AEES - 2021-06 - Ignition System

Automotive Electrical-Electronic Systems
IGNITION SYSTEM FOR SI ENGINES
TRAN DANG LONG

HCMUT - 2021
1
©TRẦN ĐĂNG LONG – ĐHBK, 2021
Goals of the Course
 Students can describe functions and roles of an ignition system
KNOW  Students can define major technical parameters of an ignition system

 Students can remember values of major technical parameters
 Students can describe components of an ignition system
 Students can describe working principle of an inductive ignition system
UNDERSTAND  Students can describe roles of ignition timing and adjusting mechanism
 Students can define common causes of misfire
 Students can draw schematic diagrams of ignition system
 Students can calculate major parameters of ignition system
 Students can explain circuit diagrams of ignition system
APPLY  Students can select a proper spark plug for an SI engine
 Students can read spark plug tips
 Students can check ignition system
 Students can diagnose common failures of ignition system
2
A INTRODUCTION B STRUCTURE C INDUCTIVE
Brief history Ignition coil (bobine) IGNITION
Functions & Roles Spark plug (bougie)
Technical requirements Distributor (“delco”) Overall schematic diagram
Terms and specifications High tension cord Theory of inductive ignition
Categories Igniter Dwell angle control
Electronic Control Unit
D SPARK DISTRIBUTION E IGNITION TIMING ( )

Effects of 𝜃 on engine and vehicle’s performances
Distributor
𝜃 adjustment with mechanical mechanisms
Direct ignition with wasted spark
𝜃 adjustment with computer-based control
Direct ignition with coil-on-plug
𝜃 adjustment for anti-knocking
F DIAGNOSTIC TECHNIQUE G CAPACITOR DISCHARGE

Spark-plug tip observation
IGNITION (CDI)
Secondary voltage waveform observation Overall schematic diagram
Failures & Troubleshooting Operating principle
3
IGNITION SYSTEM FOR GASOLINE ENGINES
Key Takeaways
 Auto-ignition temperature
 Effect of ignition timing on engine performance
 Anti-knocking VS. High power
 Self-inductance
 Dwell angle = duration of primary energy storage
 Ignition timing = time that primary energy releases
 Plasma = Air/Fuel mixture is electrically broken down
 No plasma = No primary energy or Energy leakage in

secondary circuit
4
INTRODUCTION
 History of Development
 Functions & Roles
 Technical requirements
 Technical terms & specifications
 Classifications
5
IGNITION SYSTEM / HISTORY (1/4)
N. Callan H.D. Ruhmkorff J.J.E. Lenoir
1799-1864 1803-1877 1822-1900
1836 Nicolas Callan invented the first induction

coil that can produce high-voltage AC from a
low-voltage DC supply
1851 Heinrich Daniel Ruhmkorff patented an Ruhmkorff coil

induction coil consisting of a transformer and
a mechanical vibrator to produce high-
voltage pulses from low-voltage DC supply
1860 J.J. Etienne Lenoir invented the first spark

plug in conjunction with a Ruhmkorff coil for
the first SI engine running with coal gas Spark plug & SI engine of Lenoir
6
MAGNETO IGNITION
• Consist of
 a spinning magnet
 a fixed transformer
 a primary circuit breaker
• Self-contained operation
• Simplicity, reliability
R. Bosch
1861-1942
1902 Robert Bosch patented and commercialized
high-voltage magneto ignition in conjunction
with a distributor to deliver electric power to
spark plugs invented by Gottlob Honold (one G. Honold
1876-1923
of Bosch’s engineers)
7
Battery-powered ignition system
Trembler coil
<1910 Battery-powered ignition using a trembler coil

(Ruhmkorff coil) produced a constant train of sparks.
In the 4-cylinder engine of the Ford Model T, a rotary
switch was used to deliver DC power to each trembler
coil corresponding to firing order
1909 Charles Kettering, co-founder of Dayton Engineering

Laboratories Co. (DELCO), patented the first battery-
powered ignition system including an ignition coil Ford Model T
and a primary circuit breaker that can produce a
single spark and a high voltage up to 10 kV
C. Kettering
1910 DELCO battery-powered ignition system was first 1876-1958
commercialized in Cadillac cars
8
1948 Delco-Remy invented transistorized ignition system, producing up to 20 kV
from battery supply
Wasted-spark ignition system (twin-spark plug ignition system) was first
introduced in 2-cylinder engine of Citroen 2CV.
1963 Transistorized ignition system was first used in Pontiac cars as an option
Hyland Electronics commercialized Capacitor Discharge Ignition (CDI) System
1968 Transistorized ignition systems was first officially used in Fiat Dino
1980s GM introduced high-energy wasted-spark ignition system that can produce up

to 100 kV.
1990s Computer-controlled ignition system rapidly matured
Present Coil-on-plug ignition system widely used
9
IGNITION SYSTEM / HISTORY
Quizzes:
1. Name major types of ignition system in history?
2. When was battery-powered single-spark ignition
system first introduced?
3. Features of ignition systems used in present days?
10
IGNITION SYSTEM / FUNCTIONS
 Spark energy:
~40 mJ
 Burning time:
0.9-1.5 ms
 Spark plug lifetime:

~50000 km
 Transform low-voltage battery supply (6-12 V) into high-voltage pulses

(15-30 kV) resulting in powerful electric sparks lasting for sufficiently
long durations of time to ignite combustion at proper crank-angles
11
IGNITION SYSTEM / ROLES
 Ignition system Vs. Engine output performance
Thermal efficiency (max. IMEP) VS. Comfort (smooth, low noise level)
 Ignition system Vs. Vehicle performance
• Driving comfort: torque reduction during gear-shifting in automatic transmissions
• Safety driving: torque reduction for anti-skidding, suppressing oversteer or understeer
while cornering
 Engine malfunctions caused by ignition failures

• Misfiring, starting failure, wrong firing order
• Reduced power, overheated coolants, overheated exhaust manifold, pop-backs in intake
manifold, knocking (detonation), pre-ignition, catalyst deactivation
• DTC – Diagnostic Trouble Code: P0300, P0301, P0325
 Engine diagnose via ignition system

• Mechanical faults: worn piston ring & cylinder wall; coolants in combustion chamber
• Fuel system faults: lean mixtures, rich mixtures, water in fuel
• Others: wrong valve timings, valve leakage, EGR valve leakage
12
IGNITION SYSTEM / ROLES
Quizzes:
1. Describe important roles of ignition system on SI engine
powered vehicles?
2. How faults in ignition system affect engine performance?
3. Which engine faults can be diagnosed via ignition system?
4. Summarize the roles of ignition system using an infographic?
13
IGNITION SYSTEM / TECHNICAL REQUIREMENTS
 Generate powerful enough electric sparks in all

operating conditions
 High intensity work
 Withstand harsh environment with high vibration, high
pressure, high temperature, and chemical corrosions
 Durability, stability, reliability
 Low-maintenance
 Easy to be repaired and replaced
14
IGNITION SYSTEM / TERMS & SPECIFICATIONS
Technical terms & specifications Symbol Unit Notes
Max. secondary voltage 𝑈 , kV Secondary voltage achievable without spark plug
𝛿𝑝 𝑝 (Pa) & 𝑇 (oC) when 𝐼 is interrupted;

Firing (Breakdown) voltage 𝑈 kV ~𝑀 𝑀: air/fuel mixture coefficient; 𝛿 (mm):
𝑇
electrode gap (Paschen formula)
Spark kV 𝑈 kV Secondary voltage when spark occurs
Electrode gap resistance 𝑅 () reduced once broken down,
Plasma voltage 𝑈 kV
depending on air/fuel mixture
Burn time 𝑇 s Spark duration
𝑈 ,
Reserve ratio 𝐾 -
𝑈
Ignition timing 𝜃 OCA Crank angle before TDC when 𝐼 is interrupted
𝑇
Dwell angle (time) 𝜃 % 100% 𝑇 (s): duration of primary current
𝑇
1 𝐿 (H) & 𝐼 (A): primary inductance and
Primary energy 𝑊 J 𝐿 𝐼
2 current, respectively
Spark energy 𝑊 J 𝑊 <𝑊
𝑛 1 𝑛 (vg/ph): engine speed; 𝑁 : number
Ignition cycle of 4-stroke engine 𝑇 s
120 𝑁 of cylinders
Secondary equivalent resistance 𝑅 ,  𝑅 +𝑅 +𝑅 𝑅 : high tension cord resistance
15
Standard Secondary Voltage Waveform
Breakdown voltage (8-12 kV in idle)
Plasma voltage
Spike occurs as plasma
(3-4 kV in idle (<6 kV))
breaking down
Spark kV point
(4-6 kV in idle) 2-3 oscillations to release
residual energy
0V 0V
Primary current Burn time

Rest time Primary current rise limitation 0.9-1.5 ms (#5) Rest time, zero primary current (#7)
Dwell time (#1) Release residual energy (#6)
• Secondary voltage rise (#2)

• Breakdown & Ionization (#3)
• Electric spark (plasma) formation (#4)
16
IGNITION SYSTEM / TERMS & SPECIFICATIONS
Quizzes:
1. Is it easy to generate electric sparks with large ?
2. How does vary with respect to engine operating conditions? (temperature,
load, air/fuel ratio, electrode gap)
3. Under which conditions can achieve the maximum value? Explain why?
4. Explain the relationship between and ?
5. How to calculate , ?
6. How does electrode gap resistance vary with respect to air/fuel mixture?
7. Explain the following situations:
• Electric spark can occur in open air but fails to occur in combustion chamber.
• Engine fails to run higher than 3000 rpm due to misfire.
• Engine fails to fast accelerate.
17
IGNITION SYSTEM / CLASSIFICATIONS (1/6)
Types Conventional Electronic Computer Direct
Energy storage Induction(0) Induction(0) Induction(0) Induction(0)

Primary circuit breaker Mechanical(1) Electronics(2) Electronics(2) Electronics(2)
Ignition timing sensor Mechanical(1) Electronics(3) Electronics(3) Electronics(4)
Ignition timing adjustment Mechanical(5) Mechanical(5) Electronics(6) Electronics(6)
Electric spark distribution Mechanical(7) Mechanical(7) Mechanical(7) Electronics(8,9)
(0) Ignition coil (bobine) (5) Centrifugal mechanism + Vacuum mechanism

(1) Contact breaker (6) Computer control (ECU – Electronic Control Unit)
(2) Transistor (7) Distributor (“delco”)
(3) Camshaft position sensor inside distributor (8) Wasted spark ignition
(4) Crankshaft position sensor + Camshaft position sensor (9) Coil-on-plug (pencil coil)
Practice: Draw schematic diagrams of

inductive ignition systems
18
Conventional Ignition System
Quizzes:
1. How is the number of cam lobes compared to the number of cylinders?
2. How to drive operating cam and distributor?
3. Define direction of rotation of distributor and firing order?
19
Electronic Ignition System
(Distributor not illustrated)
Distributor
Quizzes:
 IGT ignition trigger signal 1. How is the number of tooth
 IGF ignition flag signal of G1 sensor compared to
the number of cylinders?
 Ignition timing sensors inside distributor
2. How to drive G1 and NE
sensors?
20
Computer Controlled Ignition System
Gasoline engines with OBD-I
Distributor
OBD-I 1st generation On-Board Diagnostics to prevent excess emissions (CO, HC, NOx)
21
Direct Ignition System with Wasted Sparks
Gasoline engines with OBD-I/II
 The use of twin

spark plugs
Quizzes:
Is it necessary to
use camshaft
position sensor in
wasted-spark
ignition systems?
OBD-I/II 1st/2nd generation On-Board Diagnostics to prevent excess emissions (CO, HC, NOx)
22
Direct Ignition System with Coil-on-Plug
Gasoline engines with OBD-II
 Refer to the slide

of ME-Motronic
OBD-II 2nd generation On-Board Diagnostics to prevent excess emissions (CO, HC, NOx)
23
COMPONENTS
 Ignition coil (Bobine)
 Spark plug (Bougie)
 Distributor (“delco”)
 High tension cord
 Igniter
 Control unit (ECU, ECM)
24
COMPONENTS / IGNITION COIL (Bobine)
 Pulse transformer
 Voltage ratio: ~100:1
 Voltage class: 25-50 kV
 Resistance: 0.3-2  / 8-19 k
25
COMPONENTS / IGNITION COIL / TYPES
Inductive Ignition System with Distributor
 Dwell time  energy storage in primary windings

 Primary energy discharge  electric spark
26
Inductive Ignition System with Wasted-Spark
27
Inductive Ignition System with Coil-on-Plug
28
Capacitor Discharge Ignition (CDI)
 Energy storage in capacitor instead of in primary windings

 Capacitor discharges energy to primary windings  electric spark
29
COMPONENTS / IGNITION COIL
Quizzes:
1. Describe functions of ignition coil?
2. Describe operation of ignition coil in inductive ignition system?
3. Describe operation of ignition coil in CDI system?
4. Describe the roles of capacitor in CDI system?
5. Describe the roles of capacitor in inductive ignition system?
?? ??
30
COMPONENTS / SPARK PLUG (BOUGIE)
31
COMPONENTS / SPARK PLUG (BOUGIE)
Quizzes:
1. Name common spark-plug manufacturers in market?
2. Describe functions of spark plug?
3. What are common electrode gaps?
4. How does electrode gap affect electric spark formation?
and combustion ignition? Explain why?
32
COMPONENTS / SPARK PLUG / TYPES
BOSCH spark-plug
designations
33
(1) (1)
(2) (3)
Nickel
Surface air-gap (3) Air-gap (1)
Platinum
Surface-gap
(2)
Iridium
Center electrode
materials Ground electrode designs Spark-plug heat range 34
Quizzes:
1. What are advantages of center electrode materials including Nickel,
Platinum, and Iridium?
2. What are advantages of Surface-gap? Surface-air gap?
3. How many sparks simultaneously occur in spark-plugs having multi-
ground electrodes?
4. What are advantages of spark-plugs having multi-ground electrodes?
Hints
• Misfire usually occurs during fast acceleration
• Misfire can cause severe damages in three-way catalysts
• Strong electric sparks result in fast electrode wear
35
Quizzes:
1. Which type of spark-plugs is hotter during operation, “hot”
spark-plugs or “cold“ spark-plugs? Explain why?
2. How to select proper spark-plugs corresponding to engine
speed ranges and operating conditions? Explain why?
Hints
• Optimum operating temperature
for center electrode: 850-900 oC
• Speed range and load condition
in which engine usually works
strongly affect combustion
chamber temperature
36
COMPONENTS / SPARK PLUG / INSTALLATION
  
  
37
COMPONENTS / DISTRIBUTOR (“DELCO”)
38
39
1. Distributor with Built-in Inductive Timing Sensors
Cảm biến Ne
Cảm biến Ge
1989 Toyota Corolla
Quiz: Calculate distance in crank angles between two Ne tooth?

40
1. Distributor with Built-in Inductive Timing Sensors
Inductive camshaft
position sensor
Practice: Check conditions of inductive timing

sensors: resistance, output signal
41
2. Distributor with Built-in Hall Timing Sensors
Practice: Quiz:
Check Hall-effect sensor Under which conditions output is LOW?
42
Quizzes:
1. Describe functions of distributor?
2. How to drive distributor?
3. Describe types of ignition timing
sensors in distributor?
4. Describe output waveforms of
ignition timing sensors in distributor?
43
COMPONENTS / HIGH TENSION CORD
Quizzes: While engine is running,

1. What faults can be detected by disconnecting a high tension cord?
2. What should be taken care of when disconnecting a high tension cord?
44
COMPONENTS / IGNITER
a)
b) c)
a) Loại đơn
b, c) Loại tích hợp
 IGT Ignition control signal
 ON Turn-on primary current
 Store energy in primary windings
 OFF Interrupt primary current
 Discharge energy  Electric spark
 IGF Feedback signal  Ignition OK

45
COMPONENTS / CONTROL UNIT
46
INDUCTIVE IGNITION SYSTEM

 General schematic diagram
 Working principle
 Dwell angle adjustment
47
1. General Schematic Diagram
Quizzes:
1. Describe functions of each block?
2. What is the supply voltage of

ignition system during operation?
Explain why?
48
2. WORKING PRINCIPLE
Phase #0 (#7):
Rest time
• =0 • =0
• =0 • =0
extremely
high
0V 0V
Rest time
Secondary voltage waveform

49
Phase #1:
Primary energy storage
• Igniter = ON • = 0  max
• =0V •
extremely
high
0V 0V
Primary
Primary current current
rise (#1) limitation
Dwell time

50
Phase #2:
Secondary voltage rise
• Igniter = OFF  interrupted
•  ~200-300 V
•  ~20-30 kV
strong
Firing line
electric
field
0V 0V

Secondary voltage waveform • Breakdown & Ionization (#3)
51
Phase #3:
Ionization & Breakthrough
• = ~8-12 kV (idle)
Breakdown voltage
(8-12 kV in idle)
Firing line
largely
reduced
0V 0V

52
Phase #4:
Electric spark formation
• = ~4-6 kV
• 0
Breakdown voltage
(8-12 kV in idle)
Heat
Firing line
radiation
Spark kV point
(4-6 kV ở idle)
0V 0V

53
Phase #5:
Burn time (spark duration)
• = ~3-4 kV (< 6 kV)
• Large goes through the gap
• Combustion ignited
Heat
Plasma voltage
(3-4 kV in idle (<6 kV)) radiation
0V 0V
Burn time
0.9-1.5 ms
(#5)

54
Phase #6:
End of spark duration
• Spike due to increased
• oscillation
• Small unable to maintain spark
Spike at the
end of spark
duration increased
Oscillations
of release
residual
energy
0V 0V
Release residual energy (#6)

55
Phase #7:
End of ignition sequence
• =0 • =0
• =0 • =0
extremely
high
0V 0V
Rest time, zero primary current (#7)

56
3. Dwell angle adjustment
Quizzes:
1. Explain effect of
on , and heat
losses in primary
windings?
2. Should be a
constant during
operation? Explain why?
57
ELECTRIC SPARK DISTRIBUTION

 Distributor-Type Ignition System
 Direct Ignition: Wasted-Spark Ignition System
 Direct Ignition: Coil-on-Plug Ignition System
58
ELECTRIC SPARK DISTRIBUTION (1/4)
1. Distributor-Type Ignition System
Quizzes:
1. How many sparks
simultaneously occur?
2. What faults may be caused
by distributor malfunctions?
Practice:
• Define the terminal in
distributor cap for cyl. #1?
• Define firing order in
distributor cap?
59
2. Direct-Ignition System: Wasted-Spark
 Eliminate malfunctions of distributor

 Firing voltage in combustion stroke: 8-12 kV (idle)
 Firing voltage in exhaust stroke: 2-4 kV
60
2. Direct-Ignition System: Wasted-Spark
Quizzes:
1. Define companion cylinder
pairs if firing order is
known?
2. Is it possible to operate
without camshaft position
sensor?
Practice:
 Firing order: 1-3-4-2 • Connect high tension cords
 Firing order: 1-5-3-6-2-4 to companion cylinder pairs?
61
3. Direct-Ignition System: Coil-on-Plug
 Eliminate malfunctions of high tension cords

 Reduce working intensity of ignition coils
 More reliability  preventing misfire
62
IGNITION TIMING ADJUSTMENT

 Roles of ignition timing
 Basics of ignition timing adjustment
 Checking ignition timing
 Mechanically-controlled ignition timing
 Computer-controlled ignition timing
 Anti-knocking
63
IGNITION TIMING ( ) ADJUSTMENT
1. Roles of in SI engine powered vehicles
Effect on Engine Performance Effect on Vehicle Performance
• Thermal efficiency (torque, power) and • Torque reduction during gear-shifting

comfort trade-off in automatic transmissions
đ
• Thermal efficiency and anti-knocking • Tractive force reduction to suppressing
trade-off oversteer or understeer while
cornering (ESP – Electronic Stability
• Quick warm-up after starting
Control)
• Fast heating Three-Way Catalyst after
• Tractive force reduction to suppress
starting
skidding while driving (TCS – Traction
Control System)
64
2. Basics of adjustment
Quiz:
Explain effect of
engine performance:
• Fuel economy (g/kWh)?
• Specific power (kW/kg)?
đ • Coolant temperature?
Start of ignition • Exhaust gas temperature?
• Smooth operation?
Hints
đ,
• p-V diagram
đ,
đ, • Practical meaning of IMEP ( )
65
Combustion duration
Vs.
Combustion cycle
66
3. Checking ignition timing
Quizzes:
Hints
1. Describe working principle of timing light in
measuring engine speed and determining • Timing light is used to determine
ignition timing? firing cycle of one cylinder
2. What should be care while using timing light?
67
Quizzes:
1. Should be a constant in all operating conditions? Explain why?
2. How should be adjusted with respect to engine speed and load?
3. Compared to idle mode, how should be varied with increase of speed?
Explain why?
4. Compared to idle mode, how should be varied with increase of load?
đ
Explain why?
5. Why should be small for engine starting?
6. Why small leads to quick warm-up after starting?
7. In vehicles using automatic transmissions, flames can be found at the exhaust
pipe outlet during kickdown operation? Explain why?
Hints
• Kickdown operation  Automatic down-shifting for acceleration
68
 Operating cam driven directly by rotor

can rotate relatively to rotor shaft
 Contact breaker disc can rotate relatively

to distributor housing
 Rotor rotate freely to distributor housing

đ
Quizzes: Calculate ignition timing adjustment ( ) once

each of the following component is rotated an angle
of in the same rotation direction of rotor?
a) Operating cam
b) Contact breaker disc
c) Distributor housing
69
MECHANICAL IGNITION TIMING ADJUSTMENT
1. using Centrifugal Mechanism
70
Quiz:
• Which mechanical
đ factors strongly
affect adjustment
characteristics of a
centrifugal
mechanism?
Revolution / rpm
https://www.hotrod.com/articles/set-ignition-curves-create-optimal-performance/
71
Quiz:
• Define the direction of rotation rotor in the
below centrifugal mechanism? Explain why?
đ
72
2. using Vacuum Mechanism
Quiz: Describe the relationship between engine load and

intake manifold pressure? Explain why?
73
2. using Vacuum Mechanism
Quiz:
• Which mechanical
đ factors strongly
affect adjustment
characteristics of a
vacuum
mechanism?
Vacuum / Hg
https://www.hotrod.com/articles/set-ignition-curves-create-optimal-performance/
74
Quizzes:
1. Draw a schematic diagram to connect the below ignition system to intake manifold?
2. Define the direction of rotation of distributor’s rotor?
3. Explain the direction of movement of magnetic pick-up coil as engine load increases?
75
COMPUTER-CONTROLLED IGNITION TIMING
Working principle
Initial ignition timing
mechanically pre-defined
Ignition timing correction as a

function of 𝒄𝒐𝒐𝒍𝒂𝒏𝒕 , EGR, anti-knocking,
torque reduction, etc.
Basic ignition timing as a function of speed, load

76
COMPUTER-CONTROLLED IGNITION TIMING
Working principle
Hints Quiz: Explain advantages of

• Ability to fulfill engine’s requirements? computer-controlled
• Ability to fulfill vehicle’s requirements? ignition timing?
77
IGNITION TIMING ADJUSTMENT ( )
Quizzes: Consider an inductive ignition system for a 4-cylinder

engine using distributor in conjunction with inductive
Ne, Ge sensors
1. Calculate firing cycle (seconds) with respect to engine speed (rpm)?
2. How to define the time when the primary current should be interrupted if
either or is already known?
đ
Hints
 Draw the time plots of Ne và Ge signals
 Define the desired in time plots of Ne và Ge signals
 Use the current Ge signal (e.g. cyl. #1) to define the time
of ignition for the next cylinder (e.g. cyl. #3)
78
ANTI-KNOCKING USING IGNITION TIMING
Negative Impacts of Frequent Knocking
Knocking combustion in spark-ignition engines, Z.Wang et al. [2013]
Quiz: How to feel knocking occurring?
79
Theory of Knocking
Quizzes:
1. What are knocking and pre-ignition?
2. How knocking happens?
3. How pre-ignition happens?
4. Which phenomena occurs after

ignition? Vorentflammungseinfluss des Motoröls bei hochaufgeladenen
Ottomotoren mit direkter Einspritzung [2016]
80
Causes of Knocking
1. Low-octane fuels
2. High compression ratio
3. Too advanced ignition timing
đ
4. High boost pressure
5. Lean mixtures
6. Carbon deposits in combustion
chamber, exhaust valve seats
7. Bad knocking sensor
8. Too high coolant temperature
Knocking combustion in spark-ignition engines
Z.Wang et al. [2013] 9. Improper spark-plug heat range
81
Knocking Detection
Knock sensor
Quiz:
What are symptoms of bad
knock-sensor?
82
Anti-Knocking Algorithm
Quiz: Describe the goals of anti-knocking in

SI engines by adjusting ignition timing?
83
ENGINE DIAGNOSTICS
VIA IGNITION SYSTEM
 Reading spark-plug tips

 Interpreting secondary voltage waveform
 Common failures in ignition system
84
ENGINE DIAGNOSTICS VIA IGNITION SYSTEM
1. READING SPARK PLUG TIPS (1/2)
1. Normal 1 2
2. Carbon fouled
3. Oil deposits
4. Wet
3 4
5. Burned
6. Worn electrodes
7. Broken electrodes
85
1. READING SPARK PLUG TIPS (2/2)
1. Normal 5 6
2. Carbon fouled
3. Oil deposits
4. Wet
7
5. Burned
6. Worn electrodes
7. Broken electrodes
86
1. READING SPARK PLUG TIPS
Quizzes:
1. Interpret spark-plug tips?
2. Which types of spark-plug tip can be observed when
using a spark-plug having incorrect heat range?
87
2. SECONDARY VOLTAGE WAVEFORM (1/3)
Breakdown voltage (8-12 kV in idle)
• Only use specialized Plasma voltage

Spike occurs as plasma
oscilloscope and high-voltage (3-4 kV in idle (<6 kV))
breaking down
probes (>40 kV)
• Use specialized coil-on-plugs Spark kV point
for direct ignition systems (4-6 kV in idle) 2-3 oscillations to release
residual energy
0V 0V
Primary current Burn time

Rest time Primary current rise limitation 0.9-1.5 ms (#5) Rest time, zero primary current (#7)
Dwell time (#1) Release residual energy (#6)

• Breakdown & Ionization (#3)
88
Parameters Reading Causes Checks
Breakthrough voltage • < 8 kV at idle • Wrong electrode-gap • Too small electrode-gap
• Reduced compression • Valve leakage
• >12 kV at idle • Wrong electrode-gap • Too big electrode-gap (worn)

• Too high compression • Carbon deposit inside cylinder
Spark kV point • > 6 kV at idle • Fuel supply system
• Large 𝑅 due to lean mixture
• Large 𝑅 ,
• Broken high tension cord
• Bad electrical contacts
Plasma voltage • Steep Increase upon time • Large 𝑅 due to lean mixture • Fuel supply system
• Strong oscillation • Turbulences in combustion • Wrong valve timing

chamber • Valve leakage
• EGR valve leakage
• Too high exhaust backpressure
• Coolant water inside cylinder
Burn time • < 0.9 ms • Weak primary energy • Low primary current (bad circuit)
Voltage spike as • No spike • No plasma (no ignition) • Carbon fouled

plasma breaks down • Spark-plug cap burned
• High tension cord cracked
Voltage oscillation at • Almost no oscillation or • Weak primary energy • Low primary current (bad circuit)
the end very weak oscillation • Energy leakage outside • Bad secondary electrical contacts
combustion chamber • High tension cord broken or cracked
• Sparkplug cap burned
89
Test procedure Reading Causes Check
1. Idle mode • Faults occur at only one • Local faults • Check components related
& comparison among cylinder to the bad cylinder
cylinders • Faults occur at all cylinders • Faults in common systems • Check common systems
• Plasma voltage appears to • Complete energy leakage • Carbon fouled

be smooth, no spike and no • Sparks outside cylinder
oscillation at the end(*)
2. Snap-test (sudden push • Rise of plasma voltage(**) • Lean mixture as throttle • Fuel supply system
accelerator pedal stick suddenly opened • Bad electrical contacts
• High tension cord broken
the floor and then
• Spark-plug cap burned
release)
• Smooth plasma voltage and • Sparks outside cylinders • Bad electrical contacts
unchanged upon engine • High tension cord broken
speed • Spark-plug cap burned
3. Running at ~2500 rpm • Spike and oscillation occur • Good ignition at 2500 rpm • Carbon fouled due to
at the end although they injector leakage
disappear at idle(*)
• Normal plasma although • Good mixtures at 2500 rpm • Lean mixture due to injector
rise of plasma voltage clogged
observed during snap-
test(**)
4. Running at >2500 rpm • Unable to run • Misfire • Bad ignition coil

90
Quizzes:
1. What are symptoms of misfiring?
2. How to quickly determine the misfiring cylinder?
3. How does misfiring have negative impacts on three-
way catalyst?
4. How to automatically detect misfiring? (algorithm)
Hints
• Unburned mixtures can be ignited in exhaust manifold
• No ignition, no power to be generated
91
COMMON FAILURES IN IGNITION SYSTEM
92
ASE certification test
1. A scan indicates the #1 and #4 cylinders of a four-cylinder engine are

misfiring. According to the schematic diagram above, which of the following
is causing these misfires?
A. There is an open at point A in the system.
B. There is an open at point B in the system.
C. There is an open at point C in the system.
D. There is excessive resistance at point D of the system.
93
2. The number 2 and 3 cylinders of a four cylinder engine are producing less
secondary voltage than the 1 and 4 cylinders. According to the diagram above
which of the following is causing this condition?
A. There is an open at point A of the ignition system.
B. There is an open at point C of the ignition system.
C. There is resistance at point C of the ignition system.
D. There is resistance at point D of the ignition system.
94
3. A spark plug's electrode is covered with thick black carbon deposits. Which
of the following is correct?
A. The engine has a vacuum leak.
B. This reading shows normal wear.
C. The piston rings are worn.
D. The fuel injector is leaking.
4. Technician A says pre-ignition occurs when a flame front ignites in the

combustion chamber before the spark plug fires. Technician B says installing
the wrong spark plug in an engine can result in detonation. Who is correct?
A. Technician A B. Technician B
C. Both A and B D. Neither A or B
95
5. One spark plug's ceramic insulator is longer than the others. Which of the
following is correct?
A. Spark plugs have different heat ranges.
B. Spark plugs are self-cleaning.
C. Spark plug resistance can be tested using a digital multimeter.
D. All of the above.
96
CAPACITOR DISCHARGE IGNITION
 Schematic diagram
 Working principle
97
Schematic Diagram of AC-CDI
 AC-CDI vs. DC-CDI

 High power electric spark
 Short burning time
98
Working Principle of AC-CDI
State #1: Off State #2: Charging
State #3: Storage State #4: Ignition
99
Quiz:
Draw a schematic diagram of a DC-CDI system?
100
Practice: Make a computer-controlled

AC-CDI unit for motorcycles
1. Make an AC-CDI unit for motorcycles
2. Use microcontroller (e.g. Arduino UNO R3) to measure
engine speed from inductive crankshaft position sensor
3. Manually adjust via microcontroller & PC
4. Automatically adjust upon engine speed
101

AEES - 2021-06 - Ignition System

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AEES - 2021-06 - Ignition System

Uploaded by

Copyright:

Available Formats

Automotive Electrical-Electronic Systems

IGNITION SYSTEM FOR SI ENGINES

TRAN DANG LONG

KNOW  Students can define major technical parameters of an ignition system

D SPARK DISTRIBUTION E IGNITION TIMING ( )

F DIAGNOSTIC TECHNIQUE G CAPACITOR DISCHARGE

 Effect of ignition timing on engine performance

 Anti-knocking VS. High power

 Dwell angle = duration of primary energy storage

 Ignition timing = time that primary energy releases

 Plasma = Air/Fuel mixture is electrically broken down

 No plasma = No primary energy or Energy leakage in

1836 Nicolas Callan invented the first induction

1851 Heinrich Daniel Ruhmkorff patented an Ruhmkorff coil

1860 J.J. Etienne Lenoir invented the first spark

<1910 Battery-powered ignition using a trembler coil

1909 Charles Kettering, co-founder of Dayton Engineering

commercialized in Cadillac cars

1980s GM introduced high-energy wasted-spark ignition system that can produce up

1990s Computer-controlled ignition system rapidly matured

Present Coil-on-plug ignition system widely used

 Spark plug lifetime:

 Transform low-voltage battery supply (6-12 V) into high-voltage pulses

 Engine malfunctions caused by ignition failures

 Engine diagnose via ignition system

 Generate powerful enough electric sparks in all

Max. secondary voltage 𝑈 , kV Secondary voltage achievable without spark plug

𝛿𝑝 𝑝 (Pa) & 𝑇 (oC) when 𝐼 is interrupted;

Primary current Burn time

Dwell time (#1) Release residual energy (#6)

• Secondary voltage rise (#2)

Types Conventional Electronic Computer Direct

Energy storage Induction(0) Induction(0) Induction(0) Induction(0)

(0) Ignition coil (bobine) (5) Centrifugal mechanism + Vacuum mechanism

Practice: Draw schematic diagrams of

 The use of twin

 Refer to the slide

 Dwell time  energy storage in primary windings

 Energy storage in capacitor instead of in primary windings

Surface air-gap (3) Air-gap (1)

1989 Toyota Corolla

Quiz: Calculate distance in crank angles between two Ne tooth?

Practice: Check conditions of inductive timing

Quizzes: While engine is running,

 IGF Feedback signal  Ignition OK

INDUCTIVE IGNITION SYSTEM

2. What is the supply voltage of

Secondary voltage waveform

Secondary voltage waveform

• Secondary voltage rise (#2)

• Secondary voltage rise (#2)

• Secondary voltage rise (#2)

Secondary voltage waveform

Release residual energy (#6)

Secondary voltage waveform

Rest time, zero primary current (#7)

Secondary voltage waveform

ELECTRIC SPARK DISTRIBUTION

 Eliminate malfunctions of distributor

 Eliminate malfunctions of high tension cords

IGNITION TIMING ADJUSTMENT

1. Roles of in SI engine powered vehicles

Effect on Engine Performance Effect on Vehicle Performance