2.

Testing of IC engine
and emission control

16 marks

BY – SAM SIR MO. – 7774987792 EMAIL – SHAKIRWORK7@GMAIL.COM INSTA – SHAKIR._43

catalytic converter
With the passage of the United States Clean Air
Act in 1970, auto manufacturers were faced with
the task of substantially reducing emissions.

The main purpose of the use of catalytic

converters in exhaust emission control system
is to convert harmful pollutants to harmless
gases.

NOx, HC and CO present in exhaust gases, all

these are treated in catalytic converters
producing (compound) gases CO2, H2 and N2
which can be safely released in the
atmosphere.
A catalytic converter consist of a cylindrical unit of
small size like a small silencer and is installed into
the exhaust system of a vehicle such as scooter,
motor cycle, car or auto-rickshaw.

It is placed between the exhaust manifold

and the silencer.

Inside the cylindrical tube (converter) there is a

honey comb structure of a ceramic or metal which
will be coated with alumina base material. This
coating is porous and increases the surface area,
allowing more reactions to take place and thereafter
a second coating of precious metals platinum,
palladium or rhodium or combination of the same.
This second coating serves as a catalyst.
TWO-WAY CATALYTIC CONVERTERS
•Allows oxidation ( the addition of oxygen to the substance or the removal of hydrogen
from the substance) of CO (carbon monoxide) to less-harmful CO2 (carbon dioxide)
•Allows oxidation of HC (unburned hydrocarbons) to CO2 (carbon dioxide) and H2O
(water)

In this design, exhaust gases are directed to flow through the substrate, containing
precious metals platinum and palladium, which allow the chemical reaction to occur. The
exhaust gases increase in temperature as the conversion process takes place.

Because of the intense heat created by this process, exhaust gases leaving the converter
should be hotter than the gases entering the converter. This also explains why heat
shields are required on most units.

Two-way converters operate relatively efficiently with a lean fuel mixture. Ineffectiveness
in controlling NOx (nitrogen oxides) led to the introduction of three-way converters.
THREE-WAY PLUS AIR CATALYTIC CONVERTERS

•Allows reduction of NOx (nitrogen oxides) to N2 (nitrogen) and O2 (oxygen)

•Allows oxidation of CO (carbon monoxide) to less-harmful CO2 (carbon dioxide)
•Allows oxidation of HC (unburned hydrocarbons) to CO2 (carbon dioxide) and H2O (water)

•Inside this converter there are two substrates. The front, coated with the precious metal rhodium, is used
to reduce NOx emissions into simple N2 and O2. This process is most effective when little O2 is present
(rich mixture).

Since a rich mixture is high in HC and CO, an air pump and tube supply additional O2 to this mixture before
it enters the second substrate.

The second substrate, coated with the precious metals palladium and platinum, allows oxidation of HC and
CO to less harmful emissions CO2 and H2O.

This system was not very efficient and was phased out in the early '80s, when the current three-way
converter was introduced.
ECU - Electronic control unit
Electronic control module or unit is a generic term for any embedded system that controls one or more of the
electrical systems or subsystems in an automobile.

This unit is located close to the area engine area or it can be found under the vehicle's dashboard right behind the
glove compartment. However, the location of the engine control unit in different vehicles can greatly vary depending
on the design of the vehicle.

The engine control unit or ECU of vehicle is the main component of engine system that enables the use of all the
other devices. It is also known as the power train control module, and it usually installed under the dashboard of
vehicle.

It receives electrical signal in the form of voltage or current from various sensor.

These signals are then stored and operate as a controller applying multidimensional performance for a number of
sensors and the actuators that are installed on the engine of vehicle such as the injector, ignition system and other
engine related devices.
Need of ECU

The need for sophisticated engine controls to meet emissions and fuel-
economy standards

o Advanced diagnostics

o Simplification of the manufacture and design of cars

o Reduction of the amount of wiring in cars

o New safety features

o New comfort and convenience features

o Increase the performance

❖ It is an electronic device which has base numbers and parameters filled in its
memory.

❖ With multiple sensors around a vehicle feeding the ECU data it can manage and
control the electronic systems efficiently by giving orders to improve their
output.

❖ Each ECU typically contains a dedicated chip that runs its own software and
requires power and data connections to operate.
Key elements of an ECU
Core Outputs

✓ Microcontroller ✓ • Relay drivers

✓ •Memory ✓ • Injector drivers

✓ • SRAM Logic outputs

✓ • EEPROM ✓ •Communication links

Inputs

✓ Supply Voltage

✓ Digital inputs Analog inputs

Emission Norm standards ( Bharat stage )
Emission standards are requirements that set specific limits to the amount of pollutants that
can be released into the environment.

Many emission standards focus on regulating pollutants released by automobile and other
transport vehicles but they can also regulate emission from industry, power plant and small
equipment such as lawn mowers and diesel generator.

The Bharat Stage norms have been styled to suit specific needs and demands of Indian
conditions.

The differences lie essentially in environmental and geographical needs, even though the
emission standards are exactly the same.

In 1989 the first Indian emission regulation were introduced for emission limits.
Following are Changes in automobile manufacturers in achieving BS6 norms of diesel engines 6W19,6S22

1. Reduction in HC emission by 45%

2. Reduction in NOX emission by 70%
3. Reduction in PM emission by 80%
4. Use of Lean NOX traps
5. Use selective catalytic reduction (SCR)
6. Use of Diesel particulate filter
7. Five times reduction in Sulpher %
8. OBD for all diesel vehicles
9. Real Driving Emission introduced in vehicles
10. Fumigation
11. Catalytic converter monitoring
12. Misfire detection
BS6 Phase II emissions regulations for bikes, scooters explained

❖ OBD-2 technology becoming mandatory on all two-wheelers sold from April 1, 2023 onwards.

❖ E20 fuel continuing to grow its presence across the nation.

BD stands for onboard diagnostics, and to put it simply, this is a
computer system on the vehicle that monitors and regulates its
operation.

An onboard computer receives data from the vast array of sensors

across a vehicle and uses these readings to ensure proper functioning
and alert the user in the case of improper functioning.

It also incorporates a connector that allows service technicians to

hook up a diagnostic tool and view information about what’s going
wrong with the vehicle and where.