3. 7oost ,ress$re and Co!pression 2atio 7he air pressure 3hich is pressuriGed *y the tur*ocharger is the 1oost pressure. f the *oost pressure is increased4 the inta%e air a)ount into the cylinder is also increased and the po3er output 3ill *e increased. 5o3ever4 the *oost pressure can not *e increased 3ithout li)itation. ;s increasing the *oost pressure4 the actual co)pression ratio is also increased4 so %noc%ing shall *e occurred at high co)pression pressure. 7he actual co)pression ratio represents ho3 the inlet air into the cylinder co)pressed actually is. &o4 the *oost pressure is regulated *y 3aste gate valve. 7he %noc%ing is the self ignition pheno)ena 3hile the fla)e is spreading after the ignition of the spar% plug4 the un<*urn )ixture can *e easily self<ignited at high te)perature condition *y high co)pression. &o4 the %noc%ing is occurred as )uch as the actual co)pression ratio high. 1y this reason4 the co)pression ratio of the tur*o engine in specification is s)aller than that of the @; engine. !or exa)ple4 if the engine having the represented co)pression ratio of 1. is supercharged 3ith 1 at)4 then the air a)ount 3ill *e 2 ti)es and the actual co)pression ratio 3ill *e 2. and then %noc%ing 3ill suddenly *e occurred. :enerally4 co)pression ratio of the co))ercial tur*o engine is set lo3er than that of the @; engine *alancing 3ith the po3er4 tor?ue and fuel efficiency. 7he %noc%ing can *e prevented *y controlling the ignition ti)ing in the @; engine *ut the %noc%ing control *y the ignition ti)ing in tru*o engine is not easy *ecause the %noc%ing is affected *y the *oost pressure. 7he )axi)u) po3er and fuel efficiency is )ade =ust *efore the %noc%ing is occurred 56 Chonan Technical Service Training Center Engine Principles *ecause the co)*ustion speed is )ost fast at this situation. 1y sensing the %noc%ing noise4 the ignition ti)ing can *e fully advanced *y E(/ Aelectronic control )oduleB until the %noc%ing is occurred. 7he sensor for detecting the shoc% noise is the %noc% sensor. 7he %noc% sensor converts the vi*ration a*out ' %5G into an electrical signal. 1y attaching at the cylinder *loc%4 this signal is treated *y co)puter 3ith the engine rp)4 cran% angle4 and the inta%e air a)ount to control the ignition ti)ing for preventing the %noc%ing 4. 3$rbo 'ag 7he tur*o charger is an air co)pressor for ho3 )uch air is supplied. 1y using the negative pressure ac?uired 3hen the piston goes do3n and the flo3 inertia for inta%e air4 the @; engine can )a%e the charging efficiency of $"M,"N. n the tur*o charger4 charging a)ount is 1.2M1." ti)es higher than @; engine if the displace)ent volu)es are sa)e. 7herefore4 it is possi*le to )a%e s)aller engine than @; engine if the po3er and the tor?ue are sa)e. 5o3ever4 it has a defect4 so called the tur*o lag. 7he tur*o lag is the ti)e delay fro) starting the acceleration to the actual rp) increasing of the engine. Especially4 it is occurred 3hen the car is started4 accelerated suddenly4 or speed up fro) the lo3 speed. 7he process is li%e thatC at first4 the throttle valve is opened4 then the air a)ount is increased4 then the co)*usted gas is increased and the exhaust gas te)perature is increased. ;fter that4 the rp) of the tur*ine is increased *y the increasing exhaust gas4 so that the supplied air a)ount *y the co)pressor is increased. 1y this process4 the inta%e air a)ount is increased )ore. ;ccording to this process4 the engine acceleration is delayed fro) the starting of acceleration to the actual rp) increasing of the engine. 7o )ini)iGe the tur*o lag4 there are )any researches and develop)ents. !or exa)ple4 as the si)plest )ethod4 there is a )ethod for increasing the exhaust speed pushed into the tur*ine 3heel. 1y reducing the dia)eter of noGGle of exhaust pipe4 as the exhaust speed can *e increased 3ith the sa)e displace)ent volu)e4 the tur*o lag can *e )ini)iGed. 5o3ever4 in this case4 the )axi)u) po3er is li)ited. 7o attach s)all t3o tur*o instead of large one4 it is possi*le to reduce the tur*o lag. !or exa)ple4 in the $<cylinder engine4 one tur*o is attached at each 3<cylinder. -oing so4 it is possi*le to prevent the exhaust interference as 3ell as to increase the po3er. 7his )ethod is called as the t9in t$rbo type. 8n the other hand4 the t9o 9ay t9in t$rbo type also accepts the t3o tur*o4 *ut =ust one tur*o 3ill *e driven at the lo3 speed to )aintain *etter response and t3o tur*o 3ill *e driven at the 57 Chonan Technical Service Training Center Engine Principles high speed for enhancing tor?ue. 5y*rid tur*o !or another exa)ple4 there is a hybrid t$rbo type in 3hich the supercharger is used for the lo3 speed4 and the tur*ocharger is used for high speed. n the electronic control engine4 0@3 A6aria*le :eo)etry 7ur*ochargerB is used to reduce the tur*olag and to increase the tor?ue of the engine. 7he 0@3 uses a set of ad=usta*le vanes4 or noGGles4 to direct flo3 into the tur*ocharger tur*ine. When the vanes are closed4 flo3 is directed tangentially into the tur*ine 3heel. 7his i)parts )axi)u) energy into the tur*ine4 causing the tur*ocharger to spin faster. (onversely4 3hen the vanes are opened4 they direct flo3 into the tur*ine in a )ore radial direction. 6:7 A6aria*le :eo)etry 7ur*ochargerB 7his reduces the angular )o)entu) of the flo3 going into the 3heel4 producing less tur*ine 3or% and ulti)ately slo3ing do3n the tur*ocharger. ". $percharging yste! and Heat 7he tur*ine shaft of tur*ocharger is supplied lots of engine oil to cool and to lu*ricate. 7herefore4 engine oil in the tur*o engine is deteriorated easier than @; engine. ;s co)*usting )ore )ixture4 the charging syste) can not avoid increasing te)perature of co)*ustion cha)*er. ;s the tur*ocharger perfor)s the *oosting using the exhaust gas energy4 the *oosting efficiency 3ill *e *etter at the higher te)perature of exhaust. !or exa)ple4 *y adopting the heat resistance )aterial to the parts such as the exhaust valve 3ith natriu) and the stainless exhaust )anifold4 and )a%ing the supercharger of high heat resistance )aterial4 the perfor)ance shall *e enhanced. 7he inlet air should have as lo3er te)perature as possi*le. 1ecause the air density is lo3ered as the te)perature is higher4 the actual 58 Chonan Technical Service Training Center Engine Principles co)pression ratio 3ill *e decreased as the te)perature is increased 3ith the sa)e volu)e and the oxygen a)ount 3ill also *e decreased. f the inlet air is hot4 the co)press )ixture at the co)pressing stro%e has higher te)perature easy to )a%e a %noc%ing. When the air is co)pressed the te)perature is increased. 7his is the sa)e in the charging process. &o4 the *oosting effect is reduced as the a)ount of increased te)perature. 7herefore4 the heated air should *e cooled using a radiator *efore it reaches at the throttle valve. 7his cooling device is the intercooler. 7here are t3o types in the intercooler4 air cooling and 3ater cooling syste). ;ir cooling type Water cooling type 3he air type intercooler cools the inlet air te)perature using the 3ind get fro) the running of the vehicle. 7he intercooler is attached at the front or side of the radiator. 7he structure of intercooler is si)ilar 3ith the radiator4 *ut the flo3 is not the 3ater *ut the co)pressed air *y the charger. 3he 9ater type intercooler cools the co)pressed hot air using an additional cooling 3ater separated fro) the engine cooling 3ater. 7he 3ater has higher heat capacity than air4 so the 3ater type is )ore effective than air type4 *ut it has high cost for parts and )aintenance. $. $percharger 7he supercharger drives the *lo3er and co)pressor to *oost using the engine po3er. t can )a%e higher tor?ue and not )a%e any response delay such as the tur*o lag. 5o3ever4 the driving force for supercharger is fro) the rotation of the cran%shaft4 so the engine po3er shall *e consu)ed. 7he )axi)u) po3er output is lo3er than tur*ocharger. 7here are so)e %inds in the supercharger4 typically4 the #oots 1lo3er and the 0yshol) (o)pressor. 3he 2oots 7lo9er has *een used in vehicle engine. 7he *oost control is perfor)ed *y co)puter. t is operated 3hen the high output is needed such as for accelerating and driving in high speed. 59 Chonan Technical Service Training Center Engine Principles #oots *lo3er 7he structure of the roots *lo3er is4 to send the air fro) one side to other side *y rotating t3o elliptical shaped alu)inu) rotors coated 3ith special resin4 in the oval housing. f the *oost pressure is over charged4 the valve is opened to return so)e a)ount of the charged air. 0yshol) co)pressor 3he 'yshol! co!pressor had *een used in industrial field not in vehicle engine. 7he structure is that t3o rotors including 3 and " scre3 *lades respectively are co)*ined in the elliptical shaped housing. t is driven *y a 6 *elt lin%ed 3ith the engine. 7he rotor is )ade of alu)inu) alloy coated 3ith resin of teflon. When it is rotating4 airs supplied fro) one side is accu)ulated and trans)itted to other side so the air is co)pressed. (onse?uently4 the inta%e air is co)pressed up to 2 ti)es. n the supercharger4 the roots *lo3er is not a co)pressor *ut a fan as %no3 fro) the na)e. n the @; engine4 the air is charged *y the negative pressure generated 3hen the piston goes do3n4 *ut the supercharger is additionally e?uipped the *lo3er for enhancing the charging efficiency *y positively sending the air. 7he 0yshol) co)pressor is a co)pressor so that it can send the co)pressed air li%e the tur*ocharger. 60 Chonan Technical Service Training Center Engine Principles Chapter &. '$brication yste! 1. 3he 2ole o- Engine :il 7he )ain role of the engine oil is to )ove the dyna)ic syste) such as the piston in the cylinder and the cran%shaft s)oothly. 7o do so4 the oil for)s a oil fil) at the )etal surface to reduce the friction *et3een the )etal surfaces. ;t the sa)e ti)e4 the engine oil can secure the co)*usted gas not to lea% to the cran%case4 cools the piston and valve4 and reduce the shoc% trans)itted fro) the piston to the cran%shaft as 3ell as clean the engine inside. ;s the lu*rication is already )entioned in the section of 2ournal 1earing4 here4 3e 3ill explain the other roles of the oil. 7he first is the sealing role in 3hich the engine oil *et3een the piston ring and cylinder prevents the lea%ing the co)pressed air or co)*ustion air. 8il =et 7he cylinder head and the piston cro3n directly contacts 3ith the hot co)*usted gas. 7he cylinder head is cooled not only *y the cooling 3ater *ut also *y the oil at the dyna)ic syste). 7he heat of piston cro3n is trans)itted to the cylinder 3all via the piston ring. ;lso the piston cools do3n *y spraying the engine oil. ;nother i)portant role of the oil is to reduce the shoc%. 7he co)*ustion force is very strong up to several tons 3eight force. 7his force is trans)itted fro) the piston to piston pin4 to (onnecting rod4 to cran% pin and to cran%shaft. n that process4 the oil a*sor*s shoc% at the piston pin and the cran% pin. 61 Chonan Technical Service Training Center Engine Principles Except that4 the engine oil can 3ipe out the foreign )aterials such as car*on particle generated *y *urned oil and )etal particles fro) the 3ear of )etal surfaces. 7he oil also prevents inside of the engine fro) *eing rusted *y che)icals fro) the co)*ustion. 2. '$brication Method n old style engine4 the lu*rication )ethod 3as so called the plash type in 3hich the *ig end of connecting rod hit and sprayed the oil contained in the oil pan under the connecting rod. @o3adays4 the lu*rication oil is sent to necessary portion *y the oil pu)p and collects to the oil pan. ;ccording to the oil circulation )ethod4 there are the dry<su)p type and the 3et<su)p type. 7he lu*rication device consists of the oil pan containing oil4 the oil filter purifying the oil4 the oil pu)p sending the oil to each portion. 3he 9et4s$!p is e?uipped in )ost car. 7he oil contained in the oil pan is filtered *ig foreign )aterials using the oil strainer consisting of steel )eshes and sent to the oil -ilter *y oil pu)p to eli)inate any tiny foreign )aterials. 7here is a oil gallery in the engine *loc%4 it is a oil passage for each dyna)ic parts such as cran%shaft4 cylinder head4 connecting rod and cylinder 3all. Wet<su)p type -ry<su)p type 7he oil is returned to the oil pan fro) the piston4 connecting rod4 cran%shaft and cylinder head. When the car is turned rapidly or accelerated or decelerated a*ruptly4 the oil in the oil pan is leaned one side so it can not *e pu)ped 3ell. &o)e engines have a separator4 a %ind of partition in the oil pan to prevent the oil fro) leaning. !or the special engine for racing car4 the cavenging p$!p ta%es the oil 62 Chonan Technical Service Training Center Engine Principles and air together4 and the oil and air are separated *y a separator and then oil is contained to the separated oil tan%. 7his is the dry4s$!p type. ;s the dry<su)p )ethod does not contain the oil in the pan4 the oil pan can *e thinner. &o4 the lo3er part of engine is s)aller and the engine is designed to have lo3er 3eight center. 5o3ever4 the device should *e co)plexed. t is applied only to the special case for e?uipping the opposed engine. &o)e engine e?uips a se)i<dry<su)p type having the oil pu)p for collecting the oil in the oil pan. 3. ,arts o- '$bricant yste! 7he 3 )ain parts consisting of the lu*ricant syste) are oil pu)p4 oil filter and the oil cooler cooling the heated oil. 7here are )any %inds in the oil p$!p ta%ing up the oil in the oil pan. 7he passenger car uses a gear pu)p co)*ined 3ith toothed 3heel and lin%ed to the cran%shaft directly. 3he gear p$!p co)prises of a driven gear in the pu)p *ody and the drive gear lin%ed 3ith the tooth of the driven gear. When the drive gear is rotating4 the driven gear is also rotating. 5o3ever4 the centers of each gear are departing each other so the oil *et3een the) is pu)ped fro) the inlet port to outlet port. ;ccording to the tooth shape4 there is an nvolute type4 the 3rochoidal type4 and so on. :ear type oil pu)p 7he oil sending a)ount *y the oil pu)p is proportional to the engine rp). ;t the high rotation of the engine4 the oil pressure is too high. ;t the lo3 te)perature4 the degree of viscosity of oil is increased so the oil pressure is too high. 7he device for )aintaining the oil pressure should *e e?uipped. t is called the press$re reg$lator or the relie- valve. 7he oil -ilter purifying the oil fro) the car*on or )etal particles. ; folded filter paper is inserted into the cleaner case. 7here are t3o types for the replace)ent the ele)ent type and the cartridge type. 7he cartridge type is replaced the filter 3ith case4 the ele)ent type is replaced only filter ele)ent 3hen the filter is replaced. 7he proper 3or%ing te)perature of the engine oil is a*out +.L. f the te)perature is too lo34 the friction *eco)es high *ecause of high viscosity. f the te)perature is too high4 the oil pressure is lo3ered so lu*ricating a*ility 3ill *e degraded and also the oil in the high perfor)ance engine can *e easily deteriorated. 63 Chonan Technical Service Training Center Engine Principles &o the oil cooler is re?uired for the high perfor)ance engine. 3he kinds o- oil cooler are divided into the 3ater type and the air type. 3he 9ater type oil cooler )aintains the oil te)perature using the engine cooling 3ater4 and the air type oil cooler uses the running 3inds. 7he air type has si)pler device4 *ut the cooling efficiency is lo3er than the 3ater type. 7he 3ater type is )ore co)plicated4 *ut it ensures the )ore sta*le cooling efficiency. 4. Engine :il ;s 3e have )entioned4 the engine oil 3or%s for reducing the 3ear4 cooling the piston and the cylinder head4 sealing the gap *et3een the piston and cylinder4 releasing the shoc%4 cleaning the engine inside4 preventing the %noc%ing and so on. 7he re?uired characteristics of the engine oil are as follo3s4 < Proper viscosity at 3or%ing condition < :ood lu*ricant perfor)ance < 5igh heat and corrosion resistances < ;nti<*u**le 7he )ost i)portant characteristic is the viscosity. 7herefore4 the engine oil is classified *y t3o aspects4 the viscosity or the ?uality. 7he co))ercial engine oil is sold in case of 1W4 4W or 2.W. ;t the case4 there are na)e of )anufacturer4 *rand na)e and oil na)e 3ith the viscosity class and the ?uality class.
n the viscosity classification4 according to the standard *y &;EA&ociety ;uto)otive EngineersB4 the lo3er viscosity has lo3er nu)*er and higher viscosity has higher nu)*er. !or cold 3eather4 letter HWI is added. !or exa)ple4 certain classification li%e that the nu)*er 3. is for general purpose4 and the nu)*er 2. is for 3inter4 is the single grade using one nu)*er syste) only. ;nother classification li%e that a range is represented such as "W<3. or 1.W<3.4 is the !$lti grade. n this case4 *y co)paring the "W<3. 3ith the 1.W<3.4 the "W<3. has lo3er viscosity than 1.W<3. at lo3 te)perature4 *ut has higher viscosity at the high te)perature. :enerally4 3hen the te)perature is increased4 the viscosity of oil 3ill *e decreased. 7o indicate ho3 the viscosity is changed4 the viscosity inde# is used. f the viscosity is not easily changed4 then the viscosity index of the oil is high. 7he higher viscosity index is easier to use. n the B$ality classi-ication4 the standard *y the ;PA;)erican Petroleu) nstituteB is used. 64 Chonan Technical Service Training Center Engine Principles !or gasoline engine4 the letter H&I follo3ed fro) other alpha*et letters is assigned. !or the diesel engine4 the letter H(I follo3ed fro) other alpha*et letters is assigned. !or exa)ple4 letters fro) &- to &: are assigned for the gasoline engine. 7he %ind of engine oil and replacing period are decided *y type of engine4 driving condition and a)*ient te)perature4 so please refer to the )anual carefully to select the engine oil. 7he replacing running ti)e is a*out 1.4...%) for &-4 and 1"4...%) for &E4 and &! 1"4...%) for gasoline engine roughly. !or tur*o engine4 the engine oil should *e replaced at every "4...%) running ti)e *ecause the driving condition is very tough. 7he )aintenance intervals for each engines are varies4 refer the )anuals for the each engine. 65 Chonan Technical Service Training Center Engine Principles Chapter (. Cooling yste! 1. Cooling syste! 8f the total heat energy generated *y the co)*ustion of fuel )ixture in gasoline engine4 a*out 3.N is converted into the %inetic energy to push the piston4 another a*out 3.N is 3asted 3ith exhaust gas4 another a*out 3.N is trans)itted to coolant through the piston and the other a*out 1.N is lost *y friction. ;)ong the)4 if the heat trans)itted to the co)*ustion cha)*er 3all is not eli)inated as ?uic%ly as possi*le4 the piston or the cylinder 3ill *e defor)ed *y this heat or the fil) of lu*ricant oil 3ill *e *ro%en. f this heat is cooled excessively4 the )uch heat energy 3ill *e trans)itted to the coolant so that the heat efficiency 3ill *e degraded. 7herefore4 cooling syste) should *e controlled to )aintain the proper te)perature according to the driving situation. 7he cooling syste) for vehicle engine is classified into the 9ater4cooling syste! and the air4cooling syste!. 7he air<cooling syste) is hard to cool unifor)ly and easy to )a%e a loud noise4 so no3adays al)ost this syste) is not used in the vehicle. ;ccording to the flo3 type of 3ater cooling syste)4 there are the C4t$rn -lo9 type flo3ing fro) one side of the engine to the sa)e side4 and the cross -lo9 type flo3ing fro) one side to the opposite side. ;dditionally4 according to the flo3 direction4 it can *e classified into the longit$dinal -lo9ing type flo3ing along to the longitudinal direction of the engine4 and the lateral -lo9ing type along to the lateral direction of the engine. n the 3ater<cooling syste)4 the cooling 3ater is circulated *y 9ater p$!p fro) lo3er portion of the 3ater =ac%et to the radiator. -uring running4 strong 3inds can cool the radiator4 ho3ever4 3hen the car is stopped or slo3ly driven4 a -an should send 3inds in force. 7he cooled 3ater shall *e returned to the 3ater =ac%et *y the pu)p. 1y installing a ther!ostat *et3een the 3ater =ac%et and the radiator for sensing the cooling 3ater te)perature4 if the cooling 3ater has too lo3 te)perature4 the ther)ostat *loc%s the 3ater passage. 7he )ost used ther)ostat is the 3ax type in 3hich 66 Chonan Technical Service Training Center Engine Principles a 3ax is secured *et3een capsules4 and the 3ax opens and closes the valve using the expansion and shrin%ing *y heat. 7he ther)ostat 3or%ing te)perature is a*out +"L. 2. 2adiator 7he radiator is a *ody radiating heat4 in this case4 it is a device for radiating the heat into the at)osphere. ;s the heater is called also as radiator4 the cooling device in a car is called as radiatorC especially this is called as heat core. 7o enhance the efficiency of radiator4 the area should *e large as possi*le. :enerally4 the radiator co)prises a radiator core )anufactured *y 3elding )any )etal fins around a tu*e flo3ing cooling 3ater therein and t3o tan%s containing the cooling 3ater at *oth sides of the core. 7he tan%s are attached at the upper portion and lo3er portion of the heat core to flo3 hot 3ater to upper tan% and cold 3ater to lo3er tan% using the convection principle. -o3n flo3 type (ross flo3 type F<turn flo3 type t is the )ost used type so called the do9n -lo9 type. 7here is the cross -lo9 type in 3hich the tan%s are attached at the left and right side to flo3 in horiGontal. n the cross flo3 type4 the height of radiator can *e lo3ered and the 67 Chonan Technical Service Training Center Engine Principles design of front grill can *e freely changed. 5o3ever4 it has larger flo3 resistance. !or another exa)ple4 there is an C4t$rn -lo9 type in 3hich the radiator core is divided in up and do3n at the center portion4 and the cooling 3ater flo3s into the one side of the upper core and returned fro) the lo3er core side. 7he alu)inu) )aterial is )ore used in *oth the tu*e flo3ing 3ater and the fin colliding 3ith 3ind. 7o )a%e *e lighter4 the resin tan% including nylon 3ith glass fi*er instead of *rass or alu)inu) is )ore used. 5igh te)perature 0o3 te)perature 7he radiator is e?uipped 3ith a radiator cap to supple)ent the cooling 3ater. (onventionally4 this cap is =ust a cover so the cooling 3ater can contact outer at)osphere directly. @o3adays4 the cap secures the inside of the radiator that is the press$ri?ed radiator cap. n the at)ospheric pressure4 the 3ater is *oiling at 1..L and not increasing the *oiling point. 1y pressuring the cooling 3ater4 the pressure is increased and the *oiling point of 3ater 3ill *e higher so the difference 3ith the outer te)perature is larger. 7herefore4 the cooling effect shall *e increased. ;t the press$ri?ed radiator cap4 a press$re valve and a vac$$! valve are attached4 When the cooling 3ater is a*out 11.M12.L and the inside pressure is high4 then the pressure valve 3ill *e open to ta%e out the cooling 3aterC 3hen the te)perature is lo3 and the pressure is lo3ered4 then the vacuu) valve 3ill *e open to suc% the cooling 3ater to the radiator. &o the pressure of cooling 3ater is )aintained unifor)ly. 3. Cooling o- the Cylinder Head 7he )ost heated part of the engine is the co)*ustion cha)*er. 7he cylinder and the cylinder head are cooled *y the cooling 3ater4 the piston is cooled *y the engine oil. 7his heat affects to the te)perature of fuel )ixture4 the co)*ustion condition4 and the te)perature of exhaust gas4 that is4 to the engine perfor)ances. 5o3 to cool the cylinder head is the )ost i)portant thing. 7he )ost cylinder head parts are )ade of alu)inu) alloys *ecause it has high heat conductivity and light 3eight. ;s the inta%e port having the si)ilar te)perature of outer at)osphere and the exhaust port ta%ing out the 68 Chonan Technical Service Training Center Engine Principles so hot exhaust gas are nearly installed4 they )ay defor)ed *y the difference of the heat expansion. 7herefore4 it is very i)portant to cool 3ith *alancing the each part te)perature. 7he cooling 3ater is too% into the cylinder head fro) the 3ater =ac%et at the cylinder *loc%4 and flo3n around the exhaust port heated *y the exhaust gas4 and then too% out via the inta%e port. -oing so4 the te)perature difference a)ong the cylinder head4 the exhaust port and the inta%e port can *e )ini)iGed. t is possi*le to prevent the engine parts fro) *eing defor)ed or distorted *y the difference of the heat expansion. ;dditionally4 the each te)perature around each cylinder head in the series of cylinder should not have *ig difference. &o the te)perature of each cylinder should *e si)ilar as possi*le. !or exa)ple4 if the cylinders are se?uentially cooled fro) the front to the end4 then the later cylinder can not *e effectively cooled *ecause the cooling 3ater is already heated. n so)e cases4 the cooling 3ater is distri*uted to each cylinder at the *eginning of the cooling to *e cooled e?uivalently. 7he oil can *e used for cooling the cylinder head. 5o3ever4 the portions of the cooling effect *y the oil is a*out 2.N4 the )ost cooling is perfor)ed *y the cooling 3ater. 4. :verheat 7he 3ater te)perature of the engine is decided *y the *alance *et3een the generated heat capacity fro) engine and the radiated heat capacity fro) radiator. f the cooling is not enough4 then the cooling 3ater can *e *oiled. (onse?uently4 3ater vapor can *e e=ected fro) the radiator cap. 7his is called overheat. f the car is going 3ith overheat state4 then the perfor)ance 3ill *e degraded4 at last the engine 3ill *e stuc%. f the engine is nor)al and the ther)o)eter is varying4 then it )eans that overheat 3ill *e occurred. 7he )ain reasons are fourC one is that the 3ind a)ount passing the radiator is too s)allC another is that 3ind te)perature is too highC the third is that a)ount of cooling 3ater is too s)all and the last is that the engine is 3or%ing in hard situation continuously. When a car has aero parts or large fog la)p so the 3ind passing is hindered4 or 3hen the car runs unpaved road so the radiator covers 3ith dirty thereon4 then the cooling 3ater can *e easily overheated. n other case4 if the fan *elt is not tightened or *ro%en then the cooling 3ater can *e easily overheated *ecause the 3ind a)ount sent to the radiator is reduced. 7o tune up the tur*o engine4 3hen a large intercooler is installed in front of the radiator4 then4 then 3ind a)ount 3ill *e reduced and the cooling 3ater )ay *e overheated. f the 3ater pipe is old so the cooling 3ater is lea%ed4 or the *elt for driving the 3ater pu)p is loosened4 then the cooling 3ater )ay *e easily overheated *ecause the cooling 3ater is deficiency. 69 Chonan Technical Service Training Center Engine Principles Chapter ). *$el yste! 1. Carb$retor n the gasoline engine4 the car*uretor or the E(/ is used for )ixing the air and fuel. 7he )ost 4<cylinder engine uses the E(/ syste)4 only so)e s)all engines use the car*uretor. (ar*urator fuel syste) Electronic fuel syste) 7he car*uretor uses spraying principle for )ixing the gasoline and the air. 7hat is4 a fuel spraying hole is )ade at the venturi and the air flo3 at the venturi is high. &o the pressure at the fuel spraying hole is decreased. &o the gasoline 3ill *e follo3ing the air flo3 in the fog for) and it is )ixed 3ith air. 7his pheno)ena is called as the 0ent$ri e--ect na)ed *y the inventor. 7o enhance this effect4 the ventury is )ade in narro3 as possi*le. 7his inside dia)eter is called the !ain bore si?e indicating the siGe of the car*uretor. 1y define the dia)eter of the venturi a*out the )ain *ore siGe4 the gasoline a)ount can *e controlled according to the air flo34 so the air<fuel ratio can *e )aintained unifor)ly. 7he pipe for supplying the gasoline is the !ain =et Afuel spraying holeB. 1y selecting proper =et according to the driving state4 it is possi*le to cover the 3ide range of rp). 5o3ever4 3hen the engine is rotating 3ith lo3 speed such as idling state4 the pressure in venturi is lo3ered so the proper a)ount of gasoline is not in=ected. When the engine is rapidly accelerated4 the a)ount gasoline should *e larger than nor)al state. 5o3ever4 it is not so easy to control these variations. 7o overco)e these hindrances4 various car*uretors have *een developed. Especially4 in the )otor sports4 as the displace)ent volu)e is deter)ined4 the car*uretor is )ost i)portant device for enhancing the engine perfor)ance. 7he operation of car*uretor is li%e thatC at first4 the gasoline fro) the fuel tan% is contained into the -loating cha!berC 3hen the a)ount of gasoline in the float cha)*er is reduced then the float goes do3n and the )ore gasoline is supplied fro) the fuel tan%. When a driver presses the accelerator pedal4 the throttle valve is opened and air flo3 passing the venturi part so that the gasoline 3ill *e ta%ing out fro) the )ain =et. 7he car*uretor has this si)ple structure4 so the cost is lo3 and it has fe3er defects. 5o3ever4 for the )odern engines 3hich need to enhance the e)ission4 the fuel efficiency and the po3er output4 the car*uretor has )any pro*le)s. 70 Chonan Technical Service Training Center Engine Principles 2. Mechanical *$el In=ecting 6evice 1asically4 as regarding the negative pressure as the air a)ount in=ected4 the car*uretor supplies proper a)ount of gasoline using only )echanical device. 7herefore4 it can not )aintain the air<fuel ratio unifor)ly. t is need to control the in=ected fuel a)ount exactly using the predeter)ined the air<fuel ratio to prevent fro) 3asting the fuel or to enhance the engine response. ; ne3 syste) is developed in 3hich the inhaled air a)ount is )easured directly4 and the gasoline is sprayed to the inta%e )anifold 3ith the opti)iGed the air<fuel ratio using the )echanical device. 7his is the 14=etronic invented *y 1osch. 1y co)paring 3ith the car*uretor4 the fuel in=ecting device is in=ecting the fuel to the )anifold directly. 7herefore4 it has good response at the start and at accelerating and decelerating. t is hard for this device to )a%e the vapor lock in 3hich flo3 of fuel is *ro%en *y vaporiGing the fuel in the )iddle of fuel pipe. ;dditionally4 it does not )a%e icing that the car*uretor is froGen. 7he )ain feature of the K<=etronic is that installing a circular plate na)ed sensor plate in front of the throttle valve4 the gasoline a)ount is controlled using that the opening state of this plate is changed *y the air a)ount. When the throttle valve is open4 the air presses the sensor plate installing in the air flo3 )eter. 7he lever supporting this plate is connected to the device for controlling the in=ected fuel a)ount4 and the gasoline is in=ected to the fuel in=ecting device *y a response to the plate operating. ;s a syste) replacing the car*uretor4 the K< =etronic has *etter reliance. 5o3ever4 it so)eti)es in=ects the fuel in the sa)e )anner of car*uretor and controls the fuel a)ount )echanically. 7herefore4 it is hard to control the )ixture ratio precisely. n so)e cases4 *y accepting an E(/ to a portion of the syste)4 the KE<=etronic supple)enting these 3ee% points is developed. 5o3ever4 step *y step4 the full E(/ syste) is replacing these )echanical syste)s in order to regulate the exhaust gas and to enhance the fuel efficiency. 3. Electrical *$el In=ection yste! 7he )ain part of the electrical fuel in=ecting syste) is the fuel in=ecting device deciding the a)ount of fuel to )a%e proper )ixing ratio *y )easuring the inlet air a)ount. 7his syste) co)prises of the device of )easuring the air a)ount4 the device of in=ecting the fuel4 and the device of controlling theses operations. 7he representative )echanical fuel in=ecting device4 the K<=etronic4 uses the sensor plate for device )easuring air a)ount4 and trans)its the )ove)ent of sensor plate to the valve controlling fuel supplying. (ontrarily4 the electrical fuel in=ecting syste) the )easured air a)ount *y the air flo3 sensor is sent to co)puter as an electric signal to decide the fuel a)ount 3ith the result fro) the sensor for chec%ing the engine status. 1y these devices4 it is possi*le to control the air<fuel ratio precisely. 71 Chonan Technical Service Training Center Engine Principles 7he structure of the fuel in=ector is differed according to the )anufacturer and the applied engine type. Except the air flo3 sensor4 )ost parts are si)ilar. 5ere4 3e 3ill explain a*out the !ass air -lo9 type using the air -lo9 !eter as the air flo3 sensor. 7he filtered air through the air cleaner is )easured its a)ount at the air flo3 )eter4 and ta%en into the surge tan% Ainta%e collectorB via the throttle *ody including throttle valve connecting to the accelerator pedal. 7his air is distri*uted to the inta%e )anifold of each cylinder4 and inhaled into the cylinder 3ith the gasoline in=ected fro) the -$el in=ecting valve ;in=ector< to the )anifold or inta%e port. ;t this ti)e4 a controller decides the gasoline a)ount opti)iGed to the driving status and running condition of the vehicle. 7his is called as the ECM. Electronic Control Mod$le. 7he driving status is the electrical signal fro) the 9ater te!perat$re sensor4 the intake air te!perat$re sensor4 and the throttle position sensor4 and the running condition is the signal fro) the speed sensor and the signal indicating the air conditioning 3or%ing status. 7hese signals are sent to the E(/. 1y )e)oriGing the data concerning to so)e co)*inations of these signals and the control )ethod 3hich indicate 3hat a)ount of gasoline is in=ected according to the co)*ination to the co)puter installed into the E(/4 the co)puter can in=ect proper a)ount fuel decided *y the co)puter according to the accelerator operating4 fro) the in=ector. 4. *$el $pplying yste! 7he gasoline4 the fuel4 is contained in the fuel tan% and sent to the fuel in=ection device after eli)inating dust and 3ater *y filter. 72 Chonan Technical Service Training Center Engine Principles 3he -$el tank is )ade of galvaniGed steel to prevent rust4 as 3ell as the plastic tan% is )ore used. 7o protect the fuel fro) leaning one side4 there are so)e partitions4 called separator4 and level gauge is attached. 3he -$el p$!p has various types. 7he car*uretor uses )echanical pu)p4 E(/ syste) uses electrical pu)p using electric )otor )ostly. ; reg$lator. pressure controller4 is attached for sending the gasoline to the in=ector after controlling the gasoline pressure 3ithin the specific range. 73 Chonan Technical Service Training Center Engine Principles !or in=ecting the gasoline4 an in=ector is used. 7he in=ector has a needle valve closing the front of the noGGle so the valve is open *y flo3ing an electric current to the solenoid to in=ecting gasoline. n the in=ecting )ethod4 there are a ingle ,oint In=ection A,IB in=ecting gasoline to the collecting portions of )anifold4 and a M$lti ,oint In=ection AM,IB in=ecting gasoline to each )anifold corresponding 3ith each cylinder. 7he &P has the in=ector at the sa)e place as the car*uretor does4 *ut this )a%es the )ixture )ore effectively than car*uretor does. 7he /P can *e classified to point in=ection4 group in=ection and *an% in=ection according to the in=ecting ti)ing. Each )anifold has in=ector. 7he point in=ection perfor)s in=ecting operation at the inta%e stro%e of each cylinder according to the engine rotation. 7he gro$p in=ection perfor)s the in=ecting operation 3ith a group of cylinders 3hich have the se?uential inta%e stro%e. 8f course4 the point in=ection can in=ect the gasoline 3ith )ost opti)iGed ti)ing and a)ount. 5o3ever4 the electrical circuit for driving the in=ector is )ore co)plicated. &o4 so)e co))ercial car accepts the group in=ection. &i)plifying the group in=ection is the bank in=ection. ;t the inta%e stro%e and the co)*ustion stro%e in 3hich the piston goes do3n4 the needed gasoline is in=ected after dividing into t3o turns and ta%en into the cylinder after gathering at the inta%e stro%e. -ue to the si)ple structure4 it ensures the 74 Chonan Technical Service Training Center Engine Principles )ost efficiency in the gasoline in=ection. &o it is the )ost used )ethod in the gasoline engine. 75 Chonan Technical Service Training Center Engine Principles Chapter 1+. Ignition yste! 1. ,oint type Ignition 7he ignition syste) is to fire the )ixture co)pressed in the co)*ustion cha)*er )a%ing a fla)e 3ith a spar% plug. When the plus and )inus poles of the 126 *attery is shorted4 a spar% can *e )ade. 5o3ever4 it is too 3ea% to ignite the )ixture. 7herefore4 this voltage should *e *oosted up to 1.4...M3.4...6. 7he ignition syste) consists of a device for *oosting the voltage4 a device for distri*uting the ignition ti)ing and a series of spar% plug. 7o *oosting the voltage4 an ignition coil4 an electric inducer4 is used. 7he ignition coil co)prises of a iron core shaped of rod4 the secondary coil 3ound 3ith a*out 2.4...O 3.4... turns using a hairy thin copper 3ire around the core and the pri)ary coil 3ound 3ith 1".O3.. turns using copper 3ire of .."M1)) dia)eter over the secondary coil. When a current is flo3n at the pri)ary coil4 the iron core 3ill *e an electro)agnet. ;nd at ti)e 3hen the current at the pri)ary coil is *ro%en4 a *oosted high voltage is induced at the secondary coil. 7he distrib$tor has a device for controlling the current flo3ing at the pri)ary coil and a ca) having the sa)e nu)*er of extruded portions in the )iddle of it. When this ca) presses the ar) *y rotating4 the point attached in front of the ar) is opened to cut the current of the pri)ary coil Acontact breakerB. ;nd the distri*utor has also a device4 overlapping 3ith the contact *rea%er4 for distri*uting the *oosted voltage of the secondary coil to each plugs. ;t the ca) of the contact *rea%er4 an advancing device for controlling the ignition ti)ing at the variations of engine speed to send the *oosted high voltage to the spar% plug in ti)e. ;s the ca) should rotate 3ith 1>2 of the engine rp) to )atch the ignition ti)ing of the plug4 it should *e attached at the end of ca)shaft having the sa)e rotation speed. 7he advancing device shall *e explained at the section of gnition 7i)ing in detail. ;fter that4 the high voltage generated *y the ignition coil is sent to each spar% plug through a series of High43ension Cord. 7his ignition syste) is called contacting or point type. f the driving for the contact *rea%er is perfor)ed *y a transistor4 then it is called the full transistor type. !urther)ore4 developing the syste)4 the distri*utor is driven *y a co)puter in the distri*utor<less ignition device. 2. *$ll 3ransistor type Ignition n the point type ignition device4 the point is opened *y the ca)4 and high voltage is induced at the secondary coil 3hen the current at the pri)ary coil is cut. &i)ilarly4 3hen the s3itch is turn off4 a s)all un3anted spar% 3ill *e )ade at the contact point. ;s the sa)e of )echanical inertia4 the electrical current has the inertia. 7his un3anted spar% 3ill *e prevented *y inserting a condenser 3ithin the ignition circuit. !urther)ore4 the point 3ould *e *urned or not 3or% nor)ally at the high speed. 7herefore4 for inter)itting the current of the pri)ary coil4 a transistor is developed instead of the )echanical point. ;s *eing )any %inds in the transistor. the application )ethod is various also. When it is used for a s3itch4 @P@ type transistor is used. 7his consists of a *ase )ade of P type 76 Chonan Technical Service Training Center Engine Principles se)iconductor and t3o @ type se)iconductors at the *oth side4 one is a collector4 and the other is e)itter. n nor)al state4 the current is not trans)itted fro) the e)itter to the collector of @P@ type transistor. 5o3ever4 if a little current A*ase currentB is applied *et3een the e)itter and the *ase4 then an a)plified current is induced fro) the e)itter to the collector. Fsing this characteristic4 it can *e utiliGed as a s3itch. nstead of the ca) and point in the distri*utor4 the signal generator is e?uipped for detecting the ignition ti)ing4 the electrical signal is sent to the igniter including a transistor. 7hen the *ase current )ade *y the signal generator is applied to *et3een the e)itter and the *ase4 and then an a)plified current is generated fro) the e)itter to the collector. Fsing this current a)plifying4 the inter)ittent current is applied to the pri)ary coil4 so a *oosted voltage can *e generated at the secondary coil. 3he signal generator consists of a rotor having the sa)e nu)*er of extruded portions 3ith that of the cylinder4 a per)anent )agnet4 and a pic%<up coil detecting the change of )agnetic flux. ;s the signal rotor rotates 3ith the 1>2 speed of the engine speed4 the extruded portions passes through the gap *et3een the pic%<up coil and the per)anent )agnet corresponding 3ith the ignition ti)ing. 7he )agnetic flux generated *y the per)anent )agnet 3ill *e changed4 so an induced current 3ill *e flo3n at the coil. 7his current is used for the *ase current of the transistor. -oing so4 the trou*le fro) the contact *rea%er can *e resolved. 3. 6istrib$tor4less Ignition n the full transistor ignition syste)4 the pri)ary coil current s3itching is perfor)ed *y the signal generator and the transistor4 3hile the advancing and distri*uting of secondary current is perfor)ed *y the sa)e device used in point ignition syste). 7he distri*utor<less ignition syste) is that the advancing of ignition ti)ing is perfor)ed *y a co)puter using an electrical signal fro) the sensor for ignition ti)ing4 and the ignition is perfor)ed using generated secondary current fro) the ignition coil installed near the ignition coil. 7he )ain feature of this ignition device is the high<tension ca*le connecting the ignition coil X the distri*utor X the spar% plug. ;s this ca*le 3ill *e short only for connecting the spar% plug and the coil =ust near*y or this cord is not needed in so)e cases4 the trou*les fro) the electro)agnetic 3ave interference fro) the high current of the high<tension ca*le or the ignition faults fro) the electrical resistance of the ca*le can *e prevented. ;dditionally4 the electrical advance device is )ore co)pact than the )echanical one. 77 Chonan Technical Service Training Center Engine Principles nductive type cran%shaft position sensor 8ptical type cran%shaft position sensor n the sensor for deciding the ignition ti)ing4 the cranksha-t position sensor or the ca!sha-t position sensor4 one type co)prises of a ti)ing rotor driven *y the ca)shaft and a pic%<up detecting the position of the rotor electrically. ;nther type co)prises of a 0E- attached at the rotor *lade driven *y the ca)shaft and a photo diode to decide the ignition ti)ing. n the ignition )ethod4 there are the individ$al ignition !ethod and the bank ignition !ethod. ndividual ignition syste) 1an% ignition syste) n the ndividual ignition )ethod4 the ignition coil is installed at each cylinder to ignite se?uentially according to the order decided *y the E(/. n the *an% ignition )ethod4 the ignition spar% is occurred at t3o cylinders at the sa)e ti)e *y one ignition coil. n this ti)e4 one cylinder is in the co)pression stro%e and the other cylinder is in the exhaust stro%e. 7he ignition spar% at the co)pression stro%e is effectively used4 *ut the spar% at the exhaust stro%e is )eaningless. n this )ethod4 the used a)ount of the transistors and coils is half of individual ignition )ethod4 so the cost 3ill *e do3n. 78 Chonan Technical Service Training Center Engine Principles 4. park ,l$g 7he spar% plug ignites at the co)pressed )ixture to fire it according to the spar% arc *y the high voltage generated fro) the ignition coil. 7he spar% plug contacts4 at first4 3ith the )ixture having the si)ilar te)perature of outer at)osphere in the inta%e stro%e4 ;fter that4 it contacts 3ith the exhaust gas over 2...L and generates high voltage of 2.4...6. 7herefore4 it is the device 3or%ing in )ost severe condition. 7he spar% plug is used for )any %inds of engine in co))on4 and )anufactured 3ith a standardiGing specification internationally. 7here are )any %inds according to the di)ension4 structure4 perfor)ance and characteristic Aespecially4 heat characteristicB. 7his is distinguished *y the alpha nu)erical indicator. 7his indicating character differs fro) the )anufacturer4 so *e careful 3hen replacing the). :enerally4 spar% plug is classified as 14))4 12))4 and 1.)) according to the siGe of attaching scre3. 7o )a%e the co)*ustion cha)*er co)pact4 the s)aller plug is the *etter. 5o3ever4 the s)aller can *e the easier to *e affected *y heat. t is very i)portant to inspect the te)perature situation of the engine in order to use the spar% plug. 7he spar% plug4 during driving4 is affected *y the various te)peratures. 7he )ost affecting te)perature is the co)*usted a)ount of fuel )ixture per ti)e. ;s the engine is high speed4 the te)perature of plug 3ill *e high. Even in the sa)e driving condition4 the te)perature differs according to the heat range of the plug. 7he heat range is the degrees of 3hich the spar% plug radiates the heat ac?uired fro) the cha)*er. ;s the plug easily radiates the heat4 the heat range is high. n racing engine4 the cold type having high heat range should *e used to prevent the te)perature fro) increasing easily. (ontrarily4 if the engine is usually used in lo3 speed4 the hot type having lo3 heat range should *e used to prevent fro) *eing cold easily. 7he heat range is represented 3ith nu)eric character on the plug. t differs 3ith the )anufacturer. t should *e selected according to the used standard plug. f the plug not corresponding 3ith the engine features and driving conditions4 for exa)ple4 if it is used in the lo3 te)perature4 then car*on slug 3ill *e deposited on the end portion of the plug4 so it doesnEt 3or%. f the te)perature is excessively high4 then the )ixture is exploded *efore the ignition is 3or%ed4 that is pre<ignition 3ill *e occurred. 79 Chonan Technical Service Training Center Engine Principles Chapter 11. Co!b$stion and Co!b$stion Cha!ber 1. Co!b$stion ,rocess 7o get high output and to enhance the fuel efficiency4 it is necessary to co)*ust the )ixture of fuel and air perfectly as soon as possi*le 3hile the co)*ustion process. 7herefore4 to enhance the engine perfor)ance is to learn the relationship 3ith the co)*ustion and to study ho3 to increase the fuel efficiency. 7he )ixture of fuel and air *y the car*uretor and in=ector is4 at first4 inhaled into the cylinder through the inta%e valve 3ith the s3irling flo3. ;nd then it is co)pressed 3ith the s3irl flo3 *y the piston going up fro) the 1-( A*otto) dead centerB. ;t this ti)e4 the fog state fuel is converted into a vapor state *y the heat fro) the cha)*er 3all and adia*atic co)pression4 and the strong flo3 of the )ixture. &o)e co)ponents )ay change to the fla))a*le gas. When a fla)e is applied to the gas 3ith high te)perature4 then a fla)e %ernel is )ade *et3een the electrodes of the plug. 7his fla)e %ernel is a co)*usting gas unit having high te)perature )ade fro) the reaction the fuel gas and the oxygen in the air. 7his co)*usting gas unit i))ediately heats the )ixture there<around. 7he )ore )ixture surrounding the %ernel reacts 3ith )ore oxygen *y this heat and then converts into larger co)*usting gas unit. Within a short ti)e4 this se?uence is 3idely spread so the 3hole )ixture is converted into the co)*usting gas. 7his is the co)*usting process of the )ixture. ;s the ti)e for *eing the spar% is only a*out 2>1... seconds A2 )ille secondsD )sB4 if the te)perature around the fla)e %ernel is lo3 or the %ernel is *lo3n out *y the s3irl of the )ixture4 then the )ixture can not *e co)*usted. 7his pheno)enon is called the )isfire. n the process of the co)*ustion4 the *oundary *et3een the co)*usting gas and the co)*usted gas is called the fla)e surface. 7he expansion velocity of the fla)e surface is the fla)e velocity. 7he fla)e velocity is the sa)e )ixing the co)*ustion velocity 3hich is the speed of fla)e developing 3ith statistic fuel gas4 the expansion velocity 3hich is the speed of gas expansion *y the co)*usting heat4 and the velocity of the gas flo3. 7he co)*ustion velocity is changed *y the co)ponent of the fuel and air<fuel ratio 3hich is the 3eight ratio *et3een the fuel and air. 5o3ever4 it is very slo34 i.e. several c) per second4 ;s adding the gas expansion velocity 80 Chonan Technical Service Training Center Engine Principles and flo3 velocity to the co)*ustion velocity4 the fla)e velocity is a*out 1"M2.) per second4 even it can *e 3.) per second. 7herefore4 the flo3 of )ixture is very i)portant. 2. Air4-$el ratio and *la!e 0elocity 7o enhance the engine perfor)ance4 the fla)e velocity should *e fast and the a)ount heat energy 3hich 3ill *e converted into the %inetic energy should *e as large as possi*le. 7he fla)e velocity is decided *y the three )ain ele)ents including the co)*ustion velocity4 the gas expansion velocity4 and the )ixture flo3 velocity. 7o co)*ust the )ixture fast4 these ele)ents should *e )aintained in the *est condition. (onsidering the co)*ustion velocity and gas expansion velocity4 the fla)e velocity is decided *y the )ixture ratio 3hich is the ratio *et3een the fuel and air and the te)perature and the pressure of the )ixture. 7he te)perature and the pressure are decided *y the te)perature of cha)*er and co)pression ratio. 7o consider the te)perature and pressure is very co)plicated4 so here4 3e assu)e these conditions are constant. We focus on the fuel co)ponent and the )ixing ratio. 7he gasoline is a li?uid consisting of 4M12 car*on ato) in chain lin% and various )olecules including hydrogen ato). f the co)ponent ratio is changed or a )aterial is added to accelerate the co)*ustion4 then the co)*ustion velocity and the gas expansion velocity shall *e faster. 7he )ixing ratio is a nu)*er representing the ratio of fuel a)ount and the air a)ount. t can affect to the co)*ustion velocity. &o it can *e represented *y the three indicating nu)*er such as the air4-$el ratio Aor AD* ratioB4 the e#cess air ratio4 and the eB$ivalency ratio. 7he air<fuel ratio is the value calculated *y 3hich 3eight of air included into the )ixture is divided *y the 3eight of fuel included into the )ixture. t is called the AI2D*CE' 2A3I:4 or AD* ratio. When the air and fuel are )ixed4 the ;>! ratio for co)plete co)*ustion theoretically is called the theoretic AD* ratio. 7he theoretic ;>! ratio of the regular gasoline is a*out 14.'. f the actual ;>! ratio is less than the theoretic ;>! ratio4 then the a)ount of the gasoline is )ore than the theoretic ;>! ratio so it is indicated as #(54 other3ise4 as 0E;@. !or the )ixture is co)*usted in the *est condition and for the fla)e velocity is fastest4 the ;>! ratio is little s)aller than the theoretic ;>! ratio4 that is 13."M14. 7his )eans that 3hen the fuel is little )ore than air4 the co)*ustion is *etter. 7he co)*ustion velocity has the )axi)u) value at the ;>! ratio of 12M134 3ith )ore gasoline a)ount. 7herefore4 the engine po3er output 3ill *e 81 Chonan Technical Service Training Center Engine Principles )axi)u) at the ;>! ratio of 12M13. 8ther3ise4 the output 3ill *e reduced. n the aspect of fuel consu)ption ratio4 the consu)ption ratio 3ill *e )ini)u) value a*out the ;>! ratio of 1$4 that is4 little lean state has the *est fuel efficiency. ;fter co)*usted4 if any oxygen is not re)ained4 then the gasoline is not co)pletely co)*usted. 3. Ignition 3i!ing 7he ignition ti)ing is 3hen the co)pressed )ixture is fired4 that is the ti)ing for )a%ing a electrical fla)e at the spar% plug. :enerally4 it can *e thought 3hen the )ixture is fully co)pressed and the piston reaches at the 7-( Atop dead centerB is the *est ti)ing for the ignition. 5o3ever4 it is too late. 7he reason is that the co)*ustion velocity of the )ixture is changed *y the gas flo3 velocity. ;s the engine speed is increased4 the gas flo3 3ill *e faster and faster. 7herefore4 the fla)e velocity 3ill *e faster. &o4 to ignite 3hen the piston is at the highest point is too late. 7he *est ti)ing is 3hen the piston is al)ost at the highest point that is4 3hen the area of fla)e surface is al)ost half of the co)*ustion cha)*er. 7he ignition ti)ing is represented *y the rotation angle of the cran%shaft a*out the 7-( of the piston. n ter)s of the angle4 if the ignition ti)ing is set to 4.M3.P *efore the 7-(4 then the co)*ustion cha)*er has the )axi)u) pressure at the 1"M2.P after the 7-(. f the ignition ti)ing is too early perfor)ed4 then the co)*ustion is occurred *efore the piston reaches at the highest point. n this case4 the co)*ustion force 3ill press the up rising piston4 so the force 3ill *e reduced. f the ignition ti)ing is too late4 then co)*ustion force 3ill press the do3ning piston. &o the co)*ustion force 3ill not *e 3or% effectively. ;s the fla)e velocity is as fast as the engine speed4 the ignition ti)ing should *e corresponded 3ith the engine speed in order to )axi)iGe the pressure of co)*ustion cha)*er at the 7-( of the piston. 7his operation is to advance the angle of the ignition in considering of the cran%shaft rotating angle4 so it is called the advance angle. n the syste) for perfor)ing the advance angle4 there are the )echanical type and the electrical type. 7he )echanical advance angel device is asse)*led *et3een the distri*utors applying currents to the spar% plug. 1y detecting the engine speed )echanically4 the ti)ing for applying current is controlled according to the engine speed to advance the ignition ti)ing of the spar% plug. !or exa)ple4 in the vacuu) advance angle device4 the advance angle is perfor)ed *y the operation proportional to the negative pressure of the device connected to the car*uretor 3ith pipe using the pheno)enon in 3hich the negative pressure in the inta%e port is increased according to the engine speed. 7he electrical advance angle device is that the engine speed and the inta%e air pressure are detected *y the sensor4 and the *est ignition ti)ing is decided *y the co)puter. 4. 9irl E--ect ;s the fla)e velocity is fast4 )ore heat energy can *e converted into the %inetic energy. deally4 the )ixture should *e exploded 3hen the piston =ust passes the highest point to trans)it the expansion force of the co)*usted gas to the piston )ost effectively. !or full co)*ustion4 in ter)s of cran%shaft rotation angle4 the ti)e of 4.M$.P rotation should *e needed. &o4 the actual situation differs fro) the ideal situation. 82 Chonan Technical Service Training Center Engine Principles 7o ensure the fast co)*usting4 the gasoline should *e )ixed 3ith air 3ell to *e ena*le to perfor) the che)ical react *et3een hydrogen car*on and oxygen. 7o do so4 the gasoline particle fro) the in=ector should *e tiny and easy to *e vaporiGed as possi*le. ;nd the in=ector orifice should face to the inta%e valve in order not to adhere the gasoline particles to the inta%e port 3all. !or so)e racing engines4 t3o in=ectors )ay *e attached at each cylinder. ;dditionally4 in order to *e )a%e the fla)e velocity *e fast4 the flo3 velocity of gas should *e faster. When the engine is rotating in slo3 speed4 the flo3 velocity of the )ixture is very i)portant ele)ent. When the engine is rotating in high speed4 the flo3 of )ixture is high4 so the )ixing is 3ell and the fla)e velocity is enough fast. 5o3ever4 3hen the engine speed starts to *e decelerated4 the piston do3ning speed is lo34 so the )ixture flo3 velocity is lo3ered and the gasoline fog 3ithin the )ixture can not *e easily vaporiGed. 7herefore4 so)e researches and develop)ents for direction of inta%e port4 for reducing the siGe of inta%e port and for using t3o inta%e ports in 3hich one inta%e port is closed to flo3 in 3hirl 3hen the engine 3or%s in lo3 speed4 to )ix the fuel 3ith air enough. 7he flo3 of 3hirl is divided into the s9irl of 3hich direction is in horiGontal and the t$!ble of 3hich direction is vertical. 7he i)portant thing in the s3irl is that the s3irl generated at the inta%e stro%e should *e re)ained even should *e )uch stronger in the ignition<co)*ustion stro%e.
&3irl 7u)*le 7o do so4 one )ethod is that a little gap called sB$ish area is )ade *et3een the )ost far position fro) the plug and the end portion of the piston cro3n4 to *lo3 the )ixture *y s?uish area 3hen the piston is near the highest point. ". 1nocking Even it is rarely occurred in no3adays4 the engine )a%es a noise 3hen the car is 83 Chonan Technical Service Training Center Engine Principles accelerated in high load condition. 7his is the typical %noc%ing. 7his co)es fro) that the co)*ustion is not started fro) the fla)e %ernel of the spar% plug and expansion of the fla)e surface4 *ut fro) the early co)*usting of the )ixture in the end Gone 3hich 3ill *e co)*usted at last. ;s the fla)e surface is a *oundary4 inside of the surface is filled 3ith the co)*usted gas and outside of the surface is filled 3ith un<*urn gas. 7hat is the co)*ustion is spreading fro) the fla)e surface. 1efore this fla)e surface is not reached4 the un<*urn gas is self co)*usted *y the pressure of the gas expansion. 7his gas 3ith the high pressure and high te)perature %noc%s the cylinder head and piston4 so the engine has har)ful da)ages. 7he %noc%ing is occurred at once4 then the piston and cylinder have the a*nor)ally high te)perature4 so the se?uential %noc%ings can *e easily follo3ing. 1ecause that the %noc%ing is generated at the end Gone of the co)*usting cha)*er4 the *ore 3ill *e enlarged *y the &58#7 &7#8KE and it is easily generated in the engine having longer fla)e spread distance. 7herefore4 the )odern engine is e?uipped 3ith the spar% plug4 especially the center pl$g4 at the center of the cha)*er or 3ith a sB$ish area enhancing the )ixture flo3 *y )a%ing the end Gone *e narro3er. @o3adays )ost car doesnEt )a%e any %noc%ing during driving. 7he engine is developed to prevent fro) %noc%ing. 8n the other hand4 there is a research for enhancing the engine perfor)ance using the %noc%ing. 7he %noc%ing4 as the firstly concerned4 is occurred at the lo3 engine speed in 3hich the co)*ustion of )ixture is lag *ehind of the a*nor)al co)*ustion. :enerally4 it is occurred at the ignition ti)ing is advanced 3hen the co)pression ratio is increase or the fla)e velocity is high. 7herefore4 *y detecting the %noc%ing4 if the engine is run 3ith )axi)u) advance of ignition ti)ing4 the *est co)*usting condition can *e )ade. %. Abnor!al Co!b$stion 7he all co)*ustion contrary 3ith the nor)al co)*ustion in 3hich the co)*ustion starts fro) the spar% plug and spread over all cha)*er are called a*nor)al co)*ustions. 7he %noc%ing is the representative exa)ple. 7here are also other types of a*nor)al co)*ustions. R ,2E4I@/I3I:/ 5 ,:34I@/I3I:/ ;s the P#E is H*eforeI and the P8&7 is H;fterI4 these ignition )eans that the )ixture can *e co)*usted *y the other fla)e *efore or after the nor)al ignition is occurred. 7he ,2E4I@/I3I:/ is occurred at the 84 Chonan Technical Service Training Center Engine Principles co)pression stro%e *y any reason such as re)aining at the car*on slug attached at the plug4 cha)*er 3all4 piston or valves. 7he ,:34I@/I3I:/ is that the )ixtures not co)*usted at the nor)al fla)e period *y )isfire4 un<*urned gas is co)*usted at the co)*ustion stro%e. 1oth of the) are very si)ilar 3ith the %noc%ing4 so they can )a%e a great affects at the parts around the cha)*er. S 2C/ :/ ;s *eing also called as dieseling4 this is the pheno)enon that the engine is still 3or%ing even the ignition s3itch is off. 6ery si)ilar 3ith the P#E<:@78@4 the car*on slug 3or%s as a fla)e seed. 7his is generally occurred 3hen the %ey is off 3ith the overheated car*uretor engine. 7his is na)ed fro) that the diesel engine co)*usts 3ithout ignition. T A*3E2 *I2E 7his is also called as the ;!7E# 1F#@. 7his is that the inco)pletely co)*usted gas is exploded at the exhaust syste) 3ith a *ig co)*ustion sound. When the accelerator is turn to open or close a*ruptly4 the exceeded gasoline is exhausted into the cha)*er and then the inco)pletely co)*usted )ixture is exploded at the catalyst converter or at the )uffler. 7his can )a%e da)age to the exhaust syste). U 7AC1 *I2E n the state that the al)ost of the co)*usted gas is ta%en out at the exhaust stro%e4 there are so)e a)ount of re)ained gas. 7he re)ained gas 3ith high te)perature )a%e a ignition the air>fuel )ixture at the *eginning of inta%e stro%e. n so)e cases4 the fire can reach *ac% to the air cleaner. 7his is )ainly occurred at the car*uretor syste). 7hese a*nor)al co)*ustion is not often occurred in nor)al driving situations4 ho3ever4 *e careful to )aintain the engine. &. hape o- Co!b$stion Cha!ber ;ccording to the co)*ustion )ethod4 the engine perfor)ance shall differ. 7hen4 3hich shape of the co)*ustion cha)*er is the *est for engine perfor)ance. t )ay *e true that the faster fla)e velocity is the *etter in order to increase the engine output. With the sa)e gasoline and ;>! ratio4 3e can consider the follo3ing five ite)s for the 85 Chonan Technical Service Training Center Engine Principles engine po3er. R 7he a)ount of the inhaled )ixture shall *e plentiful A/ore fuel4 )ore heatB S 7he flo3 =ust *efore the ignition shall *e proper. A7he faster is the *etter4 ho3ever4 too fast )a%es a )isfireB T 7he ignition plug should *e installed at the center of the co)*ustion cha)*er Ato ensure fast co)*ustion of )ixtureB U 7he co)pression ratio should *e as high as possi*le AWith high co)pression4 heat efficiency is goodB V (o)*ustion cha)*er should *e co)pact siGe to prevent heat fro) losing. Ato ensure the heat energy converted into %ine)atical energyB !irst of all4 concerning the inhalation a)ount of )ixture in R4 this is decided *y the attaching angle4 nu)*er4 siGe4 lift and shape of the inta%e valve. t is explained in the inta%e< exhaust valve section in detail. n the )ixture flo3 in S4 here4 ho3 the )ixture is ta%en into the cylinder is the )ost i)portant point. Even the )ixture flo3 is 3ell4 if the shape of valve inside and piston cro3n are co)plicated4 then the gas 3ill not *e expanded s)oothly4 so it should have the si)ple shape as possi*le. 7he plug position in T is decided *y the nu)*er and position of the inta%e<exhaust valves. n the 4<valve engine )ost used no3adays4 the plug shall *e installed at the center of the co)*ustion cha)*er4 ideally. ;s the co)pression ratio )entioned in U is higher4 the co)*ustion 3ill *e faster *ecause the te)perature and pressure of the co)*ustion cha)*er =ust *efore ignition is high. 5o3ever4 if the co)*ustion is too fast4 86 Chonan Technical Service Training Center Engine Principles then the co)*ustion is perfor)ed a*nor)ally. &o the cha)*er can *e da)aged *y this a*nor)al co)*ustion such as %noc%ing. 7o )a%e that the heat can not *e lost easily as )entioned in V4 consider thatC as the inside area of the co)*ustion cha)*er is *igger4 the heat loss 3hen the exploded gas presses the piston 3ill *e higher4 that is4 the heat energy 3hich 3ill *e converted into the force energy 3ill *e lost. With the sa)e volu)e of the co)*ustion cha)*er4 as the inside surface area of the cha)*er is s)allerC the heat converting ratio 3ill *e higher. 7herefore4 3hen the ratio *et3een the &F#!;(E and 680F/E of the co)*ustion cha)*er is the D0 ratio4 this ratio represents the co)*ustion efficiency. 7he s)aller &>6 ratio is *etter for the co)*ustion efficiency. (. Intake4E#ha$st 0alve 5 Co!b$stion Cha!ber 7o get *etter vol$!e e--iciency4 )ore a)ount of inta%e air is needed4 and the flo3 of inta%e< exhaust should *e )ade s)oother. 7he siGe and shape of the inta%e port is i)portant as 3ell as the attaching angle4 dia)eter and nu)*er of the valves should *e appropriate to enhance the volu)e efficiency. 7he larger dia)eter of valve is the *etter. f the valve is too large4 it is heavy so it has large inertia force 3hen it is open and close. 7herefore4 it 3ill hinder the engine fro) rotating 3ith high speed. 7he siGe of valve should *e opti)iGed. 7he 4<valve engine having t3o set of inta%e<exhaust valve is )ore applied recently than the 2<valve engine having one set of inta%e<exhaust valve. 7he three<valve engine having t3o inta%e valves and one exhaust valve 3as noticed. 5o3ever4 the plug 3as not installed at the center of cha)*er4 and the exhaust valve 3as too large so the t3o inta%e valve syste) is 3orse than 4 valve syste). 7he cha)*er types of 4<valve engine are the ,E/3 2::* type having the roof shaped cylinder head and the ,oly4spherical type having the so)e overlapped spheres. n the *oth types4 a pair of inta%e<exhaust valve is facing 3ith each other4 and the spar% plug is located at the center. t satisfies the re?uire)ent condition for the excellent volu)e efficiency. 1ig valve angle &)all valve angle 7he valve inclined angle is the angle of inta%e< exhaust valve a*out the center line of the cylinder. 7he valve angle is the angle *et3een the center lines of each valve. 7hese angles )a%e an i)portant affect to the cha)*er 87 Chonan Technical Service Training Center Engine Principles shape4 the &>6 ratio4 the co)pression ratio4 and the shape of inta%e<exhaust ports. f the valve angle is to *e larger4 then the valve dia)eter can *e )ade 3idely4 and the inta%e< exhaust gas 3ill *e flo3n )ore s)oothly. 5o3ever4 the cha)*er is to *e larger also4 so it has de)erits such that the co)pression ratio 3ill *e reduced4 and the &>6 ratio is to *e large. @e3 type engine has the co)pact co)*ustion cha)*er of 3hich valve angle is s)aller than ever. 7he -ive4valve engine having the three inta%e valves and t3o exhaust valves is for high perfor)ance *y enlarging the cross area of the valve and lightening the valve 3eight. 5o3ever4 it has )ore co)plicated cha)*er so the &>6 ratio 3ill *e larger as 3ell as the )echanis) around the valve 3ill *e )ore co)plicated. ). ,iston 5 Co!b$stion Cha!ber 7he piston head for)s the co)*ustion cha)*er *y facing the inta%e<exhaust valves portion of cylinder head. 7o co)*ust the )ixture fast4 the inside surface of the cha)*er should have fe3er extruded or recessed portions to flo3 the )ixture s)oothly4 and the &>6 ratio should *e s)all as possi*le. 7herefore the piston head should *e flattened. n actual4 considering other ele)ents such as the valve angle4 the cylinder head shall have the recessed shape. 7herefore4 to increase the co)pression ratio4 the piston head should *e extruded4 highly. !urther)ore4 if the engine has high co)pression ratio4 then the gap *et3een the cylinder head and piston head should *e narro3 so it need to )a%e the valve recess *e larger to prevent the valve fro) a*nor)ally operating. With these li)itations in the )echanis)4 there are )any researches for *etter co)*ustion. 7he piston has an i)portant role to trans)it the co)*ustion force to the connecting rod effectively4 so the other portions except the piston head should *e precisely designed. 7he co)*usted gas is sealed 3ith the piston ring. 7o ensure the sealing4 the gap *et3een the piston and cylinder Apiston clearanceB should *e s)all as possi*le. 7he piston 3ill *e cooled *y the lu*ricant oil and the heat 3ill *e radiated through the piston ring. 7he ther)al expansion coefficient of the alu)inu)4 the )ain )aterial of the piston4 is 23 relatively higher than steel of 3hich ther)al expansion coefficient is 12O1"4 3hich is the )ain )aterial of the cylinder. 7herefore it is hard to )atch the piston siGe to the cylinder siGe. !or exa)ple4 as the *ac% side of the piston head is reinforced4 it is )ade little s)aller than the s%irt part and the piston dia)eter along to the inserting axis of piston pin is little s)aller than the perpendicular axis. ;s the connecting rod rotates the cran%shaft4 the piston 3ill press the connecting rod 3ith inclined direction. 7herefore4 the piston )ay *e tre)*ling along the lateral direction so the s%irt 3ill stri%e the cylinder 3all. 7his is called the piston slap or the sides knock. 7his is the cause of the noise or po3er loss *y friction. 7o )ini)iGe this slap4 the center of the piston pin is offset a*out 1M2.")) along to the )ove)ent direction of the connecting rod. -oing so4 the force pressing the piston to the 88 Chonan Technical Service Training Center Engine Principles lateral direction 3ill *e reduced. t is called the offset piston. 89 Chonan Technical Service Training Center Engine Principles Chapter 12. ,er-or!ance. *$el cons$!ption. /oise. 0ibration 1. 2eB$ired ,er-or!ances 6arious perfor)ances are re?uired for the engine. Each perfor)ance is related 3ith each other in co)plex )anner4 so these affect to the perfor)ance of the vehicle. !urther)ore4 as ti)e is going4 3hich perfor)ance is )ore i)portant has *een changed. 5o3ever4 the output po3er is the )ost i)portant ite) *ecause the purpose of the engine is developed )a%ing a po3er for the vehicle. (onventionally4 to operate engine for )ore 3or% should need )ore fuel to *e used. #ecently4 *y enhancing the engine efficiency4 *etter fuel efficiency and *etter output can *e ac?uired. 7o develop the co)*ustion efficiency of the engine is concerned to the purification of the exhaust gas. 7he car*on )onoxide and the hydrogen car*on a)ong the three )a=or har)ful )aterials in the exhaust gas )ay not *e exist if the gasoline can *e co)pletely co)*usted4 in ideal. 7he one4 the nitrogen oxide is also one of the i)portant pro*le)s. (onsidering that the engine 3eight is 1.M1"N of 3hole 3eigh of the vehicle4 another )ethod for ac?uiring *etter output and fuel efficiency at the sa)e ti)e is to )a%e engine *e co)pact and light. With the sa)e output4 the po3er of vehicle having lighter engine 3ill *e higher. 7he lighter and co)pact engine enhances the fuel consu)ption. ;lso4 to ensure the good steering4 the vehicle should *e light and the 3eigh *alance is distri*uted ".D". at the front and the rear or si)ilarly. Engine also should have the features to *e driven *y the driverEs 3illingness. !or exa)ple4 3hen the driver presses the accelerator pedal4 if the engine output is too high4 then it is not so good for the safety. 7he response4 ho3 to act 90 Chonan Technical Service Training Center Engine Principles according to the pressed a)ount of the accelerator pedal4 can )a%e a *ig affect to the drive condition. ;s the engine get the driving force *y the co)*ustion of the fuel4 the noise and vi*ration can not *e avoided. t is i)portant to prevent these noises and vi*rations fro) trans)itting to the passenger. ;dditionally4 as the engine is one )echanical part of the vehicle4 ho3 to )aintain the engine is also an i)portant factors. 2. What is :$tp$t? 7he engine is the device converting the heat energy to the force. 7he *asic perfor)ance is represented *y the three )a=or factors such as the -$el cons$!ption indicating ho3 )uch gasoline is co)*usted4 the torB$e indicating ho3 )uch force is generated there*y4 and the po9er indicating ho3 )uch 3or% is perfor)ed per unit ti)e. ;)ong the)4 the fuel consu)ption is easy to *e notified *ecause it is easily detected *y )easuring used fuel a)ount. 7hen4 3hat are the others4 the po3er and the tor?ue? ;s 3e have explained fre?uently4 the 3or%ing principle of the gasoline engine is that the expansion force *y the co)*ustion of the gasoline is converted into the force pressing the piston to rotate the cran%shaft. When ascending up to the inclined road4 3e press the accelerator pedal to get high po3er. When running constantly in the even road4 3e =ust press the accelerator a little. ;s connecting to the throttle valve controlling the a)ount of inta%e air4 the pressed depth of the accelerator pedal directly affects to the open a)ount of the throttle valve. 7he fuel in=ection a)ount is decided *y the a)ount of the inta%e air. When the air is 91 Chonan Technical Service Training Center Engine Principles inhaled 3ith little a)ount *y little pressing the pedal4 the gasoline in=ection a)ount 3ill *e s)all. When the air a)ount is large *y pressing deeply4 then the fuel in=ection a)ount 3ill *e increased. 7hat is4 the ratio *et3een the air a)ount and the fuel a)ount is already preset4 so the accelerator pedal controls only the inhale air a)ount. &o4 pressing the pedal little4 the )ixture a)ount is s)all and the po3er of engine4 3hile pressing the pedal )ore4 the po3er of engine 3ill *e increased *ecause the )ixture a)ount is increased. :enerally4 the engine perfor)ance is decided *y the engine force. 7he force is represented in unit of %g. n the vehicle4 as the ulti)ate force is the rotating force driving the 3heel4 it is prefer to represent in unit of tor?ue4 i.e. %gY)4 ac?uired *y )ultiple the )agnitude of force 3ith the distance *et3een the center of rotate to the force applying point. n another aspect of engine perfor)ance4 ho3 )uch 3or% is possi*le 3ithin certain ti)e period is also i)portant. 7his 3or% a)ount is the po3er represented *y horse po3er. 3. 2epresenting Method -or ,o9er :enerally4 the )ost i)portant ele)ent of the engine perfor)ance is the output Apo3erB. When a ne3 engine is installed4 so)e one says HWhat horse po3er has it?I 7his horse po3er is the 3or% efficiency4 that is4 the unit indicating the 3or% a)ount during specific ti)e period4 so called the dyna)ic output Apo3erB. 7his concept 3as suggested *y the 8a!es Watts 3ho invented the stea) engine in England. 7o co)pare the dyna)ic perfor)ances of the so)e %inds of the stea) engines4 as the horse po3er used for 3ater pu)ping 3or%s in the coal )ine4 the one horse po3er is "". ftYl*f>s. (onverting into the )etric syste)4 it 3ill *e '" %gY)>s. 7his is the po3er for pulling up the '"%g 3eight per 1) in one second. !or the unit of the 5orsepo3er4 it 3ill *e represented 5P in a**reviation4 or the P& Pferdestar%e fro) :er)any. 7he P& is )ore usually used. n & unit syste)4 representing 3ith W A3attB4 1 P& is a*out '3".4W. &o4 1..P& is '3."%W4 1..%W is 13$P&. n the vehicle catalogue4 3e can see additional 3ord such as A@etB or A:rossB in front of the unit of P&>rp). ;s the engine output is generally )easured 3ith *eing set the engine to the )easuring e?uip)ent4 the )easured output is changed according to the )easuring condition4 and there is dispersion in )easured values. 7herefore4 to indicate the output4 @et value and :ross value are used. 7he :ross value is )easured value 3ith engine only4 and the @et value is )easured value 3ith *eing set the engine to the vehicle. !or the gasoline engine4 the @et value is 1"N less than the :ross value. f there is no notice4 the larger value is the :ross one. 92 Chonan Technical Service Training Center Engine Principles 7he po3er is the function of the ti)e. 7he engine po3er 3ill *e increased proportional to the rp) *ecause the 3or% a)ount per ti)e is increased 3hen the rp) is higher. 5o3ever4 3hen the engine rp) is increasing4 the dyna)ic parts can not run over the certain value4 or the engine can not inta%e or exhaust faster than li)it4 or the engine po3er is excessively 3asted for driving engine itself if the rp) is over than certain rp). 7hat is the engine po3er has certain li)it value. 7his is the )axi)u) po3er output. n catalogue4 it is indicated 3ith the rp) thereat. 4. What is 3orB$e? 7he tor?ue or the t3isting force 3hich is applied to a rotational )atter such as *olt4 axis rod and 3heel. t depends not only on the applied force *ut also on the length of the lever ar) upon 3hich the force acts. 1y definition4 tor?ue is e?ual to force )ultiplied *y the leverageC the length fro) the center of the rotor to the point 3hich a force is applied. n engine4 the tor?ue is e?ual to force of 3hich the piston going do3n force )ultiplied *y the distance fro) the center of cran% pin to the center of cran%shaft. &o4 the )agnitude of the tor?ue of certain engine is decided *y the force of 3hich the piston presses the connecting rod4 that is4 the co)*ustion force. 7he perfor)ance graph of tor?ue is representing that 3hich piston is pressing the cran%shaft 3ith ho3 )uch force 3hen the engine is rotating at 3hat rp). ;s this force 3ill *e trans)itted to the 3heel finally4 the i)pulsive force of the vehicle is s)all if the engine tor?ue is s)all4 the i)pulsive force of the vehicle is high if the engine tor?ue is high. 7he expansion AexplodedB force is deter)ined *y )any ele)ents4 especially4 *y the a)ount of the inhaled air into the cylinder. With plentiful of air4 it is possi*le to get high po3er. (onsidering the relationship *et3een the inhaled air a)ount and the rp) of engine4 3hen the engine has lo3 speed of rotation4 the )ove)ent of piston is also slo3 and inhaled air a)ount is lo3. When the engine has high speed of rotation4 the )ove)ent of the piston is fast and the inhaled air a)ount is high. 5o3ever4 if the engine has too high speed4 then the inta%e valve )ay close *efore the air is not fully inhaled into the cylinder yet. n this case4 the inhaled air a)ount per stro%e Avolu)etric efficiencyB is decreased. 7herefore4 the engine tor?ue curve has the pea% shape. !or exa)ple4 co)pare the engine tor?ue *et3een the 2"..rp) pic% engine and the "...rp) pic% engine. 7he for)er engine has the *est perfor)ance at the 2"..rp) *ut not so good perfor)ance at the "...rp). 93 Chonan Technical Service Training Center Engine Principles 8n the contrary4 the "...rp) pic% engine has a good perfor)ance at high speed *ut it has lo3 perfor)ance at lo3 speed. &o4 the engine characteristics are different *et3een a*ove engines even though the )axi)u) tor?ues are sa)e. ". 3o enhance ,o9er 7he engine po3er is a 3or%ing a)ount during a specific ti)e. 7he engine po3er can *e increased as high as the cylinder volu)e high4 the co)*ustion force high and the rp) high. 7he engine siGe is represented *y the displace)ent volu)e. 7he cylinder displace)ent volu)e is the exhausted gas a)ount fro) certain cylinder during the piston )oves fro) the 1-( to 7-(. 7he total displace)ent volu)e is the su) of volu)e of all cylinders. 7he cylinder displace)ent volu)e is calculated fro) )ultiple the cross sectional area *y the stro%e of the cylinder. t is represented *y unit of cc or W. When the total displace)ent volu)e is *igger4 the engine output 3ill *e also higher. 7o co)pare the engine perfor)ance4 the P&>W is used. 7he P&>W )eans that ho3 )uch horsepo3er is generated per 1W of displace)ent volu)e. !or the passenger car4 generally4 the )ore cylinder has higher value of P&>W *ecause volu)etric efficiency is higher 3ith )ultiple cylinder. 1ut the de)erit of )ultiple cylinder is the )uch co)plicated structure and the high cost. 7he pressing force at the piston is calculated *y dividing a 3or% a)ount per cycle *y the displace)ent volu)e. 1y this calculation4 the pressing force at the piston is the pressure. 1ut the pressure at the piston is continuously changed *y the position of piston and the stro%e. &o4 the )ean pressure per cycle is used for a calculation. 7his is called as the )ean effective pressure4 the average pressure in the cylinder. 7o enhance the engine po3er4 the )ain three ele)ents including the total displace)ent volu)e4 the )ean effective pressure4 and the rp) should *e enhanced. 7he 3or% per certain ti)e shall *e increased *y enhancing the rp). -eciding the total displace)ent volu)e of the engine4 ho3 the )ean effective pressure is increased and ho3 the li)itation of the rp) is overco)ed are the )a=or focusing point for a developing of an engine to enhance the engine po3er. 94 Chonan Technical Service Training Center Engine Principles 95 Chonan Technical Service Training Center Methods for increasing of maximum power Ite Increasing copression ratio Increasing co!"stion press"re #igh co!"stion spee$ %oo$ shape o& co!"stion cha!er #igh heat e&&icienc' Sall S"r&ace()ol"n ratio o& co!"stion cha!er Proper ignition tiing Proper location o& spar* pl"g Place the $"ct &or ta*ing col$ air #eatproo& air $"ct an$ ani&ol$ +"ct la'o"t &or heat proo& ,tili-e intercooler Increasing inta*e press"re ,tili-e t"r!ocharger or s"percharger ."lti valve Increase inner $iaeter &or inta*e an$ e/ha"st Increase ra$i"s o& c"rvat"re Sooth inner s"r&ace Proper capacit' o& s"rge tan* 0e$"ce !ac* press"re 1i$e ca nose Increase valve overlap Proper valve tiing )aria!le inta*e s'ste Proper length o& ani&ol$ ."lti valve ."lti c'lin$er Short stro*e Increase valve $iaeter 1i$e ca nose Increase valve li&t 2ight 3eight o& valve s'ste 2ight 3eight o& ain oving parts +o"!le over hea$ casha&t4 t3ine ca 0e$"ce piston ean spee$ Short stro*e Increasing rp liit Increasing charging e&&icienc' )alve s'ste ,sing inertia energ' 5 p"lsation 0e$"ce inta*e air spee$ 0e$"ce inertia ass o& oving parts .etho$ Increasing ean piston e&&ectivepress"re 2o3 inta*e air teperat"re 0e$"ce resistance &or inta*e an$ e/ha"st Engine Principles %. D7 2atio 5 :$tp$t 7he displace)ent volu)e of cylinder is calculated *y the cross sectional area of cylinder and the stro%e. ;lso the cross sectional area is calculated *y the dia)eter of cylinder A1oreB. &o4 the )ain factors of displace)ent are the 1ore and the &tro%e. 7he *ore and the stro%e )ay differ fro) each engine even though the sa)e nu)*er of cylinder and the sa)e cylinder displace)ent. 7hat is4 so)e engine have the thin and long cylinder4 other engines have the fat and short cylinder. 7he ratio *et3een the length of stro%e and dia)eter of *ore is called &tro%e>1ore ratio. !or the passenger car4 the &tro%e>1ore A&>1B ratio is a*out ..'M1.3. 7he &>1 ratio is less than 14 the stro%e is s)aller than the *ore4 it is called hort troke. 7he &>1 ratio is higher than 14 the stro%e is larger than *ore4 it is called 'ong troke. 7he &>1 ratio is =ust 14 the stro%e is e?ual to the *ore dia)eter4 it is called B$are. With the sa)e displace)ent volu)e4 the &hort &tro%e engine has )ore potential to have higher po3er *ecause larger *ore engine can )a%e a larger valve dia)eter and can )a%e a high engine rp) 3ithout increasing the piston speed. !irst of all4 consider a*out the *ore. 7he gas a)ount 3ill *e larger as the valve dia)eter or the 6alve 0ift is larger. With larger gas a)ount4 it is possi*le to get higher output *ecause )ore gasoline 3ill *e co)*usted. ;dditionally4 if the valve dia)eter 3ill *e larger4 for the sa)e gas a)ount4 the valve lift can *e )ade s)aller. &o the valve )ove)ent 3ill *e s)all at the high speed. 5o3ever4 the larger valve dia)eter has larger dia)eter of inta%e port4 the large inta%e port engine can not )a%e the fast flo3 of inta%e gas at lo3 speed so co)*ustion )ay *e degrade. @ext4 considering a*out the piston speed. With the sa)e rp) of engine4 the piston in long stro%e should *e )ove as fast as the stro%e length. 7he piston speed has a li)itation. When the piston )oves in high speed4 the lu*ricant oil )ay not *e properly 3or%ed4 or the piston inertia force 3ill *e too high. 7he rp) of short stro%e engine can *e )ore increased than the long stro%e engine4 if the engines has sa)e li)itation of piston speed. #ecently4 the li)it of the average piston speed is a*out 1"M22) per second. 96 Chonan Technical Service Training Center Engine Principles n general4 the engine for high speed and output such as sports car shall accept &hort &tro%e or &?uare type &>1 ratio4 the engine for co))ercial car accepts the 0ong &tro%e to increase the tor?ue instead of speed. &. Co!pression 2atio 5 :$tp$t n the previous section4 the po3er can *e enhanced *y increasing the inta%e air and increasing the engine rp). ;lso there is one )ore )ethod to increase the engine po3er. 7hat is the co)pression ratio. When the piston is at the 7-(4 the space 3hich is surrounded *y the piston and the cylinder head including the inta%e<exhaust valves is the co)*ustion cha)*er. 7he co)pression ratio is that the cylinder volu)e is divided *y co)pression cha)*er volu)e. 7he cylinder volu)e is the total volu)e of co)pression cha)*er volu)e and the displace)ent of cylinder. 7he co)pression ratio represents ho3 )uch the inta%e )ixture is co)pressed. 7he co)pression ratio in the vehicle catalogue is a theoretical value *y a calculation. n general4 it is a*out , M 1. for nor)al gasoline engine and a*out 12 M 13 and for racing engine. ;s the co)pression ratio is high4 the )ixture is co)presses strongly. &o the )ixture te)perature 3ill *e high and the co)*ustion 3ill *e perfor)ed in short ti)e. 7hen the co)*ustion pressure 3ill *e high and the tor?ue and po3er 3ill also *e high. !urther)ore4 in the co)*ustion stro%e4 the expansion ratio is also high4 so the exhaust gas has not too high te)perature. &o the fuel efficiency 3ill *e good. 5o3ever4 if the co)pression ratio is too high4 the engine can easily have a*nor)al co)*ustion such as %noc%ing. &o it has li)itation. Knoc%ing is related 3ith )ixture te)perature4 flo34 cha)*er 3all te)perature as 3ell as the co)pression ratio. &o4 to increase the co)pression ratio should *e follo3ed *y the good cooling syste) for the cylinder head. !urther)ore4 the engine should have higher strength for high co)pression ratio. 7he high perfor)ance engine should *e carefully designed. 7here are theoretical co)pression ratio and the actual co)pression ratio. 7he actual co)pression ratio indicates ho3 )uch the inta%e air is co)pressed actually. !or exa)ple4 in the inta%e stro%e4 if the air is not inhaled sufficiently4 then the actual co)pression ratio is less than theoretical ratio. n the tur*o engine4 if the *oost pressure is 1at)4 then the 97 Chonan Technical Service Training Center Engine Principles actual co)pression ratio 3ill *e t3ice. &o4 the actual co)pression ratio is the i)portant factors for the enhancing the po3er. n a*ove4 the %noc%ing is affected *y the actual co)pression ratio. (. Increasing po9er by High rp! ;rp! li!it< 7o )a%e a high po3er engine4 the fuel a)ount of co)*ustion is increased. Even the fuel a)ount is increased4 if the air a)ount is not increased4 then it is no )eaning. 7herefore4 to )a%e a high po3er engine4 the inta%e air a)ount *e )ore. 7he air flo3 speed at the inta%e port is divided the inta%e air ?uantity *y the cross sectional area. 7he inta%e air a)ount 3ill *e increased *y the increasing of the engine rp). &o4 the engine output is proportion to the rp). 7he flo3 resistance of the air 3ill *e increased as the air flo3 is fast. 1y enlarging the duct or volu)e of air cleaner4 the flo3 resistance can *e reduced. 5o3ever4 the resistance around the valve is not controlled. &o4 over the certain rp)4 the po3er can not *e increased any )ore. 7herefore4 to get high output at the high speed4 the inta%e air speed should *e decreased at the high speed. 7o do so4 there are so)e )ethods to *e considered. R ncrease the nu)*er of cylinderD 3ith the sa)e total displace)ent volu)e4 if the cylinder nu)*er is increased4 then the cylinder dia)eter 3ill *e reduced and then valve dia)eter 3ill do so. 7herefore4 the inta%e flo3 velocity 3ill *e reduced. S ncrease the nu)*er of inta%e valveD 3ith the sa)e reason )entioned in R4 the air flo3 velocity 3ill *e reduced around the inta%e valve. T Enlarge the lift of inta%e valve and elongate the opening ti)eD 7he opening ti)e of inta%e valve is a*out 24.P in ter)s of cran%shaft rotation angle. n the racing engine4 it is a*out 2+.M32.P. U -esign the &58#7 &7#8KED 3ith the sa)e displace)ent volu)e4 the &58#7 &7#8KE is to )a%e the valve *e enlarged. &o4 the opening area is also large and then the inta%e air speed 3ill *e slo3. f the inta%e air speed is sufficiently slo34 the engine rp) can *e increased )ore to )a%e )ore po3er. f the engine rp) is increased4 the engine should endure against the high rp). 7hat is4 the engine should *e strengthening to ensure the high rp). :enerally4 the engine should *e lightened to reduce the inertia force4 and enhanced the strength of the *ody and parts of engine. ). 3ransient Characteristic 5 2esponse 98 Chonan Technical Service Training Center Engine Principles 7he engine )a%es large tor?ue *ut acceleration response is slo34 the engine is not a high perfor)ance engine. 7he acceleration perfor)ance or the response of the engine can *e affected *y the 3eight of the car or gear ratio. When the driving condition is changed4 the inter)ediate state *et3een *efore and after is called transient or partial state. 7he engine characteristic at partial state is called the transient characteristic of the engine. 7he transient characteristic is *asically related 3ith the changing of the rp) and the inertia force. 7he i)portant things for the response are the 3eight of the dyna)ic parts of the engine and the changing a*ility of the air>fuel 3hile acceleration. 7o reduce the inertia force of the dyna)ic parts of the engine4 the dyna)ic parts should *e )ade as light as possi*le. n the fuel in=ection type engine4 an inta%e collector Asurge tan%B has a si)ilar volu)e 3ith the total displace)ent volu)e. When the accelerator is pressed to open the throttle valve4 the air can not *e inhaled into the )anifold i))ediately *ecause of the inertia force of the air. 7herefore4 the first )ove)ent of the engine tor?ue 3ill *e delay. 7o solve this pro*le)4 if the volu)e of the collector Asurge tan%B is increased4 then the engine output shall *e increased. n so)e fuel syste)4 the gasoline )ay not *e flo3n s)oothly *ecause the gasoline sprayed fro) the in=ector. n this case4 3hen the throttle valve is open ?uic%ly4 the )ixture is leaned and then the initial tor?ue of the engine )ay *e delayed. 7o solve this pro*le)4 there is a )ethod in 3hich the in=ection a)ount is selectively increased at that )o)ent. 1+. Cylinder Array 5 ,er-or!ance 7here are three )ethod for arraying the cylinders4 in<line type4 6<type4 and opposed type. What relationship is there *et3een the cylinder array and the engine perfor)ance? 99 Chonan Technical Service Training Center Engine Principles 3he in4line type engine has the cylinder in se?uentially arrayed. 7here are fro) 2<cylinder type to $<cylinder type. n the in<line type4 the structure of the cylinder *loc% is very si)ple and the cylinder head is one *ody4 so the engine shall *e light and co)pact. t is used 3idely fro) co))ercial car to racing car. n the in<line type engine4 generally4 the cylinder nu)*er is 4 3hen the displace)ent volu)e is up to 2W. 7he cylinder nu)*er is $ )ore than 2W less than 3."W. 7he 4<cylinder engine having the displace)ent volu)e of fro) 1Wto 1."W is used for co))ercial vehicle4 and one having )ore and up to 2W is used for high perfor)ance purposed car. Engine for the displace)ent volu)e of 2W is generally )ade into 4<cylinder or $<cylinder. 7he $<cylinder engine has s)aller co)*ustion cha)*er and is easy to *e )ade 3ith &58#7 &7#8KE. &o it can *e get large )axi)u) output. 3he in4line %4cylinder engine has the long length so it needs so)e3hat high cost. 1ut4 the siGe is co)pact in co)pare 3ith the perfor)ance4 and the tur*ocharger can *e easily attached. &o it can *e utiliGed in high perfor)ance engine. ;dditionally4 the inertia force of the piston<cran% is 3ell *alanced so it sho3s good features at the anti<vi*ration. 5o3ever4 it is hard to install 3idely in the engine roo) of !! type vehicleC so generally4 it is installed at the !# type vehicle in longitudinal direction. 7he 3<cylinder or "<cylinder is rarely used in the in<line type. 1y dividing $<cylinder into t3o set of serial 3< cylinder and facing the) to array in parallel4 the length is reduced al)ost half of the in<line $< cylinder engine is the 043ype %4cylinder engine. ;s this engine has the high inta%e<exhaust efficiency *ecause the *ore dia)eter can *e enlarged easily4 it is easy to get high po3er. f the angle of 6 array is set to $.P4 the feature is closed to the serial $<cylinder engine. t can *e installed at the !! type vehicle. &o it is possi*le for the !! car to *e developed into high perfor)ance car. 3he 04type engine generally consists of $< cylinder. 1y co)*ining the serial 4<cylinder and the serial $<cylinder4 the 6+ and the 612 engines can *e )anufactured respectively. 7hey are generally installed at the large vehicle or sports car. 7he 6$ engine is not easy to *e utiliGed *ecause the 3idth of the engine is 3ider and 3eight is heavier. 3he opposed engine is the sa)e 3ith the 6< type engine having the 1+.P of the angle. 7he center of engine 3ill *e lo3er than others. 11. *$el Cons$!ption 2atio 7he fuel efficiency of the engine is represented *y the fuel consu)ption rate. 7he fuel consu)ption a)ount for the driving is changed *y the driving condition. When the dyna)ic perfor)ance is )easured *y attaching to the dyna)o)eter to co)pare 3ith other engine4 the consu)ption a)ount of the fuel should *e considered. 7herefore4 the fuel consu)ption rate is represented *y fuel consu)ption a)ount per 3or%4 and the unit is g>P&Yh. ;ssu)e that 3hen a engine is rotating 3ith 3...rp) at the dyna)o)eter4 the engine outputs ""P&4 and 11%g gasoline is used for 1 hour 3or%ing in this condition4 then the fuel consu)ption rate is 100 Chonan Technical Service Training Center Engine Principles 22.g>P&Yh. When referring to the graph of fuel consu)ption rate in the engine perfor)ance curve4 that the fuel consu)ption rate is )ini)iGed 3ith certain rp) of engine is )ore concerned than the fuel a)ount. 7he actual fuel consu)ption rate shall *e )easured in actual driving condition at the vehicle. :enerally to say4 the catalogue indicates the fuel consu)ption rate 3ith the 1.<1" )ode rate and the $.%)>h steady rate. 8n here4 the rate is =ust concerned to the engine itself. 7o reduce the fuel consu)ption rate4 the fuel is used less as possi*le and the heat should *e thoroughly converted into the dyna)ic force. &o4 it is related 3ith the heat efficiency. !or exa)ple4 the )ixture should *e co)*usted 3ith high te)perature and high pressure4 co)pletely and fast as possi*le. ;nd the heat loss to the exhaust gas and to the cylinder 3all should *e reduced as possi*le. ;s 3ell as the )echanical friction should *e reduced also. 7o calculate ho3 the engine uses the heat fro) the gasoline in classifying according to the ele)ent is the heat balance. 7o indicate this heat *alance 3ith the graph is the heat balance graph. :enerally to say a*out the heat *alance of the gasoline engine. 7he heat for output4 the heat for loss in exhaust gas and the heat for loss through the cylinder 3all are 3.N separately4 and 1.N is for others. Fntil no34 the )ost heat efficiency of the engine is a*out 3"N4 that is4 in the ter) of fuel consu)ption rate4 a*out 1'.g>P&Yh. 12. :$tp$t 5 *$el E--iciency ;s the air a)ount is increased to enhance the engine output4 the fuel a)ount 3ill *e increased4 so the fuel efficiency is degraded. 5o3ever4 if the )ixture can *e co)pletely co)*usted to increase the heat efficiency and to get higher output4 then the high fuel efficiency as 3ell as the high output 3ill *e ac?uired. ;dditionally4 the exhaust gas has less har)ful ele)ents. 7he engine heat efficiency is the ratio of the heat capacity used for 3or%ing. 7o increase the heat efficiency4 the expansion of the gas should *e as large as possi*le4 at the sa)e ti)eC the loss energy should *e as s)all as possi*le. 7he loss energies in the engine are the cooling loss *y cooling syste)4 the e#ha$st loss *y *eing ta%en out 3ith the hot exhaust gas4 and the intake4e#ha$st loss ;p$!ping loss< used for inta%e<exhaust operation. 7o increase the heat efficiency *y increasing the expansion force of the co)*usted gas is related 3ith to increase the )ixture a)ount and to increase the co)pression ratio. 7o reduce the cooling loss4 the te)perature of the co)*ustion cha)*er should *e increased. 1y changing the shape of co)*ustion cha)*er to enhance the co)pression ratio4 the cha)*er te)perature 3ill *e increased at the co)pression stro%e as 3ell as the %noc%ing is prevented. n other hand4 the )ethod using the higher cooling 3ater is also concerned. 7o reduce the inta%e<exhaust loss Apu)ping 101 Chonan Technical Service Training Center Engine Principles lossB4 7he inta%e<exhaust tu*e should *e short and have less *ent portion as possi*le. 7o enhance the air flo3 at the valve4 the dia)eter of the valve )ay *e enlarged or the nu)*er of valve )ay *e increased. 5o3ever4 in that case4 if the )ixture flo3 is too slo34 or if the structure of the cha)*er is too co)plicated4 then the heat efficiency 3ill *e degraded. 7herefore4 it should *e carefully designed. 8ne )ore4 to enhance the heat efficiency4 it should *e considered that the friction loss generated 3hen the piston )oves. 7he !echanical energy loss in driving the auxiliary e?uip)ents should *e reduced. 13. *$el E--iciency o- 0ehicle Even though the fuel consu)ption rate indicates the engine fuel efficiency4 this value is not the exact fuel efficiency of vehicle. With the sa)e engine4 the fuel efficiency )ay differ according that it is installed at heavy and large vehicle or it is installed at light and s)all vehicle. (o)paring one case that a vehicle includes a s)all engine having good fuel efficiency and another case that a vehicle includes a large engine having *ad fuel efficiency *ut high po3er4 the actual fuel efficiency 3ill *e changed *y the driving condition. !or exa)ple4 if a car is usually used in the lo3 rp) condition4 then the s)all displace)ent volu)e is )ore effective. f the car is usually used in high speed or high po3er condition4 then the large displace)ent volu)e engine 3ill *e )ore effective. !or the co)paring of the fuel efficiency *et3een engines4 the specific test )ode is re?uired. 7he specific test )ode )eans that the test )ethod and test conditions are specified. 7here are )any test )ode 3hich should *e suggested in catalogue4 the 1.<1" )ode running fuel consu)ption4 the $.%)>h steady fuel consu)ption4 !7P '" )ode and so on. n representing the fuel consu)ption rate4 for engine only4 the unit of g>P&<h is used4 the unit of %)>W indicating for vehicle 3hat %) the car can run 3ith 1W of fuel is used. 3he 1+41" !ode -$el e--iciency is ac?uired fro) dividing the running distance *y the a)ount of the used fuel4 the vehicle is tested at the dyna)o)eter according to the predeter)ined pattern cycle of idling Q start acceleration Q running 3ith constant speed Q deceleration. n the past4 the driving pattern had the )axi)u) speed of 4.%)>h4 ho3ever4 it 3as not proper to the )odern traffic condition. #ecently4 the )axi)u) speed sets 102 Chonan Technical Service Training Center Engine Principles to '.%)>h4 the 1" )ode is added to this test. 7he %+k!Dh steady -$el e--iciency is ac?uired fro) the used fuel a)ount 3hen a car is driving 3ith constant speed of $.%)>h 3ith the gross 3eight having full passengers and *aggage at the paved plain road 3ithout 3ind. :enerally4 this value is )easured in the ideal state *y the )anufacturer to suggest to govern)ent. 7he actual value is less than this value. 14. 0ibration o- Engine 7here are )any sources to )a%e vi*ration in engine. 7here are )a=or three vi*rations4 one is fro) the co)*ustion of the engine4 one another is fro) the inertia force of the reciprocal and rotational )ove)ent at the dyna)ic syste) such as piston4 connecting rod4 cran%shaft4 and others. 7he vi*ration fro) the engine is as )uch as high pressure of the co)*ustion. ;nd4 the engine having high co)pression ratio and high perfor)ance )a%es )ore noise. 7he vi*ration of the tur*o engine )a%es 2.O".N )ore noise than @; engine. n this case4 so)e devices for preventing fro) noise are used and the auxiliary devices are attached at the portions less affected *y vi*ration. ;dditionally4 *y changing the engine )ounting position or adopting the vi*ration a*sor*er 3ith the )ounting portions4 the vi*ration can not *e trans)itted to the *ody directly. 7he inertia force is one )a=or source of the vi*ration. ;s the piston )oves fro) the highest point to the lo3est point 3ith various accelerations. 7he cran%shaft )a%es a vi*ration 3aves and an inertia force fro) the rotation of the cran% pin. 7he (onnecting rod )a%es an inertia force fro) the co)*ination of the reciprocal and rotational )ove)ent. n the )ulti cylinder engine4 the pistons are connected to the cran%shaft4 so each inertia 3ill *e canceled each other. t is very co)plicated 3ith the nu)*er of cylinders4 array of the) and each ti)ing of co)*ustion. 7herefore4 using the counter 3eight4 the inertia force is *alanced 3ith the total 3eight. 7o )atch the *alance of the inertia force co)pletely is very difficult. 7he inertia force is less 3hen the dyna)ic parts such as piston and (onnecting rod have lighter 3eight. With the sa)e displace)ent volu)e4 the engine having )ore nu)*er of 103 Chonan Technical Service Training Center Engine Principles cylinders has less inertia force *ecause the parts are s)all and light. When the inertia force is s)all4 the possi*ility to )a%e a vi*ration 3ill *e fe3 and it 3ill rotate at high speed 3ith the sa)e strength. 1y lightening the 3eight of dyna)ic part4 the inertia force at each part 3ill *e s)all. With the sa)e rp)4 the strength of these parts 3ill not *e )aintained highly. :enerally4 the device having lo3er strength is lighter than the device having higher strength. 7o *e lightening is )ost i)portant point to increase perfor)ance as 3ell as to prevent vi*ration. 1". /oise o- Engine 7he noises fro) the engine are the co)*ustion noise and )echanical sounds. 7he )echanical sounds is caused *y the friction *et3een the parts. When the engine rotates 3ith high speed4 the noise 3ill *e changed and *e louder. When a driver changes the shift to up or do3n4 generally4 the driver )ay selects the proper gear *y engine noise. &o4 the sound of engine helps the driver for the driving. 7herefore4 the engine sound should *e noticed *ut it shall not the noise *ut the sound. 7he )echanical noise is )ade fro) the vi*ration of the cylinder and cylinder head *y the co)*ustion force. When the )ixture a)ount is increased or the co)*ustion pressure is higher4 then the noise 3ill *e louder. &o)eone )ay feel that the tur*o engine )a%e less noise than the @; engine. 7he reasons are the tur*ine a*sor*s the exhaust energy and the variation of the co)*ustion pressure is s)aller. 7he )echanical sounds co)es fro) the friction and *u)p the dyna)ic parts such as gear4 chain4 and valves. !or exa)ple4 the ca) hits the valve lifter4 roc%er ar) and ca)shaft hits the valves4 the valve *u)ps 3ith the valve seat and so on. 7he resonance noise fro) the vi*ration is louder than the direct )echanical noise. &o4 the causes of the noise fro) the engine can not *e exactly found. ;ny 3ay4 that there is a noise is not good situation *ecause so)e parts of the engine shall *e hit 3ith others and this is *ad for the endurance of parts. f you detect a*nor)al noise4 please chec% the syste) as soon as possi*le. (o)paring the co)*ustion noise 3ith the )echanical noise4 at the lo3 speed4 the co)*ustion noise is larger. When the rp) is over 3...rp)4 the inertial force is larger and the )echanical noise 3ill *e larger. 7he noise fro) the engine roo) 3ill *e protected *y attaching a*sor*ing )aterials under the hood and in front of the dash*oard4 the *oundary of the engine roo) and ca*in. 7he noise a*sor*ing )aterials are glass 3ool4 104 Chonan Technical Service Training Center Engine Principles felt and so on. 105 Chonan Technical Service Training Center