AUTOMOBILE ENGINEERING

UNIT 4
Fuel Supply
System
• For the engine to run smoothly and efficiently it needs to be provided
with the right quantity of fuel /air mixture according to its wide range
of demands
• Traditionally, the fuel/air mixture is controlled by the carburettor , an
instrument that is by no means perfect
• Its major disadvantage is that a single carburettor supplying a four-
cylinder engine cannot give each cylinder precisely the same fuel/air
mixture because some of the cylinders are further away from the
carburettor than others
• One solution is to fit twin-carburettors, but these are difficult to tune
correctly
• Instead, many cars are now being fitted with fuel-injected engines where
the fuel is delivered in precise bursts
• Engines so equipped are usually more efficient and more powerful than
carburetted ones, and they can also be more economical, as well as having
less poisonous emissions
Characteristics of a good fuel supply
system:
• A good fuel supply system should be able to deliver the fuel correctly
at the end of the compression stroke
• It must be able to properly atomize the fuel
• It must operate smoothly and sharply during each cycle of operation
of the engine
• It must be able to supply the fuel above atmospheric pressure
Fuel Injection system for CI Engines
• Itis important that injection begin and end cleanly, and avoid
any secondary injections.
• To accomplish this function, fuel is usually drawn from the fuel tank
by a supply pump, and forced through a filter to the injection pump.
• The injection pump sends fuel under pressure to the nozzle
pipes which carry fuel to the injector nozzles located in each cylinder
head.
• Excess fuel goes back to the fuel tank.
 FUNCTIONAL REQUIREMENTSOF AN INJECTION
•SYSTEM
Accurate metering of the fuel injected per cycle.
• Metering errors may cause drastic variation from the desired output.
• The quantity of the fuel metered should vary to meet changing speed and load requirements
of the engine
• Correct timing of the injection of the fuel in the cycle so that maximum
power is obtained
• Proper control of rate of injection so that the desired heat-
release pattern is achieved during combustion.
• Proper atomization of fuel into very fine droplets.
• Proper spray pattern to ensure rapid mixing of fuel and air.
 Contd
•…Uniform distribution of fuel droplets throughout the
combustion chamber
• To supply equal quantities of metered fuel to all cylinders in case
of multi-cylinder engines.
• No lag during beginning and end of injection i.e., to eliminate dribbling
of fuel droplets into the cylinder.
Fuel Supply System in Diesel
Engine
Components:
Fuel supply system in diesel engine is made of the following components:
• Diesel tank or reservoir
• Low pressure pump
• Filter
• Fuel injection pump
• Fuel injectors
Working:
• Diesel is pumped from the diesel tank by a low pressure pump
• It is passed through a filter
• The filter removes any unwanted impurities in the diesel
• Filtered diesel is supplied to the inlet port of the fuel injection pump
• The fuel injection pump automatically pressurizes the diesel to
the required level and supplies it to the fuel injector
• The fuel injector forces the fuel into the cylinder at the end of
the compression stroke, during each cycle of operation of the engine
• Fuel injection pump is operated by means of a cam shaft
TYPES OF INJECTION
SYSTEMS
The fuel injection systems are of 2 types:
1. Air Injection System:
• In this case fuel is injected under the pressure of air.
• For supplying high pressure air multistage air compressors are
required, which are very much costly and hence this system is not
in use.
2. Solid Injection System:
• In this case diesel fuel is directly injected by fuel pump (Bosch
Pump).
 Air Injection
•System
This system is little used nowadays, because it requires a bulky multi-
stage air compressor.
• This causes an increase in engine weight and reduces the brake power
output further.
• One advantage that is claimed for the air injection system is good
mixing of fuel with the air resulting in higher mean effective pressure.
• Another advantage is its ability to utilize fuels of high viscosity which
are less expensive than those used by the engines with solid injection
systems.
• These advantages are off-set by the requirement of a multistage
compressor thereby making the air-injection system obsolete.
 Solid Injection
•System
In this system the liquid fuel is injected directly into the combustion
chamber without the aid of compressed air.
• Hence, it is also called airless mechanical injection or solid injection
system.
• It can be classified into four types.
• Individual pump and nozzle system
• Unit injector system
• Common rail system
• Distributor system
 Individual Pump and Nozzle
•System
In this system, each cylinder is provided with one pump and one injector.

• A separate metering and compression pump is provided for

each cylinder.
• The pump may be placed close to the cylinder.
• The high pressure pump plunger is actuated by a cam, and produces the
fuel pressure necessary to open the injector valve at the correct time.
• The amount of fuel injected depends on the effective stroke of the
plunger.
 Unit Injector
•System
In this system a pump and the injector nozzle are combined in one
housing.
• Each cylinder is provided with one of these unit injectors.
• Fuel is brought up to the injector by a low pressure pump, where at
the proper time, a rocker arm actuates the plunger and thus injects
the fuel into the cylinder.
• The amount of fuel injected is regulated by the effective stroke of the
plunger.
 Common Rail
•System
In the common rail system, a HP pump supplies fuel, to a fuel header.
• High pressure in the header forces the fuel to each of the
nozzles located in the cylinders, at proper time.
• A mechanically operated (by means of a push rod and rocker arm)
valve allows the fuel to enter the proper cylinder through the nozzle.
• The pressure in the fuel header must be so high it must enable
to penetrate and disperse the fuel in the combustion chamber.
• The amount of fuel entering the cylinder is regulated by varying the
length of the push rod stroke.
 Distributor
•System
In this system the pump which pressurizes the fuel also meters and
times it.
• The fuel pump after metering the required amount of fuel is supplied
to a rotating distributor at the correct time for supply to each cylinder.
• The number of injection strokes per cycle for the pump is equal to the
number of cylinders.
• Since there is one metering element in each pump, a
uniform distribution is automatically ensured.
• Not only that, the cost of the fuel-injection system also reduces
https://www.youtube.com/watch?v=Mi85NY6hsoE
Types of Fuel Injectors
• Air Blast Injectors – These are used in air injection systems.
• Nowadays air injection systems are not in use as they require
multistage compressors.
• And hence these injectors are no more used.
• Mechanically Operated Injectors – These injectors are operated by a
mechanism similar to that used to operate IC engine valves i.e., it
uses camshaft, push rods, rocker arms, etc.
• Cam operates the plunger.
• Automatic Fuel Injector – All automobile CI enginesuse
Automatic Fuel Injectors. these
• They comprise needle valve, which is lifted up by fuel pressure.
• This fuel pressure is created by fuel pump.
Types of Nozzles
Single Hole Type:
• At the centre of nozzle body a hole of 0.2 mm dia is provided.
• Spray cone is ∠ is @ 15°.
• Used in open combustion chambers.
• High pressure is required to get same velocity. No good mixing with air. It has a
tendency to dribble.
Multiple Hole Type:
•Proper mixing with air 4 to 18 holes. Size of the holes will be 0.35 to 1.5 mm.
Pintle Type:
• To avoid weak injection and dribbling, the spindle is provided with projection called
Pintle.
• It protrudes through the mouth of nozzle body.
• It may be cylindrical or conical in shape. Dribbling is avoided.
• Used in precombustion chambers, air cells, swirl chambers.
 Electronic Fuel Injection (EFI)
•System
Electronics is introduced in automobiles in 1965.
• About 30—40% of cost of vehicles is for electronic items.
• Max power and best economy are attained by using electronics and
computers in automobiles.
• In EFI systems, there are various sensors to sense various parameters
like temperature, pressure of gases, position of throttle valve, air flow
rate etc.
• Sensors feed this data to Electronic Control Unit (ECU)—which is
basically a computer.
• This ECU—processes the data and operates injectors and other
devices to have maximum power, with best economy, and low
emissions.
 Multipoint Fuel Injection System
•(MPFI)
Multipoint Fuel Injection system is used to supply air-fuel mixture of proper
strength and in required quantity to each cylinder of a multi- cylinder
engine, at all engine speeds loads.
MPFI—Systems Functions under 2-Basic Arrangements:
1. Port Injection:
• In this case injector is placed in the intake manifold, near the inlet valve. The injector
sprays petrol into air flowing through the intake manifold. Homogenous air-fuel
mixture produced enters cylinder. Note that each cylinder has a separate injector
placed in its intake manifold.
• Advantages:
• Uniform fuel distribution
• Increase in power output
• More precise control of air-fuel ratio.
2. Throttle Body Injection:
• In this case injector is provided at a single point in the throttle body. Throttle valve
controls the amount of air entering intake manifold.
Types of fuel supply system in petrol
engine
• Gravity system
• Carburetion
• Multi Point Fuel Injection
Gravity System
Cooling & Lubrication
System
• The cooling systems job is to get the engine up to
operating temperature as fast as safely possible and keep it there
• Itis also responsible for transferring heat from the engine to
the heater core for passenger comfort
• As combustion occurs, intense heat is produced
• Without a cooling system this heat would eventually overheat
and damage the engine
The Two Main Types of Cooling Systems
• Conventional Cooling system: This system is much more common and can
be identified by its radiator cap
• Fully pressurized Cooling System: This system was first used by VW
• This system has no radiator cap and the pressurized coolant reservoir is part of the
main coolant circuit
• The reservoir cap is responsible for regulating cooling system pressures
• As pressure gets excessive the reservoir cap bleeds off air until system pressure is
acceptable
Types of cooling system
The different Types of cooling system are:
• Air cooling system
• Liquid cooling system
• Forced circulation system
• Pressure cooling system
• Air-Cooled System
It is the simplest type of cooling method in which the heat is drawn
off by moving air in direct contact with the engine.
The rate of cooling is dependent upon:
• The area exposed to the cooling medium
• The heat conductivity of the metal used & the volume of the metal or its
size in cross section
• The amount of air flowing over the heated surfaces
• The difference in temperature between the exposed metal
surfaces and the cooling air
Liquid Cooled System
• A simple liquid-cooled system consists of a radiator, coolant pump,
piping, fan, thermostat, and a system of water jackets and passages in
the cylinder head and block through which the coolant circulates
• Cooling of the engine parts is accomplished by keeping the coolant
circulating and in contact with the metal surfaces to be cooled
Pressure cooling system (Radiator Pressure Cap)
• The radiator pressure cap is used on nearly all of the modern engines
• The functions of the pressure cap are as follows:
• Seals the top of the radiator tiller neck to prevent leakage
• Pressurizes system to raise boiling point of coolant
• Relieves excess pressure to protect against system damage
• In a closed system, it allows coolant flow into and from the coolant reservoir
 The Lubrication system
• There are three basic types of oil distribution systems used in engines:
• Splash,
• Pressurized, or
• A combination of these
Splash Lubrication Systems
• Oil is applied to the cylinders and pistons by rotating
dippers on the connecting-rod bearing caps
• Each time they rotate, the dippers pass through an oil-
filled trough
• After running through the oil trough, the dippers
splash oil onto the cylinders and pistons to lubricate
them
• While splash lubrication is effective for smaller
engines and pumps, it’s not a precise process
• Parts of the pump may be insufficiently oiled or oiled
too much
Pressure Lubrication Systems
• It is a process where an oil pump precisely distributes oil to key areas of
the pump
• Typically, the oil is pumped through an oil filter and into the pump where
it is then recycled and reused; using a replaceable oil filter can further
improve the life of the oil
• The oil is transported to the key area by use of an oil pump
• Therefore, the viscosity of the oil is not as critical as with a splash tube
system
 AUTOMOTIVE SAFETY
• Active SYSTEMS
Safety system
• Provides advance warning to driver steering/controlling the
vehicle with additional assistance in
• Anti-Lock braking system (ABS)
• Electronic stability control (ESC)
• Tire pressure monitoring system (TPMS)
• Adaptive cruise control (ACC)
• Driver monitoring system (DMS)
• Night vision system (NVS)
Passive Safety system
• It play a role in limiting/containing the damage/injuries caused to driver,
passengers and pedestrains in the event of crash/accident
• Air-bags
• Seat belts
• Whiplash protection system
• Child safety system
• Pedestrain safety system
 Breakdown
•Maintenance
Breakdown maintenance is maintenance performed on equipment
that has broken down and is unusable
Advantages of breakdown maintenance
• Using breakdown maintenance when it makes sense can help
organizations focus on optimizing PM programs for critical
equipment
Disadvantages of breakdown maintenance
• Unplanned breakdown maintenance can be more costly than
preventive maintenance, because it typically causes downtime and
interrupts production
• It can also be difficult to find the root cause of a breakdown when no
maintenance strategy is in place
• Finally, breakdown maintenance can raise health and safety issues if
technicians are rushing to fix a problem and taking risks to do so
Automobile
Overhauling
• Overhauling in automobile means when your car does not run well or
performance of your car is not good then disassemble the every part
and again tuned them properly or replace some part to better
efficiency.
 Automobile Air-
• AConditioning
vehicle’s air conditioning system does not create cold air. It actually
takes the heat and moisture out of the air that is already in your car,
leaving behind cooler air
• The a/c compressor initiates the high-side of the system where it is compress
the refrigerant into a high-pressure state causing it to liquefy
• It travels through the high-pressure lines to the condenser
• The condenser which is similar to a small radiator, puts the liquid in contact with
fresh air on the outside of the vehicle, which absorbs the heat from the liquid
• It then flows into the expansion valve or orifice tube where it is restricted and
becomes gaseous into the low-pressure side of the a/c system
• Then it flows into the receiver dryer/accumulator that contains a desiccant bag
to remove and collect unwanted moisture/water and impurities