3.

Engine Construction and Operation

3-1. Classification of Automobile Engine

3-2. Operation of 4 Stroke and 2 Stroke Engine
3-3. Construction and Working Principle of SI & CI Engine
3-4. Major Engine Components
Cylinder Head
Cylinder Block
Crankcase
Piston
Crankshaft
Connecting Rod
Flywheel
c
Et .

3-5. Valve Mechanism & Valve Timing Diagram

1
3-1. Classification Automobile Engines
• Basic Engine Design
– Reciprocating Engine
• In-Line Engine
• V-Engine
• Opposite Piston Engine
• Radial Engine

In-Line V Opposite Piston Radial

 Rotary Engine
 Wankel Engine

Wankel
2
3-1. Classification Automobile Engines

■ Working Cycle
 2 Stroke Cycle Engine
 4 Stroke Cycle Engine

■ Method of Ignition
 SI(Spark Ignition) Engine
 CI(Compression Ignition) Engine

■ Method of Cooling
 Air Cooled Engine
 Water Cooled Engine

■ Fuel Used
 Gasoline(Petrol) Engine
 Diesel Engine
 Gas(LNG, CNG, LPG) Engine
 Dual Fuel Engine
 Hydrogen Engine
 Hybrid
 Fuel Cell
3
3-1. Classification Automobile Engines

 Application
 Motorcycles, 0.75 – 70 kW, SI, 2 and 4-stroke, air-cooled
 Outboard motor, 0.75 – 50 kW, SI, 2-stroke, water-cooled
 Passenger cars, 15 – 200 kW, SI and CI, 4-stroke, water-cooled
 Light commercial vehicles, 35 – 150 kW, SI and CI, 4-stroke, water-cooled
 Heavy commercial vehicles, 120 – 400 kW, CI, 4-stroke, water-cooled
 Locomotives, 400 – 3 000 kW, CI, 4-stroke, water-cooled
 Ships, 3 500 – 22 000 kW, CI, 2- and 4-stroke, water-cooled
 Airplanes, 45 – 3 000 kW, SI, 4-stroke, air-cooled
 Stationary engines, 10 – 20 000 kW, CI, 2- and 4-stroke, water-cooled

4
3-2. Operation of 4 Stroke and
2 Stroke Engine

1 = Intake 1 = Intake/Compression

2 = Compression 2 = Power/ Exhaust
3 = Power
4 = Exhaust
1:35
5
3-2. Operation of 4 Stroke and
2 Stroke Engine

1 = Intake/Compression 2 = Power/ Exhaust

2:10
6
3-2. Operation of 4 Stroke and
2 Stroke Engine
Application of 2 Stroke Engine

Gasoline 2 Stroke Engine Diesel 2 Stroke Engine

7
3-2. Operation of 4 Stroke and
2 Stroke Engine
4 Stroke Engine 2 Stroke Engine
One power stroke for every 2 revolution of crankshaft One power stroke for each revolution of crankshaft
Heaver flywheel due to unbalanced engine run Lighter flywheel due to relatively balanced engine run
Heavy Light
Design complicated due to valve mechanism Design simple due to absence of valve mechanism
More cost Less cost
Less mechanical efficiency due to more friction parts More mechanical efficiency due to less friction parts
More output due to full fresh charge intake & full burnt Less output due to mixing of fresh charge with hot burnt
gases exhaust gases
Engine run cooler Engine run hotter
More fuel consumption & fresh charge mixed with exhaust
Less fuel consumption & Complete burning of fuel
gas
Required more space Required less space
Complicate lubricating system Simple lubricating system
Less noise More noise
Intake & exhaust valves Intake & exhaust ports
More thermal efficiency Less thermal efficiency
Less engine oil consumption More engine oil consumption
Less wear of moving parts More wear of moving parts
Mainly used in mopeds, outboards, lawnmower (gasoline) &
Mainly used in cars, buses, trucks
marine engine(diesel)
8
3-3. Construction and Working
Principle of SI & CI Engine
• SI(Spark Ignition) Engine Working Principle

1:30
9
3-3. Construction and Working
Principle of SI & CI Engine
• SI(Spark Ignition) Engine
– Pressure vs Crank Angle

10
3-3. Construction and Working
Principle of SI & CI Engine
• CI(Compression Ignition) Engine Working Principle

4:12
11
3-3. Construction and Working
Principle of SI & CI Engine
• CI(Compression Ignition) Engine
– Pressure vs Crank Angle

2:00
12
3-3. Construction and Working
Principle of SI & CI Engine
• CR(Compression Ratio)

13
3-4. Major Engine Components

Ignition Coil & Spark Plug

Three Way Catalyst
Fuel Injector

Cylinder Head

Intake Manifold

Alternator Cylinder Block

Cam Shaft

Piston

Flywheel

Connecting Rod
Crankcase Crankshaft
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3-4. Major Engine Components
• Cylinder Head
– Contain valve driving mechanism
• Camshaft(OHC), Valve train
– Installed Intake and Exhaust Manifold
– Consist upper part of combustion chamber
– Material : Cast Iron, Steel or Aluminum Alloy

15
3-4. Major Engine Components

• Cylinder Block
– Contain Piston assembly
– Embedded water jacket for cooling system and oil gallery for lubricating
system
– Installed water pump, alternator, starting motor, compressor, etc.
– Consist upper part of crankcase
– Material : Cast Iron, Steel or Aluminum Alloy

16
3-4. Major Engine Components

 Cylinder Head Gasket & Head Bolt

 Cylinder head and cylinder block are fabricated by cylinder head
bolts
 Sealed by head gasket between cylinder head and block

17
3-4. Major Engine Components
• Crankcase
– Contain oil pump and strainer, engine oil
– Mount lower part of main journal bearing
– Consist of lower part of crankcase
– Material : cast iron, steel alloy, aluminum alloy

21:23
18
3-4. Major Engine Components
 Piston Head
 Change thermal energy to mechanical energy thru
connecting rod to crankshaft
 Mount piston rings
 Consist lower part of combustion chamber
 Material :Cast Iron, Aluminum Alloy

Piston Top

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3-4. Major Engine Components
Piston Ring

Top Ring

2nd Ring

Oil Ring

20
3-4. Major Engine Components
Combustion Chamber (Gasoline Engine)

Wedge Bathtub
Hemispherical

GDi Engine

21
3-4. Major Engine Components

• Connecting Rod
 Transmit force from piston to crankshaft
 Connected with piston and crankshaft by pins
 Material : nickel, chrome, chrome vanadium
steel, aluminum

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3-4. Major Engine Components
• Crankshaft
– Change reciprocating of piston movement to
rotating movement
– Different configuration depending number of
cylinder for balance
– Mount crankshaft sprocket and flywheel
– Material : cast iron, nickel alloy

23
3-4. Major Engine Components

Crankshaft Configuration

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3-4. Major Engine Components

• Flywheel
– Energy damper (Rotational
Inertia)
– Provide balance for
crankshaft
– Mount clutch/transmission
– Meshed with starter
motor’s pinion gear on
outer gear
– Material : cast iron

25
3-4. Major Engine Components

• Piston + Connecting Rod + Crankshaft +Flywheel

Connecting
Rod Piston
Flywheel

Crankshaft

26
3-4. Major Engine Components

• Camshaft
– Operate valve mechanism (open and close
intake and exhaust valves
– Mounted cam sprocket
– Connected crankshaft sprocket by timing
chain or belt
– Chilled cast iron

5:30

4:23

274:3:10
3-5. Valve Mechanism & Valve Timing
Diagram
Cam Shaft in Cylinder Block

Side-Valve Overhead-Valve
Cam Shaft in Cylinder Head

SOHC w/cam follower SOHC w/Rocker DOHC w/Tappet SOHC w/Tappet

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3-5. Valve Mechanism & Valve Timing
Diagram
Valve Timing Diagram

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3-5. Valve Mechanism & Valve Timing
Diagram
Effect of Valve Timing
Opening Closing
Valve
Early Late Early Late
Dilution with Ex- Reduce Volume Effi- Increase Cylinder Pres- Reduce Cylinder Pres-
Intake haust gas ciency sure sure
Reduce Volume Effi-
Exhaust Power Reduction Pumping Loss ciency Reduce Vacuum

2:31
2:43
2:50
VVC(Variable Valve Control) 307:53
Thank You!