Engine

• An engine is a device which transforms one form energy

into an other form of energy.
• Most of engine converts thermal energy to mechanical
work which is called heat engine.
• Heat engine is a device converts chemical energy of fuel to
thermal energy and utilize thermal energy to perform useful
work.
• These thermal energy is converted to mechanical energy.
• Heat engine can be classified into two based fuel
combustion takes place.
1. Internal combustion engine
2. External combustion engine
 Advantage and disadvantage of IC engine over EC
engine.
• Advantage
 IC engine have no requires heat exchanger (boilers and
condensers).
 It works on moderate average temperature.
 Have high thermal efficiency.
 Has low weight to power ratio.
 It can develop low power output with reasonable thermal
efficiency and cost.
• Disadvantage
 It has high vibration due to reciprocating component.
 It uses only liquid and gas fuel which is expensive.
Components of spark ignition IC engine
• Two crank shaft revolution is one compete
cycle of engine and one revolution of
chanshaft.
 Fuel-Air(F/A) or Air-Fuel ratio
• In
  SI engine the mixture is prepared at the carburetor.
And we control the mixture for induction.
• In CI engine we only control the amount of fuel.
• To know the behavior of the mixture we test the
charge using equivalence ratio.

……… stoichiometric ratio

………..rich mixture/more fuel
………..lean mixture/excess air
 Transmission and driveline

1.Function of transmission and driveline:

To transmit power/torque from engine safely and efficiently
to the ground.
To allow the vehicle to operate a wide range of speed from
standstill to the maximum speed.
Designed to satisfy the conflicting requirements of quick
acceleration, high speed and adequate fuel economy.
 2. Types of transmission
• Manual transmission
- Clutch
- Gear theory
- Manual transmission operation & analysis
• Automatic transmission
- Hydrodynamic torque convertor
- Planetary gear
- General transmission operation
 Manual transmission, types and working
principle.
• A manual transmission should:
–be able to increase torque to the drive wheels for quick
acceleration
–supply different gear ratios to match load conditions
–provide a reverse gear
–provide an easy means of shifting gears
–operate quietly with minimal power loss -A small gear
driving a larger gear increases torque and decreases
speed
-A large gear driving a smaller gear decreases torque
and increases speed
 Friction clutches
• Used to engage and disengage the engine from
transmission.
• Consists cover, pressure plate and friction disc.
• Cover is blotted with engine flywheel.
• Pressure plate is inside the cover.
• Friction disc is b/n pressure plate and flywheel.
• The disc is connected to the transmission input shat by
spline.
• The clutch designer must consider:
- activating force
- torque delivery
- energy loss,
- temperature rise,
- wear.
• The friction material must be selected to provide :
- A uniform coefficient of friction over the surface
- A coefficient of friction that remains stable with
temperature changes
- Good thermal conductivity
- Resistance to wear
- Resistance to thermal fatigue
- Good high-temperature strength
 Straight-Tooth Spur Gears

• Have straight teeth parallel to the axis of rotation.

• Sudden meshing results in high impact stresses and noise.
• Do not generate axial (or thrust) loads along the shaft axis.
• They are easier to manufacture and can transmit high
torque loads.
• For these reasons, many transmissions use spur gears for
first and reverse gears.
• This accounts for the distinctive "whine" when a car is
reversed rapidly.
 Helical Spur Gears
• have teeth, cut in the form of a helix on a cylindrical
surface.
• Teeth begin to mesh/ contact begins at the leading edge
of the tooth and progresses across the tooth face.
• Greatly reduces the impact load and noise,
• It generates a thrust load that must be absorbed at the
end of the shaft by a suitable bearing.
 Straight-Tooth Bevel Gears
• Have straight teeth cut on a conical surface.
• Used to transmit power between shafts that intersect
but are not parallel.
• They are used in differentials and rotate only when the
axles are rotating at different speeds.
• Similar to straight-tooth spur gears, they will be noisy.
Spiral Bevel Gears
• Have teeth cut in the shape of a helix on a conical
surface.
• They can be used for final drives to connect
intersecting shafts.
 Hypoid Gears

• Have helical teeth cut on a hyperbolic surface.

• They are used in final drives to connect shafts that are
neither parallel nor intersecting.
• Have high tooth loads and must be lubricated with
special heavy-duty hypoid gear oil because greater
sliding occurs between the teeth.
• The sliding increases with the amount of offset
between the shaft axes.
• With zero offset, a spiral bevel gear results, whereas
the maximum offset corresponds to a worrm wheel
configuration
 Gear ratio
• Train
  value

• Gear ratio
Gear Backlash
• Distance between the meshing gear teeth
• Allows lubricating oil to enter the high-friction area
between the gear teeth
• Allows the gears to expand during operation
Synchronizers : Synchronizers have two functions:
1. prevent the gears from clashing (grinding) during
engagement
2. lock the output gear to the output shaft
• When the synchronizer is away from an output gear,
the gear freewheels (spins freely) on the output shaft
• When the synchronizer slides against the output gear,
it locks the output gear to the output shaft
• Unsynchronized Transmission
• Unsynchronized manual transmission is the first type of manual transmission
invented in the late 19th century. This was the first time the gears were
engaged by sliding them on the shaft. Mastering this type of gearbox
required a certain skill of manipulating throttle, timing the shift correctly.
• This was the case because the gears had to be spinning at roughly the same
speed to mesh easily with each other. If the gears are spinning at different
rpm when you change gears, it could grind gears and damage the gearbox.
Those who have experienced this know that it’s not a great feeling hearing
your gearbox scream in pain.
• No wonder unsynchronized transmissions are also known as crash box
because they would often refuse to mesh and make loud grinding noise.
Learn more about double clutching an unsynchronized transmission below.
• Why is double clutching required for older cars?
• Double clutching is a technique that’s used with an unsynchronized gearbox. That’s why you don’t want to
drive a vintage car without knowing how to double clutch. Here’s how you double clutch:
• 1) push down on the clutch pedal to free up the transmissions.
2) Move into the neutral gear position.
3) Release the clutch lever and rev the engine to the right rpm for the next gear. How much to rev comes
from experience. But generally, if you are driving sedately then just a light tap on the throttle will be
sufficient. If you are going fast and revving out the engine then you need to build up more rpm while in
neutral.
4) Press clutch and shift into next gear.
• As you can notice, shifting one gear requires you to press the clutch twice. And hence it’s called double
clutching.
• Synchronized / Constant Mesh Gearbox
• Constant mesh gearbox is an improvement over unsynchronized manual transmission that needed
complicated skills like double clutching. Constant mesh gearbox is what we have in all modern manual
transmission cars.
• The main goal of a constant mesh gearbox was that gears on both the shafts remain spinning in sync with
each other. The gears on the layshaft are fixed but gears on output shaft can be moved as they sit on
bearings.
• Straight cut gear doesn’t produce this force, therefore, the rest of the
components are less likely to fail even when a large amount of torque
is applied through the gears.
• With helical gears, the transmission casing and shafts need to be extra
robust which adds weight. That’s another reason why race cars are
better off without helical gears (weight saving reasons). And did I
mention that they are easier to assemble?
• Automated Manual Transmission
• Automated manual transmission is an attempt to use the existing
manual gearbox and make it close to automatic. For this, the gear
selector and clutch are hydraulically controlled by the ECU of the car.
The ECU software decides when to shift gear and signals the hydraulic
actuators to do so.
 Vehicle maintenance
• The Importance of Downtime Prevention
• Unplanned downtime is typically caused by the lack of a proper fleet maintenance system. A preventative maintenance plan helps keep vehicles on the road and maintenance costs down. Here are a few best practices in downtime
prevention.
• 1. Address Issues Immediately with eDVIR
• An effective strategy for downtime prevention begins with routine vehicle inspections. Daily Vehicle Inspection Reports (DVIR) not only ensure your vehicles are safe and compliant, but also allow you to be proactive in vehicle
maintenance and prevent unplanned downtime.
• Many fleets are still using paper DVIR, which are time-consuming and prone to error. Paper inspection forms can get lost or damaged, and getting results to your maintenance team can take hours, impeding the repair process.
Using electronic DVIR (eDVIR) increase efficiency and ensure drivers are more accurate and clear in their reporting.
• eDVIR gives you real-time inspection results, preventing communication delays between driver and fleet manager. Any issue is immediately logged in your fleet management software, allowing you to quickly troubleshoot and
resolve issues.
• Seamless communication ensures that even when a vehicle experiences an issue, the maintenance process can begin immediately to get you back on the road quickly.
• 2. Create a Preventative Maintenance Schedule
• The best way to prevent downtime across your fleet is to keep your maintenance plan proactive and not reactive. Knowing what maintenance tasks are in the pipeline can help you schedule vehicles and anticipate expenses.
• Having a preventative maintenance (PM) schedule allows you to stay on top of regular servicing. With fleet management software, you can set reminders for certain intervals like mileage and hours of use, ensuring you never miss
a servicing.
• Streamlining your PM workflow is another great way to minimize unplanned downtime. If your fleet maintenance is done in-house, scheduling work orders in your fleet maintenance software allows you to efficiently track
maintenance tasks and automatically update vehicle status.
• Many small to mid-size fleets outsource maintenance to a third-party vendor. Historically, external repair orders have been created manually, causing bottlenecks and giving a limited view of asset health trends.
• Automating outsourced maintenance through a fleet management software allows you to quickly manage repair orders, report on maintenance trends, consolidate billing and prevent unnecessary downtime.
• 3. Track and Measure Asset Health
• Having a strong understanding of the past and current health of your assets will help you prevent future unplanned downtime. To gain this insight, it’s important to track and measure repair data and service history.
• Tracking repair data in fleet management software is a great way to conduct routine quality control and ensure maintenance is being completed properly.
• With a common platform like Fleetio, you can access detailed service history for each of your assets and track progress on all current maintenance tasks.
• Creating custom reports on asset history allows you to identify maintenance trends, forecast repairs, and track overall lifespan. This proactive approach to managing fleet information helps you minimize unplanned downtime while
maximizing asset lifespan.
• 4. Develop a Vehicle Replacement Strategy
• Unplanned downtime can happen more frequently as your assets age. Typically, asset performance declines as operating costs rise the longer a vehicle is operated.
• Though you may have guidelines for vehicle replacement, sometimes vehicles stay in operation long past their prime. The decline in performance can cause unplanned downtime to happen more frequently and affect your bottom
line.
• The best course of action in developing an effective vehicle replacement strategy is to leverage fleet data. Exporting maintenance data into easy-to-read reports allows you to audit asset health and make informed decisions for
vehicle replacement.
• 5. Monitor Part Replacement
• To properly maintain your assets, their parts have to be in optimal condition. Part failure is a common cause of unplanned downtime. Making sure your parts are in good condition during your routine quality control is the first step
in monitoring your parts.
• Sometimes you might have a recurring failure of a type of part across multiple vehicles. Trends like this can be missed when you don’t have an easy, comprehensive way to look at your fleet.
• Watching trends through your fleet management software can give you insight into recurring failures.
• Tracking and monitoring your parts both in-person and in your fleet management software ensures your parts are in top condition, consequently preventing downtime and cutting recurring costs.
• Maximize uptime with fleet management software! Request a demo or start a free trial of Fleetio today