A Summer Internship Report On

COMPARITIVE STUDY OF ENGINE COMBUSTION PARAMETERS FOR PERFORMANCE AND EMISSION OPTIMIZATION
From 01.06.2011 to 31.12.2011

Escorts Ltd, Faridabad

Parmod kumar

09ME17

Department of Mechanical Engineering Rawal Institute Of Engg. & Tech.

CERTIFICATE
This is to certify that the dissertation work titled Comparative Study of IC Engine Combustion Parameters for Performance and Emission Optimization is submitted to the
Rawal Institute Of Engg. & Tech.

in partial fulfillment of the requirement for the award of degree of Bachelor of Technology in Mechanical Engineering. This is a bonafide work carried out at Escorts Ltd. by him under our supervision. The contents of this dissertation, in full or in parts have not been submitted to any other institute or university for the award of any degree.

ACKNOWLEDGEMENT
I take this opportunity to express my gratitude to Mr.. (Head, Engine Design), Mr. (GM) and Mr(Chief Manager) who provided me the opportunity to expose myself to such a highly modern facility and guided me throughout my project work. I would also like to thank Mr.and Mr. for providing me proper knowledge on all aspects of engine design and testing. I would also like to thank the staff of the Engine Laboratory, KMC for their support and cooperation during my project work.

ESCORTS A BRIEF INTRODUCTION

Escorts have played a pivotal role in the agricultural growth of India for over five decades. It is one of the leading tractor manufacturers of the country with a manufacturing capacity of 95,000 tractors per year. Escorts produces tractors in the 27-75 HP range and has already sold over 8 Lac tractors. Its tractors are marketed under three brand names, viz. Escort, Powertrac and Farmtrac. Escorts brand of tractors is a symbol of reliability and trust and enjoys the confidence of the farming community for the last 40 years.

Powertrac brand of tractors are the most fuelefficient tractors in their respective categories that offer excellent value for money and have helped the farmers improve their quality of life.

Farmtrac brand is the most powerful premium range of tractors that give maximum productivity to the farmers. Spanning these three brands, the company has

a full range of tractors to cater to the domestic as well as overseas markets. The company is developing state-of-the-art

highly fuel efficient engines with the assistance of AVL of Austria and have also entered into a joint venture with Carraro SPA of Italy for the manufacturing of transmissions and axles. Facilities include a high-technology engine

laboratory featuring fully computerized test-beds with online control, data acquisition and analysis. Engine emissions can be tested for meeting the Bharat TREM norms, US Environmental Protection Agency (EPA) norms and European (Euro) norms.

RESEARCH AND DEVELOPMENT

KMC stands for KNOWLEDGE MANAGEMENT CENTRE. It is the Research and Development wing of Escorts Ltd. A large investment is being made to invest in further modernization of current facilities, with emphasis on Computer Aided Engineering (CAE), establishment of advanced test laboratories, stateof-the-art information Centre and other related facilities.

The R&D Centre uses advanced 3D model tested for performance, durability and reliability. Facilities include a high-technology engine laboratory featuring fully computerized test beds with online control, data acquisition and analysis. We can test engine emissions for meeting the Bharat TREM 3A norms, US Environmental Protection Agency (EPA) norms and European (Euro) norms. capabilities of the engine lab Additional are engine

performance, durability, reliability and tribology and fluid dynamics studies. An advanced vehicle-testing laboratory includes fatigue testing, dynamometer testing for chassis and power-take-off, and smooth as well as torture test tracks. Other facilities include Noise Vibration and Harshness (NVH) Lab, Metrology Lab and Materials Engineering Lab. Product styling is carried out in a computerized prototypes. ENGINE virtual environment, which is supported by a model-making shop for physical

The key differentiator is the engine technology at Escorts. Escorts has unparallel track record in this field. They offer the most Fuel Efficient & Emission Compliant Engines from 25 to 75 HP range with Advance Direct Injection (ADI) technology. DESIGN Product design to match the application while ensuring Quality & Productivity in Manufacturing.

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HISTORY OF ESCORT
The genesis of Escorts goes back to 1944 when two brothers, Mr. H. P. Nanda and Mr. Yudi Nanda, launched a small agency house, Escorts Agents Ltd. in Lahore. Over the years, Escorts has surged ahead and evolved into one of India's largest conglomerates. In this journey of six decades, Escorts has had the privilege of being associated with some of the world leaders in the engineering manufacturing space like Minneapolis Moline, Massey Ferguson, Goetze, Mahle, URSUS, CEKOP, Ford Motor Company, J C Bamford Excavators, Yamaha, Claas, Carraro, Lucky Goldstar, First Pacific Company, Hughes Communications, Jeumont Schneider, Dynapac . These valued relationships be it technological or marketing, are our highly cherished experiences treasures, which have helped us inculcate best in class manufacturing practices and to emerge as a technologically independent world class engineering
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organization.

1944 - Launch of Escorts (Agents) Ltd.

1948 - Pioneered farm mechanization in the country by launching Escorts Agricultural Machines Limited, with a franchise from the U.S. based Minneapolis Moline, for marketing tractors, implements, engines & other farm equipment. Launch of Escorts (Agriculture and Machines) Ltd.

1949 - Franchise of Massey Ferguson tractors for northern India

1951 - Escorts established Indias first private Institute of Farm Mechanisation at Delhi.

1953 -Escorts (Agents) Ltd. and Escorts (Agriculture and

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Machines) Ltd. merged to form Escorts Agents Pvt. Ltd.

1954 - 1st industrial venture of Escorts to manufacture piston rings in collaboration with Goetze of Germany, in an era when joint ventures of Indian firms with foreign companies were virtually unheard of.

1958 - Started importing Massey Ferguson tractors from Yugoslavia for marketing the same in India.

1959 - Collaboration with Mahle of Germany to manufacture pistons. Soon, Escorts became the largest producer of piston assemblies in India.

1960 - Set up of Escorts Limited

1961- Setting up of manufacturing base at Faridabad for manufacture of tractors in collaboration with URSUS of
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Poland and 50% indigenous components. Launch of Escort brand of tractors. Collaboration with CEKOP of Poland for manufacture of motorcycles and scooters. Escorts moves into high gear by nurturing the two wheeler culture. The first Rajdoot motorcycle rolls off the assembly line.

1969 - Escorts Tractors Limited was born. A technical and financial joint venture with the global giant Ford Motor Company, USA, to manufacture Ford tractors in India. The years ahead saw Escorts grow as the largest tractor manufacturer in India.

Escorts Institute of Farm Mechanisation (EIFM) established at Bangalore.

Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial democracy comes into being.

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1971 - 1st February, the first tractor FORD 3000 rolled out of the factory.

Escorts diversifies and starts manufacturing construction equipment.

1974 - Crossing national boundaries, Escorts exports for the first time. After winning a global tender, 400 tractors were exported to Afghanistan, which was perhaps the world's largest ever airlift of tractors.

1976 - FORD 3600, an advancement in Farm Mechanisation launched. Trial production of in-plant manufacturing of engine parts (Block & Head).

1977 - Escorts enters the world of self-developed technology by setting up its first independent R&D Center. Escorts Scientific Research Centre marked its beginning at
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Faridabad by developing its own Engines for E-27 and E-37. Due to constant technology absorption, indigenisation level touched 72% for FORD tractors. 2nd plant at Bangalore for manufacturing piston assemblies was set up.

1979 - Collaboration with JCB Excavators Ltd., UK for manufacture of excavators.

1980 - Foray into healthcare, Escorts Hospital and Research Center set up in Faridabad.

1983 - Escorts Tractors Limited (ETL) established a state-ofthe-art research and development centre to spearhead newer breakthroughs in Farm Mechanisation and to maintain industry leadership. Line concept introduced for engine block machining. 11,000 ton floating dry-dock Escorts I launched.

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1984 - JV Escorts - Yamaha to manufacture motorcycles

1984 - Signing of agreement with the Japanese bike giant Yamaha to manufacture motorcycles with Yamaha technology. Collaboration with Jeumont Schneider of France to manufacture EPABX systems Collaboration with Dynapac of Sweden to manufacture vibratory road compactors

1985 - Escorts Tractors Limited (ETL) offered its first Bonus Issue (1:1).

1988 - Escorts Heart Institute and Research Centre (EHIRC), a world class cardiac care facility launched in New Delhi.

1989 - Joint Venture with Claas of Germany to manufacture harvester combines.

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1990-91 - First Public Issue in February 1991, oversubscribed four times. Shares listed on Delhi and Bombay Stock Exchanges.

1993 - FORD 3620 tractor launched.

1996 - Disengagement of joint venture collaboration with New Holland and launch of FARMTRAC Tractor.

1997 - Joint Venture with Carraro of Italy for manufacturing and marketing of transmission and axles.

Joint Venture with First Pacific Company of Hong Kong Escotel Mobile Communications.

1998 - POWERTRAC series of tractors launched.

MoU was signed with Long Manufacturing Company, USA

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for setting up a Joint Venture in USA.

1999 - MoU for Joint Venture with a Polish Company POLMOT was signed for assembly, manufacturing and marketing of Farm Machinery.

2004 - Divested Escotel Mobile Telecommunications to Idea Cellular

TS16949 certification for Agri Machinery Group.

2005 Divested Escorts Heart Institute and Research Centre (EHIRC) to Fortis Healthcare.

2006 - Divested in Carraro India Ltd.

Set up new manufacturing facility in Rudrapur for manufacture of new range of railway equipment
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PROCEDURE OF WARRANTY

When we can sale the tractors to the dealers then the TSM can be handled it each one. TSM have 2 to 10 dealers if dealers have any problem in the tractors if there are some small problems like horn not working the problem can be solved by TSM( territory saler manager) at dealers place and if such big problem then company sent the claim from to the dealer then he can fill the form and the original copy can be sent to warranty department with the duplicate copy of claim form and he can also send letters .in this letter he can define the problem and the parts can come to warranty
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department then at a gate pall the warranty number can be denoted and the security can sent the parts in and the assistance mangers can check the engine. They can check such like engine in wty. And not an old engine ant then the engine to the engine workshop and the engine can be properly checked or part can be replace and short out the problem then the problem of engine can be tested and then send it to the dealer and this process is called RTV( return to vendor) and also the cost of packing and transport can be mentioned and taken from the vendor. Then the report can be sent by finance and the waste material or waste parts can be counted and that can be collected by scrap dealers.

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WARRANTY CLAIM FORM AND REPORT

PRODUCT: In this column the thing which have warranty like tractors etc.

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MODEL: In this column the name of the tractor is put like F1-60, FT-45,FT-35.

HOURS: In hours we can put the hours that is in the tractors can run how many hours like the tractors can run only 345 hours then put this value ti the hours column.

DLR CODE: The dealer code is given by the company to the dealer. When dealer is filled the dea;er code. And dealer code is different for different dealer.

TR SL NO. This is denoted for tractor serial no. and the tractor have different serial no. and put on the tractor.

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APPLICATION NO: If we can joint any thing in the application we can use this application code.

IMPLIMET CODE: We can have any work in the place so we have code, that code is known as implement no.

JOB CARD NO When dealer can saw the problem and customer is put on a sheet , this sheet is job card sheet and sheet number can be put, then we call that sheet as job card no.

ENGINE NO. Number on the can be put and every engine have a separate number.

DATE OF PDI. Pre delivery inspection before sale called date of PDI

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JOB DATE: When the dealer can be prefer the problem , then job card can done after claim.

AGG..NO. Aggregate number can be number. In this column , number is put on the damange parts.

DATE OF INSTALLATION: Dealer ship can sale the tractor in which date called as date of instalaation.

FIRST INTIMATION DATE: The first intimation date is defined as the date the in which the tractor is drawn . the customer cant go to the company for that day he can inform that date.

DEALERS NAME AND ADDRESS: The name of the dealer and address is mentioned

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CUSTOMERS NAME AND ADDRESS: The name of the customer and the address is mentioned.

CAUSAL FAILED PARTS DETAILED: Causal have like a fist problem, nut problem, can be lose and the other problem.

CONSEQUENTIAL : Then after causal the main problem is come out i.e. consequential.

FINISH CODE: The code of parts which have failed called finished code.

DEFECT CODE: Company can make a different code for different product and defect. These code is known as defect code.

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SERVICE RECORD

TRANSIT: During transport any part is broken or filled , the transport form is filled.

FAILED PARTS DISPATCHED DETAILS VIA.: Dealership can send the failed parts in detailed to the company.

RP NO./G.R.NO./POST PARCEL: In this part can send by which type.

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TSM: It can make the SCR( service concerned repart).

CLAIM DISPOSAL: Dealer can send the claim desposal can done by company.

GR.NO : Godown Receipt no.

DINIEND: Process in which time.

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CONSTRUCTION OF (FARMTRAC 45)

ENGINE

When we can construct the engine first the base is cylindrical block then the crank shaft is putted and tighted we can use CR bearing Crank pully can be placed in a crank shaft.

Then the spring lock is put on the pulley and then no. 26 bolt is used to tight the pulley with crank shaft which is at 24kg.

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then the connecting rod is put and CR bearing is used to place the connectind rod. One piston , the two piston sirdip lock which is put on the two opposite side and three ring is used oil ring, compressipn ring,tap ring.

The connecting rods can be attached with the piston pins. In oil ring the spring is here between the two plates ring . the other part of the connecting rod or we can say other side is can be attached crank and he piston ring is located 120 degree from each other. The piston is can be filled in the cylinder wit the help of ring compression and the benefits of this tool. The piston is easily fit the big end of the connecting rod can be tighted with crank shaft with bearing. The connecting rod bolts has no. 17 and can be tighted as 11 kg torque gauge. The main bolt of no.24 can

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be tighted at 21kg torque. The oil pump can used to lubricant the oil and oil pump can be driven by cam shaft with the help of oi pump gear which is attached to the cam shaft, then the cam shfat rotate, the gear is rotate and oil pump make its work easily.

With the help of oil pump , the oil is can rotate in the oil gallery and this oil is can be used for lubricant.

In the engine block or cylindrical block there are two galleries oil gallery ang water gallery .in oil gallery the oil can be rotate for lubricant and in the water gallery water can be rotate for the purpose of coating.

In this the 22 bolt can be used and of no.14 and tighted at 6kg torque.

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Then water pump is put and the water pump can be driven by fan belt in this four bolt can be used of no. 16 and tighteh with the torque of 10 kg.

Cylinder head kit can be put on the head and for the fixing of gas kit head double which is fitted in the block of the cylindrical head there are valve steal, returner(6), curter(12) and push rod is entered and after this the rocker arm is putted and 14 bolts are in rocker arm and 10 in head of no.19 at 21kg torque.

Tapid gap the intake can be take 14 to 17 mm and the exhaust 17 to 21mm rocker cover gas kit is can be used and the the rocker cover is put and tight it then the engine of farmtrac-45 is can be ready.

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ENGINE TESTING
Performance Optimization 1. Gaseous & Particulate Emission Evaluation 2. Combustion Optimization 3. Friction Measurement Computerized Engine Mapping 1. Cylinder Head Port Flow Characteristic Evaluation
2.

Oil Consumption Evaluation

Reliability & Durability Test Statutory Certification

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MATERIALS METALLURGY

AND

Material and Metallurgy selection based on exhaustive database straddling Design & Manufacturing.

TESTING
Product is rigorously tested in lab and field to achieve product reliability. Performance Optimization Durability Test Field Test Conformance to standards.

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TYPE OF ENGINE TESTS

4.1) FULL THROTTLE PERFORMANCE TEST This test is performed to find out the

performance of the engine when the throttle is at its maximum position. First the engine is warmed up till the temperature of the lubricating oil reaches 80 C. The throttle is set at the maximum position and rpm of the engine is decreased by applying load on the engine through dynamometer. Parameters recorded are torque, speed, power, fuel consumption, BSFC (brake specific fuel consumption), Smoke level, Temperature of oil and Temperature of test cell (ambient temperature). 4.2) PART THROTTLE PERFORMANCE TEST This test is performed to find out the

performance of the engine when the throttle is at various intermediate positions. During this test,
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engine speed (RPM) is kept fixed and load on the engine is decreased. But the speed increases with decrease in load. In order to keep the speed constant the throttle was decreased. The test is performed at rated speed, Intermediate speed & peak torque speed. Parameters recorded are the same as above. 4.3) GOVERNING TEST This test is performed at high idle speed, rated speed and an intermediate speed.RPM is decreased in steps of 20 and it is observed at what RPM maximum power is obtained. For a good engine, the difference between maximum power RPM and the RPM at which the test is being performed should not be more than 100-120 RPM.

4.4) FRICTIONAL HORSE POWER TEST This test is performed to find out the power lost in the engine due to friction. In this test the fuel
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supply to the engine is cutoff and the engine is rotated in the opposite direction with the help of a special dynamometer known as motoring dynamometer. The power required to do so is known as frictional horse power. 4.5) ENDURANCE TEST This test is done to estimate the life of the engine. This test is generally performed on a new engine or an engine with some part modified. The test procedure depends on type of modification done. A new engine is run continuously for 3000 hours. After every 40 hours engine oil is checked, every 100 hours FTP test is done and in every 500 hours engine oil is checked. 4.6) EMISSION TEST This test is performed to analyze the exhaust gases given out by the engine under various conditions. The amounts of carbon monoxide, hydrocarbons, oxides of nitrogen (NOx) and particulate matter are measured in ppm. The software converts these values to g/KWh. These values are compared with emission norms set by the
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government. For tractors parameters are measured at 8 points-at rated RPM 4 points are taken(full load,75% of full load,50% of full load,10% of full load),at peak torque RPM 3 points are taken(full load,75% of full load,50% of full load),at low idle speed 1 point is taken at no load. For car engines 13 points are taken whereas for genset engines 5 points are taken.

100% 75% 50% 10%

MODE : 5 MODE : 6 MODE : 7

MODE : 1 MODE : 2 MODE : 3 MODE : 4

Load No Load

MODE : 8 Low Idiling speed Peak Torque speed Rated speed

Speed
Weighatage Factor - 15% Weighatage Factor - 10%

Figure 4.1 8 Mode Emission cycle

4.7) INDISET TEST

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The setup for this test consists of four units crank detection module(CDM) that measures the crank angle, pickup that measures the pressure at pump end or cylinder as required, transducer that measures cylinder pressure and a special injector nozzle that has sensors to measure the needle lift. These units send signals to the indimeter that is connected to a computer which records and displays the reading. It is mainly conducted to know Duration of injection. Dynamic start of injection. Peak combustion pressure. Gas entry inside the nozzle. Secondary injection. Injector needle lift w.r.t crank angle. Rate of pressure rise. The result comes in the form of diagram as shown in figure3.2
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1) Combustion pressure as a function of deg crank angle. 2) Needle lift as a function of deg crank angle. 3) Line pressure as a function of deg crank angle.

5.1) ENGINE TEST CELL LAYOUT Figure 5.1 Engine Test Cell Layout No. 1 2 3 4 5 EQUIPMENT Dynamometer Test Engine Smoke Meter Fuel meter Air mass flow meter DESCRIPTION Device used to put variable external load on the engine The engine to be tested Measures the amount of smoke in exhaust Measures the amount of fuel input to the engine Measures the mass of air taken in by the engine
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Blow by Meter

Throttle Actuator

8 9 10

Particulate Meter Cable Boom Water Conditioner Lube oil Conditioner Exhaust back pressure controller

Vapors of engine oil constitute the blow by gasses. Blow by meter measures these gasses. Varies the throttle from low idle position to high position speed Measures the particulate matter in the exhaust Maintains the temperature and pressure of water input to engine for cooling Maintains the temperature and pressure of engine oil input to engine for lubrication Controls the exhaust back pressure (pressure exerted on the valves by the exhaust when it faces restrictions in the silencer). If the back pressure is more smoke will be more. Maintains the temperature and pressure of air input to engine for combustion Electronic device which controls all units Displays various parameters
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12

13

Intake air conditioner PUMA 5 Controller Control room

14 15

computer

about the engine in real time during the test as recorded by the instruments Measures and displays Cylinder pressure injector pin lift duration and injection pressure during indiset test

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Indiset

17 18

Smart Sample Controller Exhaust Gas Analyzer Host computer Printer

Analyzes exhaust gas for levels of gasses like NOX, CO etc Prints out the result

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DEFAULTS IN ENGINE
:

1. The main default is come from lubricant.

2 Piston seej

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3. Crank joint/ Seej

4. Oil gallery seej

5. Water gallery seej

6. Over heating.

7. Break and damage is also the fault in engine.

PARTS IN CYLINDER HEAD

1. Valve

2. Rocker arm

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3. Cam lift

4. Tappet.

5. Cam shaft

6. Push rode, etc.

PARTS IN CYLINDER BLOCK

1. Piston.

2. Piston rings.
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s 3. Cylinders

4. Connecting rod

5. Combustion chamber between cylinder head and cylinder block

6. Oil gallery

7. Water gallery

8. Cam shaft

9. Crank shaft.

ABREVIATIONS

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1) NOx 2) HC 3) CO 4) PM 5) ID 6) SOI 7) SOC 8) EGR

- Oxides of Nitrogen - Hydrocarbons - Carbon monoxide - Particulate matter - Ignition delay - Start of Injection - Start of combustion - Exhaust gas recirculation

9) BSFC - Brake specific fuel consumption 10) SOF - Soluble Organic Fraction 11) CRT -Continuous Regenerative Trap 12) BT 3A -Bharat Trem 3A 13) IVC -Inlet Valve Closure 14) LLR -Light Load Retard 15) DV 16) FIP -Delivery Valve - Fuel Injection Pump

17) ACS -Air Conditioning System

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