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AUTO POWER PLANT

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MODULE -1
1. Basic engine terminology- TDC, BDC, Bore, Stroke, Swept volume,
clearance volume, total volume, compression ratio.
2. Working principle of 2-stroke and 4-stroke SI and CI engines.
3. Comparison of SI and CI engine.
4. Differentiate 2-stroke and 4-stroke engines.
5. Classification of engine according to valve arrangement- I-
Head, L-Head, T- Head and F- Head engines.
6. List out the components in the valve operating mechanism.
7. Valve timing diagram.
8. Manifolds.

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COMPONENTS OF AN AUTOMOBILE

The basic structure: It consists of the frame , the suspension system, axles
wheel and tyres.
1. The engine: It provides the motive power.
2. The transmission system: It consists of clutch, gear box , propeller
shaft, differential gear.
3. The auxiliaries: The electrical systems.
4. The controls: They consist of steering system and Brakes.
5. The superstructure: The body.

Engine systems
 Cooling system

 Fuel system

 Exhaust system

 Lubrication system

 Ignition system

 Electrical system

BASIC ENGINE TERMINOLOGY

A number of basic terms are used to describe and compare engines. A

few commonly used terms explained here.
 Top dead centre ( TDC )
 Bottom dead centre (BDC)
 Bore
 Stroke
 Clearance volume
 Piston displacement
 Engine capacity
 Compression ratio
 Mean effective pressure
 Power
 Indicated power (IP)
 Brake power (BP)
 Engine torque

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Top Dead Centre (TDC): Position of Piston where Cylinder Volume is

minimum.

OR

Position of crankshaft when the piston is in topmost position.

Bottom Dead Centre (BDC): Position of

Piston where Cylinder Volume is maximum.
OR

Position of crankshaft when the piston in

lowest position.

Bore: Diameter of engine cylinder.

Stroke: Distance travelled by the piston in

moving from TDC to BDC.

Clearance volume: The volume of cylinder (including the combustion

chamber) above the piston when it is in the TDC position.

Piston displacement (swept volume): Volume swept by piston in moving

TDC to BDC.

VS =π/4 *d2*S

d= bore diameter

S= Stroke length

Compression ratio (r): This indicates the extent to which the charge in the
engine is compressed. It is calculated as the ratio of volume above the
piston at BDC to the volume above the piston at TDC.

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Indicated power (IP): The power developed within the engine cylinder.

Brake power (BP): The actual power delivered at the crankshaft.

ENGINE COMPONENTS
1. CYLINDER BLOCK

•Basic frame work of engine.

•It houses the engine cylinders, which serve as bearing and guide for piston.

•Crank case attached to the lower end of block.

•Crank case filled with oil.

•Previously crankcase was cast separately and attached to the block, but now integral
or monoblock construction.

•Cylinder heads are attached to the top of cylinder block

•Aluminium alloys – Cylinder block material.

•Density of aluminium alloy is one third of cast iron.

•Aluminium has a higher thermal conductivity than cast iron.(fast cooling)

•Saving weight in case of Al alloy is 50% compared with cast iron.

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2. CYLINDER HEAD
 It is attached to the top surface of cylinder block.

 Gaskets are used to provide tight leak proof joint at the interface.

 Cylinder head forms combustion chamber above each cylinder.

 The material used for cylinder heads are cast iron and aluminium alloy

 On the focus of weight reduction and maintain uniform temperature Al alloys are
commonly used.

3. PISTON
 Most pistons are forged or cast from an aluminium alloy for light weight
and strength.
 Connecting rods link the pistons to the crankshaft.
 A connecting rod is attached to its piston by a pin.
 The part of the piston below the pin hole is known as the skirt.
 Two compression ring and one oil ring groove are provided.

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4. Piston Rings

 Compression rings are generally made from cast iron and prevent
“Blow-by” (pressure leakage into the crankcase).
 There are generally two compression rings, both acting as gas seals.
Designs may vary from engine to engine.
 The lower ring is an oil ring which is used to wipe oil from the cylinder
wall, limiting oil seepage to the combustion chamber.
 There is a gap in the compression rings to allow for expansion.

5. Connecting Rod

 The connecting rod is typically made of ductile steel to withstand the

high loads, and incorporates bearing shells and may have a bush for the
gudgeon pin.
 The big end is connected to the crankshaft and normally has bearing
inserts called bearing shells.
 The small end may have a bronze bush for the gudgeon pin in full-
floating operation.

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FLYWHEEL

A rotating mechanical device used for store rotational energy.

Or

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In other words it can be defined as the , it store energy during power

stroke and delivers during the idle stroke.

Flywheel is used to maintain the constant angular velocity of the

crankshaft.

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WORKING OF IC ENGINE

Basically there are 2 types of internal combustion engines.

 Two stroke engine

 Four stroke engine

1. Four stroke engine (SI ENGINE)

The cycle of events that take place in a 4-stroke petrol engine as
shown in fig. The four stages are listed as,
1. Suction (Intake)
2. Compression
3. Power
4. Exhaust

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SUCTION STROKE

 Suction stroke when the piston is at top dead centre and about to
move downwards.
 The inlet valve opens at this time and the exhaust valve is closed.
 Due to the suction created by the motion of the piston towards the
BDC, the charge consisting of fuel air mixture is drawn into the
cylinder.
 When the piston reaches the bottom dead centre the suction stroke
ends and the inlet valve closes.

COMPRESSION STROKE

 The charge taken into the cylinder during the suction stroke is
compressed by the return stroke of the piston.
 During this stroke both inlet and exhaust valves are in closed position.
 The mixture which fills the entire cylinder volume is now compressed
into the clearance volume.
 At the end of the compression stroke the charge is ignited with the
help of a spark plug located at the cylinder head.
 During the burning process the chemical energy of the fuel is
converted into heat energy.
 Pressure at the end of the combustion process is considerably
increased due to heat from the fuel.

EXPANSION OR POWER STROKE

 The high pressure of the burned gases forces the piston towards the
BDC, both the valves are in closed position.
 Power produced only in this stroke.
 Both pressure and temperature decreases during expansion.

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EXHAUST STROKE

 At the end of the expansion stroke the exhaust valve opens and the
inlet valve remains closed.
 The piston starts moving from the BDC to TDC and sweeps the
burned gases out from the cylinder.
 The exhaust valve closes when the piston reaches TDC.

CI ENGINE (compression ignition)

The diesel engine gains its energy by burning fuel injected or sprayed
into the compressed, hot air charge within the cylinder. The air must
be heated to a temperature greater than the temperature at which
the injected fuel can ignite.

It is similar to four stroke petrol engine but operates at a much higher

compression ratio, the compression ratio of an SI engine is between 6
and 10:1, while for a CI engine it is from 16 to 20:1.

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Expansion or power stroke

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TWO STROKE ENGINE

The air fuel mixture from the carburettor enters the cranks case through the inlet port
during the upward movement of the piston .At the same time the mixture in the
cylinder is compressed, which is ignited when the piston is just at TDC.The
compression takes place and the piston moves imparting motion to the crankshaft.

During the downward movement of the piston the mixture in the crankshaft is
compressed and pushed into the cylinder through the transfer port, which pushes out
the exhaust gas through the exhaust port, at the same time filling the cylinder with a
new charge. This process is called cross -flow scavenging. Thus the whole cycle is
completed in two strokes, one revolution of the crankshaft.

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COMPARISON BETWEEN FOUR STROKE AND TWO STROKE ENGINE

FOUR STROKE TWO STROKE

The cycle is completed in four stroke of The cycle is completed two stroke of the
the piston. piston.

It has one power stroke in two revolution It has one power stroke in one revolution
of the crankshaft. of the crankshaft.

Heavier flywheel is needed. Lighter flywheel is required.

For the same power heavier engine For the same power lighter engine is
required required.

Lesser requirement of cooling and Greater cooling and lubrication are

lubrication. required.

It consists of valve and valve mechanisms It contains parts so cheaper in cost.

so higher cost.

More volumetric and thermal efficiency. Less volumetric and thermal efficiency.

Used in high efficiency motor cycles, cars, Used in lawn mower, scooters, motor
buses, trucks….. cycles

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ENGINE VALVE
To admit the air fuel mixture in the engine cylinder and to force the exhaust gases out
at correct timing.

Engine valves are divided into 3 main categories,

 Poppet valve

 Sleeve valve

 Rotary valve

Poppet valve is the one which is being universally used for automobile engines.

POPPET VALVE

 Poppet valve derives its name from its motion of popping up and down.

 This is also called Mushroom valve.

 It consists of a head and a stem.

 Inlet valves are larger than exhaust valves - because speed of incoming air – fuel
mixture is less than the velocity of exhaust gases which leave under pressure.

 Usually made of Austenitic Stainless Steel which is a corrosion &heat resisting

material.

 Race engines use Beryllium-Copper alloy seats with Titanium valves (21-4N) –
40% lighter than Steel.

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VALVE ACTUATING MECHANISMS

In the entire valve actuating mechanisms, a cam driven at half the crankshaft speed is
used to operate each valve.

Mainly divided into two,

 Mechanism with side camshaft

 Mechanism with overhead cam shaft

VALVE TRAIN COMPONENT

1. Camshaft
2. Camshaft drive
3. Valve tappet (valve lifter or cam follower)
4. Push rod
5. Rocker arm

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2. Camshaft drive
One four stroke cycle is completed in two revolution of the crankshaft.
Therefore each cam must open and close its respective inlet or exhaust valve
once every two revolutions of the crankshaft. That is why the camshaft is made
to rotate at half the crankshaft speed. The drive from crankshaft to camshaft
may be either chain drive or gear drive. Camshaft gear is twice as large as the
crankshaft gear.
3. Valve tappet
The valve tappet / cam follower follows the shape of the cam lobe on the
camshaft. Thus it provides a method of converting the angular movement of the
cam into a reciprocating motion in the valve train. Fixed type and adjustable
type valve tappet are available. This is placed between the push rod and cam.
Some clearance must be providing between the cam and tappet, to allow
expansion due to heat. This valve train clearance is called valve lash.
4. Push rod
 It serves to transmit the reciprocating motion of the valve lifter
to the rocker arm.
 Push rods are made of carbon-manganese steel.
 It may be either solid or hollow.
 A hollow push rod is lighter, resulting in decrease of inertia
forces.
 Hollow push rod serves as the passage for oil lubrication of the
valve actuating mechanism.
5. Rocker arm
The function of rocker arm is to reverse the upward motion of the
push rod to the downward motion of the valve and vice versa. It may
be either solid or hollow.

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ENGINE CLASSIFICATIONS
The internal combustion engine for the automotive use may be classified
according to the following considerations:

6. Engine cycles
7. Number of strokes
8. Fuel used
9. Type of ignition
10. Number and arrangement of cylinders
11. Valve arrangement
12. Type of cooling

Engine cycle

1. Otto cycle (for petrol engine)

2. Diesel cycle

Number of stroke
1. Two stroke

2. Four stroke

Fuel used
1.Petrol engine

2. Diesel engine

3.Gas engine

Type of ignition
1.Spark ignition 2. Compression ignition

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NUMBER AND ARRANGEMENT OF ENGINE CYLINDERS

1. Single cylinder engine

2. Multi cylinder engine

(a) In-line vertical (b) V – type (c) Opposed type

Single cylinder engine

A single cylinder engine has a power stroke every 720 0 of crankshaft
rotation for a 4 stroke engine. These are used generally for scooters and
motor cycles. Maximum size of single cylinder engine is restricted to 500-
600 cc.

Multi cylinder engine

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The multi cylinder engine further classified as two, three, four ,….. cylinder
engines. The inline engine in which the cylinders are placed side by side
vertically.

V- type engine in which two cylinders are placed with their centre lines at
some angle to each other. Generally this angle kept at 60 0 . Multi-cylinder
V-type engines are also available.

In opposed type engine two cylinders are arranged horizontally opposite

to each other as shown in fig.

Classification of engine according to valve arrangement

(I-Head, L-Head, T- Head and F- Head engines)

1. MECHANISM WITH SIDE CAMSHAFT

T-Head engine

• Oldest type of valve actuating mechanism.

• In this design inlet and exhaust valves are operated by separate camshaft,
which makes the mechanism complicated.
• The shape of the combustion chamber provide poor combustion and low
engine performance.

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L-Head engine

• In this the inlet and exhaust valves are arranged in a single row and
operated from the same camshaft.
• This mechanism was once quite popular on account of the following
advantage,
1. Low engine height
2. Low production cost
3. Ease of lubrication
This method is no more in use because of complicated combustion chamber
shape, difficulties in exhaust valve cooling.

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T-Head engine

• This is a combination of two system

• Overhead valve mechanism used for the inlet
valve operation.
• Side valve mechanism for the exhaust valve.

I-Head engine

• The cam operates the valve lifter which in turn actuates the valve.
Advantage:
1. Higher volumetric efficiency than the side valve design.
2. Higher compression ratios can be used.
3. Leaner air- fuel mixtures can be used.
4. Use smaller cam lobes compared to the side valve mechanism.
Disadvantage:
1. Noisy operation
2. Greater maintenance required due to more wear at more joints.
3. Larger valve lifter clearance is required.

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MECHANISMS WITH OVERHEAD CAMSHAFT

• Overhead single or double camshafts are highly efficient.

• Distance between the cam and valves are much shorter due to
which the valve response is quicker and valve adjustment can be
more accurate.
• Higher initial cost > Disadvantage

SOHC - SINGLE OVERHEAD CAM

DOHC - DOUBLE OVERHEAD CAM

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VALVE TIMING DIAGRAM

Theoretically the inlet valve should open at TDC and close at BDC. Similarly the
exhaust valve should open instantaneously at BDC and should remain open till
piston reaches TDC, where it must close. But in practice due to the inertia the
valves cannot open instantaneously and also the air fuel mixture has its own
inertia; more time taken for the intake and exhaust process to complete.

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The inlet valve is generally opened about 150 before TDC (called valve lead)
and closed after about 300 of BDC (called valve lag). Similarly the exhaust
valve is opened before about 500 of BDC and closed after 200 of TDC. The
condition when both the inlet and exhaust valves are open simultaneously
during so many degrees of crankshaft rotation is called valve overlap. The
diagram showing opening and closing of valves is known as valve timing
diagram.

MANIFOLDS
Manifolds are separate sets of pipes connected to the cylinder head which
provide the air-fuel mixture and the exhaust gases, these are known
as manifolds. It is usually made of cast iron so that it is capable to resist the
high temperature of the exhaust gases. Various manifold passages are also
called runners.

Following are the two types of manifolds used in vehicles:

1. Intake Manifold

2. Exhaust Manifold

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 Intake Manifold
The intake manifold is a cast iron or aluminium tube for carrying the air-fuel
mixture from the carburettor to the engine intake port.

Double flange

 The shape and size of inlet manifold must be such as to prohibit the formation
of the fuel droplets without restricting the air flow.
 The manifold must be large enough to allow sufficient flow for maximum
power.
 The rough interior surfaces of the manifold will increase the resistance of the
mixture flow.
 Sharp bends in the inlet manifold tend to increase the fuel separation.

EXHAUST MANIFOLD
• The exhaust manifold is the set of pipes carrying exhaust gases from the
cylinder head to the exhaust system.
• Made of cast iron to withstand heat from exhaust gas.
• Smoother flow of exhaust gases is provided by the two in one manifold
compared with simple one.

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• The exhaust manifolds are designed to minimise the restriction to the flow
of exhaust gas.
• Sometimes the cast-rib deflectors or dividers are employed inside the
manifold so that exhaust gases are guided smoothly towards the outlet.

COMPARISON BETWEEN SI AND CI ENGINES

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COMPARISON BETWEEN SI AND CI ENGINES

(MERITS AND DEMERITS)

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