Table of Content

Content Pages Pages

CHAPTER ONE----------------------------------------------------------------------------1
INTRODUCTION -------------------------------------------------------------------------1
1.1. Background of The Project --------------------------------------------------1
1.2. Statement of The Problem ----------------------------------------------------------2
1.3. Objective of The Project -----------------------------------------------------------------2
1.3.1 Main Objective --------------------------------------------------------------------2
1.3.2 Specific Objective ---------------------------------------------------------------2
1.4. Significance of The Project: -------------------------------------------------------3
1.5. Scope/Delimitations Of The Project: ---------------------------------------------3
1.6. Feasibility Project------------------------------------------------------------------ 3
1.6.1. Technical feasibility--------------------------------------------------------------3
1.6.2. Economic feasibility--------------------------------------------------------------3
1.6. 3. Operational feasibility ----------------------------------------------------------3
1.7. Organization of the Project--------------------------------------------------------4
1.8. Key Terms ----------------------------------------------------------------------------------4
CHAPTER TWO--------------------------------------------------------------------------------
LITERATURE REVIEW----------------------------------------------------------------------5
Introduction------------------------------------------------------------------------------5
2.1. Contact point type ignition system----------------------------------------------6
2.2.1 Principle of contact point type ignition system--------------------------------8
2.2.2 Component parts of contact point type ignition system-------------------------------8
CHAPTER THREE------------------------------------------------------------------------------------------12
3.1 Methods--------------------------------------------------------------------------------------------12
3.2. Materials -------------------------------------------------------------------------------14
CHAPTER FOUR: ----------------------------------------------------------------------------------------15
BUDGET AND WORK PLAN ------------------------------------------------------------------------15
4.1 Project Budget---------------------------------------------------------------------------------------15
4.2 Project Timetable---------------------------------------------------------------------------17
References---------------------------------------------------------------------------------------------18

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 CHAPTER ONE
INTRODUCTION
1.1. Background of The Project
In our country Ethiopia the Road transport plays a significant role to transport goods and
peoples from one place to another throughout the region, so to deliver good service to the
customers; the vehicles must be serviced and maintained periodically.
Basically there are two types of vehicles based on their ignition system, these are:
compression ignition (diesel) and spark ignition (gasoline). The contact point ignition
system supplies high voltage surges (some as high as 50,000 volts) to produce the spark
plugs in the engine cylinders. These surges produce electric sparks across the spark plug
gaps. The heat from the spark ignites the compressed air-fuel mixture in the combustion
chambers. When the engine is idling, the spark appears at the spark plug gap just as the
piston nears top dead center (TDC) on the compression stroke. When the engine is
operating at higher speeds, the spark is advanced. It is moved ahead and occurs earlier in
the compression stroke. [3]
Contact Point Ignition System Operation
With the engine running, the distributor shaft and distributor cam rotate. This action causes
the distributor cam to open and close the contact points. With the contact points wired to
the primary windings of the ignition coil, the contact points make and break the ignition
coil primary circuit. With the contact points closed, the magnetic field builds up in the coil.
As the points open, the magnetic field collapses and voltage is sent to the spark plugs.
With the distributor operating at one half of engine speed and with only one cam for each
engine cylinder, each spark plug only fires once during a complete revolution of the
distributor cam.
To ensure that the contact points are closed for a set time, point dwell, also known as cam
angle, is set by using a dwell meter. Point dwell is the amount of time given in degrees of
distributor rotation that the points remain closed between each opening.
A dwell period is required to assure that the coil has enough time to build up a
strong magnetic field. If the point dwell is too small, the current will have insufficient time
to pass through the primary windings of the ignition coil, resulting in a weak spark.

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 However, if the point dwell is too great, the contact points will not open far enough,
resulting in arcing or burning of the points.[2]

1.2. Statement of The Problem

As we know constructing & installing automotive ignition systemtraining models has a
great role to deliver cleare instruction and maintenance procedure . But still there is a
problem of enough ignition system models especially in automotive sectors in Kombolcha
poly technic college there is shortage of functional ignition system model to provide good
training about ignition system operation and componenets brifely. In addition to that,
local garages did not use models to test the functionality of components rather than they
use constructing & installing ignition system models,it leads to drawback of activity . The
drawback of these activity are:-
 High consumption of time
 Make confussion among trainee’s
 Create misunderstanding
Based on the above resons producing the ignition system model is more efective in
teaching learning process and testing components properly.
1.3. Objective of The Project
The proposed project has many objectives that we need to accomplish after preparing the
required model and transferred to micro, small and medium enterprises. The general and
specific objective of the project is as follow:
1.3.1 Main Objective
The general objective of thisproposed project is to construct and install automotive ignition
system training model.
1.3.2 Specific Objective
 To reduce imported models.
 To check the continuity of ignition system components.
 To clean and inspect ignition system components.
 To implement practically.
 To observe ignition system model components functionality.
 To test the performance output of ignition system practically.

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1.4. Significance of The Project:
The main significance of this project is beneficial to the institutes, trainee’s, instructors,
short term trainee’s, micro & small enterprise and local community to deliver good training
by providing better information and suitable training condition. This proposed project
shows the whole operation of the ignition system that will help institutes, Trainee’s,
instructors, short term trainings, micro & small enterprise and local community on
analyzing and improving their skill and knowledge. The proposed project has value like
minimizing the work time by enhancing the skill of the technicians. The proposed project
will implement on our satellite institute automotive department and model garage of KPC.

1.5. Scope/Delimitations of The Project:

The project is fully focused on constructing and installing ignition system model. The
scope of the project mainly addresses kombolcha poly technique college satellite campus
automotive work shop and automotive garages.

1.6. Feasibility Project

1.6.1.Technical feasibility
This project does not require additional training and high technical skills during
constructing, installing, testing, inspecting and assembling ignition system components.

1.6.2. Economic feasibility

When we see the economic aspect the proposed project has less cost compared with other
types of ignition system models. Once it is prepared, it is easy to maintain, which
minimizes maintenance costs. To produce the model, materials can purchase from local
market and we have an opportunity to use a lot of consumable materials from our
institution. It does not require high labor cost means it is performed by the technicians at
the institute. Furthermore, the institute can sale many models for other institutions which
means the project can improve the income of institute.
1.6. 3. Operational feasibility

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 The ignition system model can even operate by trainees. It is not complicated model.
Therefore; each trainee can operate this model and see its function and operation. The
components can easily remove from the model if they are not functional.

1.7. Organization of the Project

The proposed project is organized in four chapters.
The first chapter mainly focused on the background of the project, statement of the
problem, general and specific objectives, scope, feasibility study and significance of the
project. This chapter also contains key terms.
The second chapter deals about the literature review of the project.
The third chapter contains the methods how the project is done.
The fourth chapter covers project budget and work plan activity.

1.8. Key Terms

Institution: it refers all technical and vocational institution, colleges, and automotive
service provide garages.
Methodology: refers the method how the proposed project will perform.

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 CHAPTER TWO
2. LITERATURE REVIEW
Introduction
The ignition system's function is to initiate combustion in the flammable air-fuel mixture
by igniting it at precisely the right moment. In the spark-ignition (Otto) engine, this is
achieved with an electrical spark, i.e. an arc discharge between the spark plug's electrodes.
Consistently reliable ignition under all circumstances is essential for ensuring fault-free
catalytic-converter operation. Misfiring results in damage to or destruction of the catalytic
converter due to overheating during afterburning of the uncommuted mixture.
Ignition system is to generate a very high voltage from the car's 12volt battery and to send
this to each sparkplug in turn, igniting the fuel-air mixture in the engine's combustion
chambers.
The combination of the entire device required to produce an electrical spark of desired
intensity and at proper moment is called spark ignition system the spark must occur toward
the end of compression stroke automotive engines usually cranked by a small electric
motor, which is better known as a starter motor, or simply a starter.
The starter motor for SI and CI engines operates on the same principal as a direct electric
motor.
In spark ignition engines, the compressed air fuel mixture in the combustion chamber is
ignited by the sparks produced by the ignition system. [4].

Purpose of ignition system

The purpose of the ignition system is to produce the high voltage surges required to ignite
the compressed air fuel mixture in the engine combustion chamber at the proper instant
under all speed and load conditions. The ignition system is supplied a 12 volt or less battery
voltage or charging system voltage and increases to 10,000 to 30,000 volts required to
create a spark across the spark plug electrodes in the combustion chamber.
The purpose of ignition system is to create a spark that will ignite the fuel-air mixture in the
cylinders of an engine. It must do that at exactly the right instant and do it at the rate of up
to several time per minute for each cylinder of the engine. If the timing of the spark is off
by small fractions of a second, the engine will run poorly or not run at all.[4 ]

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 Requirements of ignition system
a. A strong spark
The voltage that is supplied to the plugs must be high enough to ensure the generation of
the powerful spark across the spark plug gaps. This is because the compressed air fuel
mixture has electrical resistance.
Adequate voltage must be present before a spark will arc from one electrode to another. At
the moment of ignition, the voltage across the electrodes abruptly rises from zero up to the
arcing (ignition) voltage and the plug fires. Once the spark has ignited the sparkplug
voltage drops to the sparking voltage. The air fuel mixture may ignite at any point during
the firing period of the ignition spark (spark duration). Once the spark has broken away, the
voltage is damped and drops to zero.
Although intense mixture turbulence is basically desirable, it can extinguish the spark, thus
leading to incomplete combustion. The energy stored in the ignition coil should therefore
suffice for one or more consecutive sparks, depending on individual requirements.
B. Proper ignition timing
To obtain optimal combustion of the air fuel mixture, there must be means of varying
ignition timing in accordance with the engine RPM and load

C. Sufficient durability
The ignition must have sufficient reliability to endure the vibration and heat of combustion
and high voltage of the ignition system itself. [4 ].
Types of ignition system
 Contact point ignition system
 Electronic ignition system
 Distributor less ignition system
2.1. Contact point type ignition system
Provided the composition of the mixture is stoichiometric, energy of approximately 0.2 mJ
is required for each individual ignition of the air-fuel mixture via electric spark. Over 3 mJ
are required for a rich or lean mixture. This energy represents only a fraction of the total

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energy in the ignition spark, the actual ignition energy. If sufficient ignition energy is not
available, there will be no ignition, the mixture cannot ignite, and misfiring will result.
The system must therefore deliver enough ignition energy to ensure consistently reliable
ignition of the mixture, even under unfavorable conditions. Igniting a small flammable
mixture cloud flowing past the spark can be enough to initiate the process. This mixture
cloud ignites, the flame spreads to the remaining mixture in the cylinder, and the fuel starts
to combust. Ignitability is enhanced by efficient fuel atomization and good access of the
mixture to the electrodes, as well as through extended spark duration and spark length
(large electrode gap).
The spark plug determines the location and length of the spark; spark duration depends
upon the type and design of the ignition system, as well as on the momentary ignition
conditions.
The contact point ignition system included the battery the ignition coil, the ignition
distributor, the spark plugs and the wires and cables that connect them. The distributor
shaft is driven by a gear on the camshaft and it has cam lobes equal in number with the
number of cylinders of the engine. As the distributor cam rotates it opens and closes the
contact points. When the contact points are closed the primary circuit is completed and
current flows through the coil causing magnetic field collapses creating a short pulse of
high voltage in the secondary coil the high voltage flows through the distributor cap and
rotor to the spark plug in the cylinders that is ready to fire. [2 ].

Figure 2. 1: contact-point type ignition system and model

The ignition system basically has two components, they are

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 i) The low-tension or primary circuit, which includes the battery, ignition/ starter
switch, ballast resistor, the primary winding, the contact brakes (CB) points and
the capacitor.
ii) The high-tension or secondary circuits, which includes the secondary winding, the
rotor (distributor), high-tension cables and spark plugs.
2.2.1 Principle of contact point type ignition system
Mutual inductance
Two coils have mutual inductance (M) of one Henry when a current change of one ampere
per second in one coil induces one volt in the other coil. The effect or a coil to induce on
the nearby coil is affected by the coefficient of coupling (k) the fraction of total flux from
one coil linking another coil is the coefficient of coupling. For example if all the flux of L1
links L2 then K equals unity or one if half the flux links the other K = 0.5.
The coefficient of coupling is increased by placing the coils closer together, possibly with
one would on top of the other, by placing them parallel to each other and by winding them
on a common iron core.
A high value of K, called tight coupling allows the current in one coil to induce more
voltage in the other loose coupling have the opposite effect. In the extreme effect zero
coupling there is no mutual inductance. When it is desired to minimize interactions
between coils inductor
The ignition coil generates a high voltage current by means of mutual induction that takes
place between the primary coil and the secondary coil when the primary current is suddenly
cut off by the opening of the breaker points. [3 ].
The ignition system basically has two components:-
 The low-tension or primary circuit, which includes the battery, ignition/ starter
switch, ballast resistor, the primary winding, the contact brakes (CB) points and the
capacitor.
 The high-tension or secondary circuits, which includes the secondary winding, the
rotor (distributor), high-tension cables and spark plugs.
2.2.2 Component parts of contact point type ignition system
Battery

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The battery is the heart of the electrical system of an automobile. An automotive battery is
an electrochemical secondary cell capable of producing electric energy. When discharging
(current flowing from the battery), the battery changes chemical energy into electrical
energy. It supplies current to the primary circuit of the ignition system. [1 ].

Figure 2. 2: automotive battery

Ignition switch
The ignition switch is one of the most important electronic components that is commonly
found on many road going cars and trucks. It is usually located on the steering column, just
behind the ignition lock cylinder. Ignition switch is a switch in the control system of motor
vehicle that activates the main electrical system for the vehicle, including “accessories’’.
[1].

Figure 2. 3: ignition switch

Ignition coil
The ignition coil functions as both an energy-storage device and a transformer. The coil,
which is powered by DC voltage from the vehicle's electrical system, supplies the ignition
pulses for the spark plugs at the required high voltage and discharge energy. The ignition
driver stage with its defined deactivation current combines with a primary winding
featuring specific resistance and inductance characteristics to determine the amount of
energy stored within the ignition coil's magnetic field.

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The secondary winding can be designed to provide peak voltage, spark current and
discharge duration in accordance with individual requirements.It is used to produce high
voltage surges by the principle of induction in the secondary winding. Ignition coils can be
with resistors or without resistors. [4 ].

Figure 2. 4: ignition coil

Distributor
The distributor shaft is driven by a gear on the camshaft and it has cam lobes equal in
number with the number of cylinders of the engine. The ignition distributor performs two
functions in the ignition system. First, its breaker or contact points are as a switch to open
and close the primary ignition circuit. When the points are opened, current through the coil
builds up magnetic field. When the points are opened, the magnetic field is collapsed
creating a high voltage current. Secondly, it distributes the high voltage current to the
proper cylinder at the proper time. Lobes on the cam moves against the rubbing block.
Thus pushes the movable arm so that the contact points are opened. As soon as the cam
passes out from the rubbing block, the spring pushes the movable arm in and the points are
closed again. The rotor and distributor cap form a rotary switch to distribute the high
voltage surges induced in the secondary winding of the ignition coil. Since the rotor sits on
top of the distributor shaft as the shaft rotates, the blade of the cap moves past the terminals
which are arranged in a circle around. [5 ].

Figure 2. 5: distributor

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Spark plug
It ignites the air-fuel mixture inside the engine cylinder.The spark plug provides a spark
gap inside the engine cylinder. When the engine is operating the high voltage current
produced by the ignition coil arcs across the gap and creates spark that ignites the air fuel
mixture in the cylinder. The sparking performance of the spark plug depends on: the
electrode shape, the electrode gap, the compression pressure, and the electrode temperature.
[3].

Figure 2. 6: spark plug

High tension cable
They are heavily insulated wires. They carry high voltage from the distributor cap to the
plugs and from the ignition coil tower to distributor cap center tower. They are either
carbon-impregnated linen, or graphite saturated Fiberglas core. The advantage is there is
large resistance/foot of wire which reduces radio interference without affecting output of
the engine. [2 ].

Figure 2. 7: high tension cable

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 CHAPTER THREE
3. METHODOLOGY/METHOD AND MATERIAL
3.1 Methods
The Methodology is very important because it tells your Project Committee/advisor how
you plan to tackle your project problem. It will provide your work plan and describe the
activities necessary for the completion of your project.

Get project title

Meet
t 1.Constructing and installing Automotive ignition system
training model
2.Dead engine servicing
3.Automotive vehicle lubrication & cooling system alarm
Problem identification

1. Constructing and installing automotive ignition system

training model

Selection of raw material

Make proposal No

Design the drawing

Prepare theoretical Spark
aspect battery distributor Ignition coil
plug

Yes

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 Prepare working area

Ready to create model Get components of ignition

NO
stand system
NO

Cut Weld
Drill
Measure File Inspect functionality

Making model stand Put in proper area

YES
YES

Paint

NO

Assembling

Inspect/test

YES Finishing

Figure 3.1 flow process for method

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3.2. Materials
The material selection for this ignition system model constructing component is based on its
characteristics and which material applied in the particular ignition system components.
Basically we considered the following major things:
1. Functionality of the material
2. Easy installing property
3. Economical aspect
4. Durability
5. Maintenance

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 CHAPTER FOUR:
BUDGET AND WORK PLAN
4.1 Project Budget
The budget for this project estimated as follow
Table 4.1 List of raw materials
S.no Item Type Specification Unit of Qnty Unit price Total price
measure birr cents birr cents
1 Battery GS 12V, 70Ah pcs 01 5000 00 5000 00
2 Spark plug Toyota any model pcs 4 500 00 2000 00
3 distributor Toyota any model pcs 01 4000 00 4000 00
4 Ignition switch Four terminal pcs 01 500 00 500 00
5 Fuse 5,10,15 & 20 amps pcs 10 each 100 00 400 00
6 Fuse box 12V Pcs 01 50 00 50 00
7 Female connector set pcs 01 200 00 200 00
8 Male connector set pcs 01 200 00 200 00
9 Ignition coil 12V Psc 01 1000 00 1000 00
10 Battery cable Red color pcs 01 200 00 200 00
11 Battery cable Black color pcs 01 200 00 200 00
12 MDF 1.8 mm standard 01 3000 00 3000 00
13 Angle Iron 25mm* 6m*1mm pcs 02 600 00 1200 00
14 Automotive wire 1.5 mm standard roll 01 1500 00 1500 00
15 Caster wheel Medium size pcs 04 100 00 400 00
16 pulley pcs 01 200 00 200 00
Total price 20050

Table 4.2. Consumable material

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S.no Item Type Specification Unit of Qnty Unit price Total price
measure birr cents birr cents
1 Antirust can 01 200 00 200 00
2 Paint Sliver can 01 300 00 300 00
3 brush 12 inch pcs 02 150 00 300 00
4 Thinner abro liter 04 250 00 1000 00
5 electrode 2.5*300mm packet 01 500 00 500 00
Total price 2300

Cost analysis:
Material cost = raw material cost + consumable material cost
Material cost = 20050 birr + 2300 birr = 22350 birr
Contingency cost = Material cost *10%
Contingency cost = 22350 birr *10% = 2235 birr
Total cost = material cost + Contingency cost 10%
Total project cost = 22350 birr + 2235 birr = 24585 birr

4.2 Project Timetable

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 Table 4.3. Work plan (Project Timetable)

N Activity MONTH
O APRIL MAY JUNE

WEEK 2

Week 3

Week4

Week1

Week2

Week3

Week4

Week1

Week2

Week3

Week4
1 Group making
2 Problem identification
3 Select Project topic
4 Submit Project
5 Preparing Project proposal
6 Receiving comment
7 Material selection
8 Submit Project proposal
9 Presentation Project proposal
10 Paper work
11 Constructing model bench
12 Assemble the frame with stand
13 Constructing & installing
ignition system component
14 Test the performance of ignition
system model
15 Submit Project work
16 Presentation the Project work

References
1. Automotive technology system approach 5th edition. Jack Erjavec..
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2. Automotive Electricity and Electronics 6th edition Classroom Manual.
3. Automobile Electrical and Electronic system 4th edition Tom Denton.
4. Fundamentals of Automotive Electronics 2th edition Hilliers.
5. Billiset, walter E and goings leslie F, 1952 Automotive electrical 3rdedition

APPROVAL SHEET

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Submitted By

_____________________________ ___________ _____/_______/_______

_____________________________ ___________ _____/_______/_______

_____________________________ ___________ _____/_______/_______

_____________________________ ___________ _____/_______/_______

_____________________________ ___________ _____/______/_______

Student Signature Date

Approved By

1._____________________________ ___________ _____/_______/_______

Advisor Signature Date

2. _____________________________ ___________ _____/_______/_______

Head of the Department Signature Date

3. _____________________________ ___________ _____/_______/_______

Division Head Signature Date

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