Hand Cranked Engine

FABRICATION OF HAND CRANKED ENGINE

AISSM, Pune 1
 Hand Cranked Engine

Abstract
Now a days IC engine plays a vital role in market of automobiles. The demand for
fuel has increased so need of other energy has become necessary. The main concept of
this project is the zero point fuel consumption. The magnetic force principle is the
basic requirement to work for hand cranked engine. The general property of magnet
that is attraction and repulsion forces are converted into mechanical work. The
magnetic driven engine derives it power from magnet power and constant magnetic
energy is converted into mechanical energy. The useful output is rotating motions
and the application is based on hand cranked engine which varies from different
field.
The hand cranked engine should be ideally perform exactly the same as that
of internal combustion engine. The engine, the strength of the field is controlled by
the amount of windings. This design applies the power every fourth stroke same as
normal does now. It utilizes only the repulsive force that allows field to dissipate
completely, and have no restrictive effects on the rising piston. The main advantages of
hand cranked engine are that if is pollution free and internal parts like valves and cam-
followers, can be avoided. Also no manifolds are required since there is no fuel flow.
The challenges faced in designing an hand cranked engine is that is has to be as
efficient as an internal combustion engine.

AISSM, Pune 2
 Hand Cranked Engine

I. INTRODUCTION

In today’s modern World, it is practically impossible to imagine a life without IC

Engines, which is one of the greatest man made inventions. IC Engines are primarily
used in automobiles, which is a major mode of transportation to mankind. IC engines
work mainly on gasoline and diesel which are derived from fossil fuels. The
demand of automobiles keeps increasing as the Population increases. With this increase,
the rate of fossil fuel consumption also increases. This creates a situation that brings
up a need to switch to alternative sources of fuel to produce the power similar to that
of IC engines. The challenge is not to create an engine that operates on an alternate fuel
but to produce higher efficiencies. The next source of energy that strikes our minds
is definitely electrical energy. Now-a-days, we can see automobiles that operate
fully on electrical energy or a hybrid vehicle that operates both on electrical
energy and an IC Engine. Speaking of electrical energy, it is quiet hard to store large
amounts. Thus a method has to be developed that uses electrical energy in combination
to produce better efficient engines. Government has taken many a steps to reduce the
vehicular emission by setting emission standards. However, evolution of scientific
methods for emission inventory is crucial. Therefore, analysis is done on the emissions
from various vehicles by using IVE model .The quality of air in developing countries
like India has reached a horrifyingly low level. Modal analysis to estimate a vehicular
emission to showcase the temporal emission of vehicles

AISSM, Pune 3
Introduction

A machine is any device that aids us in our daily working. I remember an example by an
actor in the Hindi film ‘Three Idiots’ - “Even a zip is a machine, since it aids us in
something!” In this regard, an engine is a machine that aids us in our working: in driving
another machine. It is used to drive small devices such as motorcycles or cars to larger
and heavier devices such as big ships or planes and war tanks. It is also used in motors
seeping water from the ground and to rotate the blades of the fan that you use in
summers. In essence, it is used at any place you where you need mechanical energy.

Thus, in its most basic form, any device can be called a heat engine that converts any
storm of energy to mechanical energy. However, in my visit, I came across the
functioning of only one type of engine: The heat engine. These are the engines used in
bikes and cars and other big driving machines. They have the same functioning as ther
engines, however their initial source of energy is chemical energy only (or in some
instances electrical energy as modern engines are being developed with that upgraded
technology. However, in my experience there were only fuel engines). This chemical
energy is derived from fuels such as diesel and petrol, sometimes mixed with oil as well.

Thus, for this paper, we will define an engine as any machine that produces mechanical
energy by using the energy of a fuel. Since in producing fuel, it does some work in a
specified amount of time, it is said to have generated power.

With this basic concept in mind, I would now explain the functioning of the various
parts of an engine. But before that, a little history is necessary to understand the roots
and need of this machine.
 Histor y

The era of Heat engines started with the innovation of the revolutionary watt steam
engines. As the name suggests, it used pressured steam to drive the piston of the engine.
This is an example of an external combustion engine, an engine that generates energy and
then transfers the energy tothe ‘working fluid’ to do the work. In the case of the heat
engine, the energy is generated through combustion outside the cylinder and then the
energy is transferred to water. The water converts into steam, which under high pressure,
drives the engine.

The development of an internal combustion engine was about 50 years later, when it was
first developed and tested in France. It was based on the Carnot cycle, by the French
engineer and physicist Carnot, often

regarded as the “father of thermodynamics”. Later the Otto cycle came into consideration,
as it was more efficient than the Carnot cycle. Karl Benz developed the first successful
commercial automobile and engines started to be commercially used. After this there were
many advancements in the engine structure and its mechanism, leading to the machine that
we use today.

The most important thing to note about the advancements in Engine is that they were done
so as to increase the efficiency of the engine and also to make it more economical. This
understanding was crucial to my experience in the internship. As pointed out by my
mentors, this is one thing that every engine manufacturer runs after, as this is what makes
its engine different from others.

Keeping this in mind as well, we will now move forward to learn the functioning of the
various parts of an engine, and also understand the reason behind their making.
 The Drinking Bird
While strolling through the Physics museum in my school, I cam across a really novel yet
useful example of ‘Heat Engine’ - “The Drinking Bird Heat Engine”

As described before, a heat engine is a device that converts any form of energy to
mechanical energy. The Drinking Bird heat Engine Does the same. It converts heat energy
to work.
 The Drinking Bird Drinking. Notice the Ether Flowing
Down - Equilising the pressure
To start the Engine, one wets the absorbant flock material on the head and beak
of the bird, with water. The liquid inside the body of the bird is ether, a substance with a

low boiling point (34.6o), which easily vapourizes at room temperature.

As the Ether in the body of the bird vapourizes, it creates high vapour pressure above the
liquid. The Ether in the tube, on the other hand, does not evapourate readily, since it
constantly gets cooled by the water. Thus, there is less vapour
pressure here.The difference in pressure forces the ether from the body of the
bird into the tube till the head.

As the liquid rises, it raises the center of gravity of the bird. Soon, enough ether enters the
head of the bird. If the bird is pivoted such that its center of gravity rises above the point
of pivot, the bird’s head topples forward, meeting water (kept in a container). At this point
the pressure in the head and the body equalze and the ether drains back into the body. The
cycle continues.

The bird can be hooked up and its pivoted motion can be used to do some useful work.
Thus, Heat Energy is converted to Mechanical Energy, making this
‘Drinking Bird’ a heat engine.
Diesel Engine

Basic Structure of an engine:

In general, an engine can be divided into three parts:
1. The head of an engine
2. The body of an engine
3. The tail of an engine

The head of an engine

The head of the engine consists of a Tipid cover, which acts as a protective cover
for the head and of the cylinder head. The cylinder head is further divided into many parts:
• Inlet valves and the Inlet Manipole
• Exhaust Valves and the Exhaust manipole
• The injector
• Push rods or cam shafts

The function of the head is very simple. The inlet valves let in air to the inlet manipole,
which connects all the inlet valves together. The exhaust valves let the smoke put of
the engine, to the exhaust manipole, which connects all the
exhaust valves. The injector, as the name suggests, injects the fuel into the body
of the engine. The injected fuel is a fine spray of diesel, through pores located
in the injector itself. The fine droplets increase the surface area of the fuel to be
combusted – resulting in maximum combustion and thus, maximum efficiency of
the Engine.

The Push rods or cam shafts (depending upon the design of an engine, either push rods, which
are connected to the valves using strips of metal or cam shafts, which make contact with the
valvesthrough a rocker arm, are used) sync the moving of a piston to the valve’s opening
and closing and also to the injector, as mentioned above.

Head of an Engine. Notice the Valves on the top and amidst all of them, the injector. Only the
Inlet Manipole (the holes) has been showm, the exhaust manipole is on the other side.
The Body and Tail

The body of the engine consists only of the cylinder of the engine. This is the
most important part of the engine, as this is the place where the combustion and
the heat production takes place. This is like the fireplace of a cold house, without
it, nothing will get the heat and energy to move forward.

The cylinder consists of a liner – an outer body that covers the piston. The piston is a the
part responsible for the conversion of chemical to mechanical energy.
The piston is connected, through a connecting rod, to a crank shaft, that transfers the linear
motion of the piston into the rotatory motion. The crank shaft is further
connected to the flywheel

The Liner which holds the piston.

The Piston – the converter:

The piston, as discussed before converts the chemical energy to mechanical energy. Its
construction is quite unique, consisting of a long cylindrical block with three rings on
it.

The first ring is just a bunch of pores spread across the cylindrical block. These
pores pour out the oil that helps in lubrication the entire piston. The usage of oil is
quite specific, since it has a flash point of 170ºC, almost 80ºC higher that the flash
point of Diesel. Thus this oil also acts as a coolant.

Lubrication of the piston is necessary since piston is the one of the most important parts
of the engine. If it stops, the engine can’t run. Thus, to ensure its
constant working, it is lubricated. It is cooled constantly by the lubricating oil as well,
since it get heated up due to the friction generated by the constant up and down
movement it does. The lubrication and cooling through oil is aided by the
second ring placed above the first. The third ring acts as a stopper, stopping the
oil to leak into the combustion chamber of the piston, where the diesel is ignited.
If the oil leaks, the combustion might stop or the engine might give a sooty output, since
burning the oil requires more energy due to its higher ignition temperature –
a requirement unfulfilled by the
piston.

The three rings of a Piston - The ring with holes, the ring of
Lubrcation, and the stopper.

The crank shaft converts the linear motion of the piston into rotatory motion. However it
has one more important function. The crank shaft is made quite heavy due to a certain
reason. Since it has more mass, it will have more inertia. Thus, when the piston moves
the crank shaft down, due to its high inertia of motion,
the crankshaft aids the piston in moving back up and compressing the air for the
ignition to happen. This very small ‘help’ by the crankshaft is so important, that if it
were not present, the piston might not even be able to rotate!
The Crankshaft of a big engine. The grooves are connected to the piston using
connecting rods.
Next comes the flywheel, which acts as a go-between between the body of the
piston and other machines – connecting them two together. It is also quite heavy, since its
inertia aids the movement of the piston. Due to its high mass, it helps lift a piston back
to the top for the power stroke.

The Flywheels of two different

engines are shown.

Last comes the tail of the Engine, consisting of the oil reservoir. The oil reservoir
supplies oil to all parts of the engine for lubrication and cooling.
The Oil Reservoir of the engine. According to one of the workers, it occupies more than
1 third of the areas of the total engine.

Now that we have understood the parts well, let us understand the working of
an engine.
Working

The Four-Stroke Engine, as its name suggests, completes 4 strokes in a

cycle. Each stroke is marked by an important change in the direction of Piston
movement.

Initially, when the vehicle is at rest, the piston is at the rim of the liner and there is no
space between the piston and the head of the cylinder.

Suction Stroke – The Piston moves down and the Inlet Valves open. Air is sucked in
since a partial vacuum is created on top of the piston as it moves down. Since air
travels from high pressure (outside) to low pressure (inside) air enters
the liner. The Inlet Valves close at the end of this stroke. The very first movement
of the piston, during the start of the engine, is done by another motor, or in some cases a
person as well.

Compression Stroke – The air inside the Liner is compressed by the movement of the
piston upwards - towards the head. This happens due to the increased
inertia of the piston, due to the presence of the crank shaft. Due to this movement,
the temperature of the air inside rises to about 550⁰C and the pressure to about
40 bars. This sudden rise in temperature is enough to burn the diesel whose flash
point is about 90ºC.

Ignition (this is not a stroke in itself. It is considered to be a part of the compression

stroke): At the end of the compression stroke, the Injector sprays the fuel – in this case
diesel. The diesel undergoes combustion, releasing energy.

Power Stroke – The energy released by the combustion of the diesel expands the air in
the liner which, in turn, drives the piston down to the bottom of the liner.
Exhaust Stroke – The Exhaust Valves open up to let the air and residual gases out. The
piston, due to the high Inertia, moves up, driving the gases out. Also the air pressure
outside is lower than the pressure inside of the liner and thus the air moves out easily.

(The Diagrams for the above strokes are given on the next page)
At the end of this stroke the Inlet Valves open again and the cycle continues.
The opening of the valves is directly controlled by the movement of the fly wheel
connected to the crank shaft. The fly wheel has gears connected to the push rods
or the cam shafts, with a gear ratio of 1:2. This means that whenever the flywheel
moves once, the push rods or the cam shaft moves twice - once for the Inlet Valve and
once for the Exhaust. This ensures the correct timing of the opening of the valves, one
of the most important aspects of an engine, for if the valves open sooner or later, the
engine won’t start or run properly.

Working:
2 - Stroke Diesel Engine

The Two-Stroke Engine combines the four strokes of a four stroke engine and
effectively completes a cycle in two strokes.
The Strokes are:

Stroke 1 (Suction + Compression) –

The piston moves down, towards the end of the liner. The Inlet Opening (No Valve
exist in a Two Stroke Engine, the piston frees the ‘an opening’ by moving down) is
free now, allowing air to rush in. This also helps in pushing the gases, generated due to the
next stroke, out of the exhaust. The piston rises up and the air is compressed. The
compression is so powerful that the air, from room temperature
is heated to 550⁰C and is at 40 bars pressure. The injector, located at the top,
sprays diesel through fine pores which ignites spontaneously due to the high
temperature (as discussed in the four stroke cycle)

Stroke 2 (Power + Exhaust) –

The combustion of the diesel produces a large amount of energy and thus
expands the air which pushes the piston down. As the piston reaches the center of
the liner, the exhaust ‘openings’ open. As the piston approaches the bottom of the
liner, the inlet openings open and let in air, which pushes the exhaust gases out the exhaust
openings and the cycle continues.
 Comparison:
4 Stroke Vs. 2 Stroke Diesel Engine

Here, I have pointed out the advantages and the disadvantages of the Two Stroke engine
over the four stroke engine and Vice Versa.

Comparison:

Advantages of a Two-Stroke Engine over a Four-Stroke engine:

1. A Two Stroke Engine has one power stroke for each revolution of the crankshaft,
unlike the four stroke, which has four. This means that when both the engines have the
same speed, the Two-Stroke Engine completes twice as
many combustions as a Four-Stroke engine, generating more power (this is
the case only if we neglect the full combustion of the fuel, which is discussed in the last
point). Thus, a Two stroke Engine has a Higher Power-to-Weight
ratio than a Four Stroke engine.
2. A Lighter Flywheel is required in a two stroke engine, as it doesn’t need to
have a high inertia, due to the high capacity of the piston to generate more power.
The above two points lead us to conclude that a Two Stroke Engine is lighter than a four
stroke engine
3. The Two stroke engine has a higher mechanical efficiency due to less number
of parts in
it.
4. The Engine Design of a Two Stroke Engine is less complicated than a Four
Stroke Engine
5. The Two Stroke Engine also lacks valves, which means the lack of a lubrication
system, since valves are the parts that require the most lubrication
in a Four-Stroke Engine. Thus, a Two-Stroke Engine can work in any position.

Advantages of a Four-Stroke engine over a twp stroke engine:

1. A Four-Stroke engine has a well-built lubrication system while the Two-Stroke
engine doesn’t. Thus, parts of a Two-Stroke Engine wear out easily.
2. A Four-Stroke Engine consumes less fuel than a Two-Stroke engine. It also
causes less pollution than a Two-Stroke Engine. This is because a Two-Stroke engine is
made for speed which sometimes leads to incomplete combustion of Diesel.

Thus, if the same amount of fuel is used in both the Two and the four stroke
engine, the Four Stroke engine will give more output, overall, than a two stroke
engine. Because of these advantages, four stroke engines are generally used in a ship or in
boats, and not two stroke engines.
Additional Par ts Four stroke diesel engines are used in many transportations. However, the
difference between the four stroke engines used in the ships and the others is the
different parts connected to the engine.

The Oil Refining and Cooling System –

The Oil Reservoir and the Oil Pipes carrying oil to various parts The Oil Pump.
of the engine.

The Oil Refining and Cooling system is larger in a Marine Engine as compared to
other transports, since it cools a bigger engine.

This system consists of an Oil Reservoir, Oil Pump and an Oil Purifier. The Oil
Reservoir, as mentioned before, forms the tail of the engine.

The Oil pump is located at the side of the engine and its sole function is to draw oil
from the reservoir at a high pressure of about 8 bars (as mentioned by the
workers). This oil passes through the oil filter, to remove any impurities that may
clog the flow and hinder the working of the engine. Thereafter it is sent to all parts

of the engine. It lubricates the parts, for their smooth functioning. It also cools the parts,
as seen in case of piston its specific heat capacity being 2.09 – almost half that of
water’s. However, the cooling is only an additional benefit. As shown later
there is a water cooling system as well.
The Fuel System –

The Fuel Pump and pipes

The fuel system also forms an additional part of an engine, as it is not considered in the
head, the body or the tail of the engine.

The Fuel system has a fuel pump, with a high capacity for pumping, and pipes connecting
the fuel pump to the injectors. The fuel pump has an opening to which a pipe is
connected, through which diesel from a tank enters. The fuel pump
draws the fuel and purifies it as well, sending it to the injectors through the pipes.
The injectors open whenever the compression stroke happens and inject the fuel in the
system.

The fuel system is like the heart in its functioning, pumping fuel to all parts of the engine.

The Fuel Governor –

Attached with the Fuel System, between
the fuel pump and the fuel pipes, this device controls the amount of fuel reaching the
injector. It consists of a rubber like compartment, controlled by
a human, which regulates the amount of fuel. Pressing the rubber compartment increases the
fuel supply to the injector and thus the rpm (revolutions of the piston per minute – these
in turn control the speed). Releasing the compartment decreases the rpm.
The Fuel Governer
The Cooling System –

Oil Cooling System: This system, as discussed before, utilizes oil to cool various parts of
the engine.

Besides these, the engine consists of two other water cooling systems.

The Fresh Water Cooling System:

Copper pipes circulating Fresh water aound the The Radiator, cooling oil
engine. through Fresh water
circulation.

This system circulates fresh water, using copper pipes, to cool various parts of
the engine. Fresh water cooling system also cools the oil circulating around the
engine, using a Radiator, as shown above.

The Sea Water Cooling System:

Heat Exchanger
Sea Water Cooling pipes

This system consists of a heat exchanger and some pipes. The heat exchanger cools the
fresh water circulating the engine. Since sea water is available in plenty, there arises no
more problems of cooling this water. This system is also used to cool various parts of
the engine, though this use is seldom because sea water is very corroding and speed up
the process of rusting.

This system is particular to a Marine Diesel engine – since salt water is available
only in the sea. It is also highly efficient and elegantly designed such that it cools
the fresh water that is being circulated as well. In fact, it is mainly used for this
purpose.
Self –

Self of an Engine

This is the starter of the engine, much like the lever in a Honda. Since the engine used in
ships are huge, they cannot be started by a human. A mechanical device
using a battery is, therefore, connected to the flywheel to rotate it. This in turn
rotates the crankshaft and the engine starts running. This device is known as a self.
Once the engine starts, there is no need for the self as the generation of power keeps
the engine running. The self withdraws itself automatically.

Turbo –
 Turbo of an Engine

This additional part is an important part of the engine as it is used to increase the power or
the energy produced by an engine.

The principle behind this part is the First Law of Thermodynamics. A turbo increases the
pressure of the Intake air supplied to the inlet valves while keeping the volume
constant, thereby increasing the total internal energy of the system. This internal
energy is then converted into heat and Mechanical energy (By the
first Law of Thermodynamics – ΔU = Q – PΔV).
A turbo’s working is quite simple beautiful. It consists of two interconnected fans. One
fan stands in the path of the exhaust Manipole and the other one in path of the inlet
Manipole. The air released from the exhaust manipole passes the fan located in its path
and rotates it at a very high speed. This in turn rotates the other fan which sucks in a
large amount of air. This air is then transported to the piston
liner, which has a constant volume. Thus, it is at a relatively high pressure and has more
oxygen than the one that was directly supplied without the turbo.

In the compression stroke the already pressurized air is pressurized more and produces
more heat. Also it has more oxygen which helps in complete combustion of the diesel.
If at this point more diesel is supplied, the engine can combust that completely,
generating more power and speed.

Although this is beneficial for us as we can get more work out of hte Engine, we must keep
the strength of an engine in mind while using a turbo. As pointed out by the workers of
the Garage, if parts of the engine are not able to bear that additional pressure produced
by the turbo, it might break them, resulting in the breaking of an engine. Also, if the
engine is not able to supply the increased quantity of diesel (i.e.
it doesn’t have the capacity or the making to do it) than that ‘unwanted’ load might

also break the engine.

Turbo Side View

Turbo Insie View
III. DESIGN OF ENGINE COMPONENTS

A. Cylinder:

Cylinder of an hand cranked engine is the simple rectangular block with a blind hole
in it. The temperature within the hand cranked engine cylinder is very low and so no
fins are needed for heat transfer. This makes the cylinder easily manufacturable. Also
the cylinder is made of aluminium, a non-magnetic material which limits the
magnetic field within the boundaries of cylinder periphery. Usage of aluminium
material makes the engine lighter unlike the cast-iron cylinder used in internal
combustion engine.

Fig 1: Cylinder

B. Piston:
 The piston is the reciprocating part of an engine. The permanent magnet
attached in the piston and the electro magnet attached in the cylinder creates a
magnetic force which drives the crank shaft with the help of the connecting rod. At
the piston top, few grooves are cut to accommodate the piston rings and the bands left
between the grooves are known as lands.

Fig 2: Piston

C. Connecting rod:

In a reciprocating engine, the connecting rod is used to connect the piston to the
crankshaft. It converts the linear motion or reciprocating motion of the piston to
the circular motion of the crankshaft.

Fig 3: Connecting rod

D. Fly wheel:
The Flywheel is made up of mild steel, it is used to convert a reciprocating energy
into rotational energy. It regulates the engine’s rotation to makes its operation at a
steady speed. Flywheel have a significant moment of inertia and thus resist changes
it rotational speed. A amount of the energy stored in the flywheel is proportional to
square of its rotational speed. Energy is transferred to the flywheel by applying torque to
it. It is used to store rotational kinetic energy.

Fig 4: Fly wheel

E. Hand cranked coil:

Hand cranked coil is formed when an insulated solid copper wire is curled around
the core or form to create the inductor or electromagnet. When electricity is passed
through a coil, it generates the magnetic field. One loop of the wire are usually
referred to as a turn or winding, and a coil consists of one or
more turns. Coils are often coated with a varnish or wrapped with insulating tape to
provide additional insulation and secure them in place. Completed coil assembly with
one or more set of coils and taps is often called windings.
 V. DESIGN CALCULATIONS

(i) Input power = voltage x current

= V xA

(ii) Hand cranked force = (N2 x I2 x K x A)/ (2x G2)

N = the number of turns in the solenoid

I = the current, in amperes (A), running through the solenoid
A = the cross-sectional area, in meters-squared, of the solenoid magnet
G = the distance, in meters, between the magnet and the piece of metal.

K = 4 x 3.14 x 10-7 (a constant).

(iii) Torque = force x radius

(iv) Power = (2 x 3.14 x N x T)/60

 VI. CONCLUSION

The proposed hand cranked engine uses electric power to run which is cleaner and
cheaper than fossil fuels. In an internal combustion engine the problem of heating is
there but for the proposed engine there is no such problem.
The proposed model introduces hand cranked engine which uses a property of an
electromagnet. Whenever the direction of the current entering the windings is changed, it
changes the polarity of its poles. The proposed engine has been made in comparison with
a 70 cc conventional internal combustion engine.
In order to design an engine with a high power rating this idea can be extended in
various models of internal combustion engines such as boxer engine, multi-piston-
single-shaft engine. By the small modification in design the engine can be modified to
generate more power, thereby improving its efficiency. So that it can be used in
commercial vehicles.
REFERENCES

[1] K.S. Nesamani, "Estimation of Automobile Emissions and Control Strategies in

India," Institute of Transportation Studies. Science of Total Environment,
ScienceDirect, University of California, 2009
DOI:10.1016/j.scitotenv.2010.01.026
[2] Sherman S. Blalock, Electro-magnetic reciprocating engine; US 4317058 A
https://www.google.ch/patents/US4317058
[3] Leland W. Gifford; Reciprocating Hand cranked engine; US 5457349 A
http://www.google.com/patents/US5457349
[4] Radhakrishna Shesha Iyengar Togare; Magnetic Piston Engine; 2010: US
7667356 B2http://www.google.ch/peatents/US7667356
[5] Leland W. Gifford ‘Reciprocating hand cranked engine’.(june 30 1993)
[6] Houtman P. Siregar ‘Electra magnetic fuel sacer for enhancing the
performance of diesel engine’.(2007)
[7] Yamaha R15 v2.0 review by Mr. Kannan (march 4 2012).