Automobile Engines

Collected and Prepared By S.N.Pattnaik A.T.O. (Automobile)

Function of Automobile Engines

Engine is the Source of Power for Automobiles

Classification of Engines
All automobile engines are Internal combustion engines. These are classified mainly according to; Arrangement of Cylinders Type of fuel used Number of Strokes per cycle (Two Stroke & Four stroke) Number of Cylinders Method of Ignition (SI & CI)

Classification of Engines
Based on Arrangement of Cylinders
Inline Here all the cylinders of the engine are in a straight line. V-Engine The cylinders arranged in two banks connected to the same crankshaft. Flat / Horizontally Opposed A Boxer engine is a V engine with an angle between the cylinder banks of 180o

Classification of Engines
Based on Type of Fuel

Petrol Diesel

Classification of Engines
Based on Number of Strokes per Cycle

Two Stroke Four Stroke

Two Stroke Engines

Two stroke engines do not have valves but has ports (openings) These engines fires once in every revolution and hence there is a boost of power produced. Two stroke engines are lighter and cost less in manufacturing.

Two Stroke Engines

Two Stroke Engines

COMPRESSION AND INTAKE
EXHAUST PORT

INLET PORT

Two Stroke Engines

COMBUSTION
SPARK PLUG

Two Stroke Engines

SCAVENGING AND EXHAUST
EXHAUST FRESH AIR

Two Stroke Engines

PRIMARY COMPRESSION AND EXHAUST

EXHAUST

Four Stroke Engines

Intake air & fuel enter cylinder Compression air & fuel are compressed Power spark plug fires, ignites fuel. Exhaust burnt gases are expelled from the engine

Components of 4-stroke engine

ROCKER ARMS CAM SHAFT

EXHAUST VALVE INLET VALVE SPARK PLUG PISTON CONNECTING ROD CYLINDER BLOCK CRANK SHAFT

SUMP

Important Terms of 4-stroke engine

TDC

BDC

Valve Timing Diagram

Inlet Valve Opens

TDC
1 4

Exhaust Valve Closes

SUCTION

COMPRESSION

POWER

EXHAUST

Inlet Valve Closes

BDC

Exhaust Valve Opens

Components of 4-stroke engine

Connecting Rods

Components of 4-stroke engine

Crankshaft

Components of 4-stroke engine

Camshaft
The part of engine which opens and closes the valves is called Camshaft. Or in other words times the valves.

Components of 4-stroke engine

Valves: Valves are provided in the engine to breathe (to take in air and to let out exhaust gases). Minimum no of valves required per cylinder are 2 (one for inlet and one for exhaust). Most Maruti Vehicles have 4 Valves per cylinder which is Most Advanced Technology.

Comparison of Engines with different no. of valves

2 valves Technology Power Developed Fuel Economy Emissions Old Less Less Most

2 valves New More More More

2 valves Latest Most Most Less

Models With Different Valve Arrangements

2 valves
Ikon Palio 1.2 Petra Diesel

3 valves
Santro Accent 1.5 Lancer Getz

4 valves
XL-7 Grand Vitara Gypsy Zen Esteem Baleno WagonR Accent 1.6 Camry Indica Xeta

SOHC Vs DOHC
Single Over Head Camshaft (SOHC) In SOHC system all inlet and exhaust valves are operated by one camshaft which is located in the cylinder head

Double Over Head Camshaft (DOHC) In DOHC system inlet and exhaust valves are operated by two camshafts located in the cylinder head

Important terms related to an Engine

CC: It represents the volume of combustion chamber in cubic centimeters Compression Ratio : Is calculated by dividing the air volume of cylinder with piston at BDC by the air volume with piston at TDC

Important terms related to an Engine

Torque Is the turning force required to turn or twist any object For example, the effort that is required to tighten Bolt with a Spanner is called Torque. Torque is measured in N-m (Newton-meter) Torque = Force x Radial Distance

Important terms related to an Engine

Engine Torque Is the turning or twisting force developed by engine at the crankshaft As the engine runs it develops some amount of torque (turning force), which varies with the rpm. A high torque at low rpm will give the vehicle good pulling power, and easy drivability.

Important terms related to an Engine

Engine Power Power is a measure of how quickly work can be done (moving the car) Power of the engine depends on its torque and engine speed (RPM). More the torque or more the rpm, greater is the power

Important terms related to an Engine

BHP Vs PS BHP and PS are the units of measurement of power developed by the engine 1 PS = 0.986 bhp

Important terms related to an Engine

Power to Weight Ratio (PWR) : Power to weight ratio (PWR) is the ratio of bhp (power) to the weight of the vehicle in tons.

PWR = bhp/ Weight of car in tons.

Higher PWR indicates vehicles capability to pull more weight and accelerate quickly (better pick-up).

Comparison of Torque, BHP & PWR

TO Q E R U Exam ple 2 N @22 2 .m 22 rpm 2 N indicates 2 .m m axim torque um developed The rpmindicates the speed of the engine at w hich m axim torque um is developed BH P 2 bhp @22 2 22 rpm 2 bhp indicates 2 the m axim bhp um developed The rpmindicates the speed of the engine at w hich m axim pow is um er developed PW R 2. 2 2 2 2. 2 2 indicates 2 the pick-up or acceleration of the vehicle.

Vehicle

R PM

Petrol Engine Fuel Systems

Purpose of fuel Systems

To supply a combustible mixture of air and fuel to the engine

Types of Fuel Systems

Carburetor type Electronic Fuel Injection

Single Point Fuel Injection (SPFI) or Throttle body Injection (TBI) Multi Point Fuel Injection (MPFI)

Carburetor Type Fuel system

It is a mechanical device that mix the fuel and air and then supply the same to the engine.

It also vary the air fuel mixture in accordance with the engine needs, e.g. for accelerating, braking, cruising etc.

Disadvantages
It was not very efficient in the mixing The overall power and fuel efficiency of the vehicle was low. Did not adhere with pollution norms

Fuel Injection System

Single Point Fuel Injection (SPFi) or Throttle Body Injection (TBI) Multi Point Fuel Injection (MPFi)

Single Point Fuel Injection (SPFI)

This was the first developed Fuel Injection System after the carburetor In this case, there is a single electronic injector spraying fuel for all the cylinders.

Multi-Point Fuel Injection (MPFI)

In the MPFI system there is separate injector for each cylinder for spray of fuel.

This leads to more effective distribution and combustion of fuel as compared to the SPFI resulting in more power, fuel economy and cleaner emissions.

Multi-Point Fuel Injection (MPFI)

Based on the timing of Fuel Injection in the Multi-Port Fuel Injection system, following classifications are made. Simultaneous MPFI Group Sequential MPFI Sequential MPFI

Simultaneous MPFI

In this system all the injectors inject fuel simultaneously into the Intake Manifold.

Group Sequential MPFI

In this system injectors inject fuel in group of 2 at a time in a sequential manner.

Sequential Multi-Port Fuel Injection

In this system one injector injects fuel at a time and the injectors are timed to release fuel exactly the moment it is needed thus providing a more efficient fuel supply.

Multi-Port Fuel Injection - Specification

All Euro-II & Euro-III vehicles manufactured by Maruti are equipped with Sequential Multi-Point Fuel Injection System

Components of MPFI system

Sensors Actuators

IAT TP MAP CMP CKP ECT VSS O2

IAC Valve ENGINE CONTROL MODULE EVAP System EGR INJECTORS FUEL PUMP

Advantages & Benefits - MPFi

Advantages: Engines with MPFi system generates lesser pollution and More Power as compared to engine having carburetor Benefits: Better fuel economy Better acceleration Cleaner environment

Engine Control System - Comparison

SPFI Technology Power Developed Fuel Economy Emissions Old Less Less Most

MPFI Current More More More

SMPFI Advanced Most Most Less

Diesel Engines

4 stroke cycle Diesel engine

48

4 stroke cycle Diesel engine

Four-stroke cycle

Induction

Compression

Power

Exhaust

Induction

Compression

Typical passenger car diesel engines have 15:1 to 24:1 compression ratios in a range from

Fuel Injection

Fundamental Difference - Petrol & Diesel

Petrol
Typically external mixture formation Additional ignition system needed Output controlled by mixture quantity Air quantity in combustion chamber determined by throttle

Diesel
Always internal mixture formation No additional ignition system needed Output controlled by quantity fuel

Air quantity in combustion chamber remains almost constant

Fuel Injection System - Diesel Indirect Injection

Pre-chamber Design Whirl-chamber design

Direct Injection

Indirect Injection
Pre-chamber design

Indirect Injection
Whirl-chamber design

Direct Injection

Fuel Injection Pumps

Centrally located pump
Cam operated in-line plunger type Rotary distributor type

Injectors with cam operated plunger type Common rail direct injection

Inline Fuel Injection Pump

In-line Fuel Injection Pump Fuel Layout

60

In-line Fuel Injection Pump -Sectional view

61

Rotary Distributor Pumps - Components

62

Rotary Distributor Pumps

Rotary Distributor Pumps Fuel Layout

64

Pump injectors

Common Rail System

Common Rail System

Common Rail system is an Electronic Controlled, Modular, Diesel Fuel Injection System.

68

Demands & Basic parameters

Emission Legislation Higher Power and Torque Fuel Efficient Smoother drivability Cost effective

69

Degrees of Freedom - Common Rail

Injection Quantity Injection Begin Injection Pressure

70

Special Characteristics
Injection Pressure is produced and governed relatively independent of the Engine Speed and can be selected freely within a wide range. Injection begin and Injection Quantity can be freely selected (EDC function)

71

How are the main characteristics of CR system achieved ?

CR uses an intermediate High Pressure Accumulator (Rail) Uses Electronic Control of Injectors (use of Electromagnetic valves)

72

Common Rail System - Components

High pressure pump Fuel rail

Regulator Rail pressure sensor

Fuel filter

Electric pump

Fuel injector

Electric fuel pump

Current absorption: 4 / 6 Amps Output pressure: Flow rate: 150 kPa 145 litres/hour

Fuel filter

The fuel filter contains the: Water level sensor

Fuel temperature sensor

High Pressure Pump

76

High Pressure Pump

77

HP Pump Working

CLICK ON THE MOVIE TO PLAY

Common Rail

Regulator

Pressure Sensor

Pressure Regulator Valve

80

Fuel injector

Glow plugs

Lubricating System

Functions of Lubricating System

Lubricates moving parts to minimize wear Minimizes power losses in the engine Serves as a cooling agent Helps to cushion the load on bearings and thus reduces bearing wear Helps form a gastight seal between piston rings and cylinder walls, and thus reduces blowby Acts as a cleaning agent

Oil Pumps

Gear Type Pump Rotor Type Pump

Gear Type Pump

Lubricating System of Swift-D engine

Cooling System

Purpose of the Cooling System

Keep the engine at its most efficient operating temperature at all speeds and under all operating conditions

Types of Cooling Systems

Air Cooling Liquid Cooling

Air Cooled Engines

The Cylinders are Semi-independent/ Independent Metal fins are provided on the heads and cylinders for heat dissipation Some air-cooled engines uses shrouds and fans

Liquid Cooled Engines

Is a mixture of water and an antifreeze solution. Coolant absorbs the heat as it passes through engine Hot coolant flows through the radiator Heat in the coolant is passed on to air that is flowing through the radiator

Layout of Components
RADIATOR CAP
ENGINE BLOCK HEATER SWITCH

RESERVOIR
HEATER CORE

RADIATOR

B - WATER JACKET C -THERMOSTAT D WATER PUMP E- RADIATOR FAN L BLOWER FAN

Water Pump

Thermostat

Ignition System

The purpose of the ignition system

To create a spark that will ignite the fuel-air mixture in the cylinder of an engine

Types of Ignition System

Contact Break Point Ignition System Electronic Ignition

Contact Break Point Ignition System

IG COIL

ROTOR

CB POINT

BATTERY

Distributor
The function of the distributor is to distribute current from the ignition coil to the spark plugs at the correct time. Mostly the distributor is a mechanical device that has an arm that rotates and distributes the current.

Contact Breaker Points

A.To Coil B. Points C.Points Dwell Adjustment

D. Point Riding On Cam E. Rotating Cam Driven by engine F. Condensor

Ignition Coil
The function of the ignition coil is to boost the battery voltage to a very high level needed for the spark to ignite the fuel. On most cars one coil is used to build current for all the spark plugs.

Electronic Ignition
DISTRIBUTOR ROTOR

IGN. COIL

MAGNET

PICK UP COIL IGN. SWITCH SIGNAL ROTOR IGNITOR

VACUUM ADVANCE CENTRIFUGAL ADVANCE BATTERY SPARK PLUGS

Electronic Ignition Operation

Centrifugal Advance System

SIGNAL ROTOR

Vacuum Advance System

PICK UP COIL

MAGNET

SIGNAL ROTOR

ENGINE VACUUM

Dual coil Distributor Less Ignition (DDLI)

In this system two ignition coils are used, (one coil for 2 spark plugs) and instead of a mechanical distributor there is an electronic device which distributes the current. Thus this system becomes very accurate, reliable and quick, giving the car better performance, efficiency and requiring negligible maintenance.

Starting System

Purpose of Starting Motor

Cranks the engine to start.

Starter Motor Circuit

Working of Starting Motor

Charging System

Purpose of Charging System

To charge the battery To handle the load of the lights, ignition, radio and other electrical and electronic equipment while the engine is running

Components
Alternator
The alternator is driven by a belt that is powered by the rotation of the engine Generate AC Voltage

Rectifier
Converts AC voltage to DC Voltage

Regulator
Regulate the voltage out put from alternator

Typical Charging Circuit

The alternator is driven by a belt that is powered by the rotation of the engine

Thank You