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Combustion chamber
Spark plug or fuel injector
Valves (in case of I-head and F-head)
Coolant water passages
3. Crank case
1.
2.
3.
4.
5.
Cylinder block
Engine components
1.
2.
3.
4.
5.
6.
7.
Cylinder block
Cylinder head
Crank case
Piston
Piston rings
Piston pin
Connecting rod
8. Crank shaft
9. Flywheel
10.Valves and valve
actuating mechanisms
11.Rocker arm
12.Cam shaft
13.Air induction system
14.Fuel system
15.Exhaust system
Materials [1]
S No.
Component
Material
Cylinder block
Cylinder Head
1. Aluminium alloy
2. Gray iron
Piston
1. Aluminium alloy
2. Cast iron
Piston rings
Connecting rod
1. Forged steel
2. Alumnium alloy
Crank shaft
Flywheel
Steel
Valves
Catalytic Convertor
[2]
Catalysts
Catalyst
Reactants / Reaction
Aluminium Oxide
(Alumina)
Platinum &
Palladium
Oxidation of CO and HC
1
CO O2 CO2
2
C x H y zO2 xCO2 yH 2O
z x 0.25 y
Rhodium
Reaction of NOx
1
N 2 CO2
2
2 NO 5CO 3H 2O 3 NH 3 5CO2
NO CO
2 NO CO N 2O CO2
1
N 2 H 2O
2
2 NO 5 H 2 2 NH 3 2 H 2O
NO H 2
2 NO H 2 N 2O H 2O
Cerium Oxide
Water-gas shift
CO H 2O CO2 H 2
Cold start up
Contributes from 70 to 90 % emission
Artificial heating:
Poisoning
Lead Poisoning
Sulphur poisoning
* Some catalyst promote
conversion of SO2 to SO3
* Eventually converted to
sulphuric
acid
degradation of catalytic
convertor ; acid rain
* Development of new
catalyst, which produce
no SO3 if Tcat<400C
References
1. Gupta, R. B., Automobile Engineering, Tech
India Publications, 7th edition, New Delhi,
2011.
2. Ganesan, V., Internal Combustion Engines,
2nd edition, Tata McGraw Hill, New Delhi,
2004.
18
Carburetor
Introduction
Construction & defects in Simple Carburetor
Classification
Typical Carburetors
Disadvantages
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19
Introduction
SI engine
Use volatile fuel; Mixture preparation outside cylinder
Formation of homogenous mixture not completed in
inlet manifold
Fuel droplets continue to evaporate during suction
and compression
Carburetion
Definition: process of formation of a combustible fuelair mixture by mixing proper amount of fuel with air
before admission to engine cylinder
Purpose: provide combustible mixture of required
quality and quantity for efficient operation of the
engine under all conditions
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20
Chemically
correct
(stoichiometric) ~15:1
Rich mixture (limited to > 9:1)
Lean Mixture (limited to < 19:1)
21
2. Cruising
o
o
3. Power
o
o
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Carburetor - Classification
Based on flow direction
Up-draught
Down draught
Cross draught
Constant choke
Constant vacuum
emulsion tube
Back suction & control mechanism
auxiliary air valve and air port
Multiple Venturi
Multi-jet
Multi-barrel Venturi
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26
Solex Carburetor
1 float
2 main metering jet
3- venturi
4 emulsion tube with lateral
holes
5 air correction jet
6 spraying orifice / nozzles
7 throttle valve
8 bi-starter valve (disc)
9 starter gasoline jet
10 starter air jet
11 starter lever
12 dashboard control
13 pilot jet
14 small pilot air bleed orifice
15 idling volume control screw
16 idle port; 17 by-pass
orifice
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Carter Carburetor
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Introduction
Construction
Operation
Maintenance
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29
Introduction - Battery
Generating
Starting
Ignition
Light
Types of Battery
1. Lead Acid
2. Alkaline
a.
b.
Nickel Iron
Nickel - Cadmium
30
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31
3.
4.
5.
Container
Plates
Separators Chemicals used
Cell covers 1. Sponge Lead (solid)
Electrolyte 2. Lead Oxide (paste)
3. Sulfuric Acid
Grids
Cell connectors (liquid)
Tapered
terminals
Sealing
Positive
Plate: Lead Peroxide
compounds
(PbO2)
Negative Plate: Lead (porous
spongy lead)
Electrolyte: Sulfuric Acid (40%)
Separators
Sealing compounds
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33
Lead
Acid
Construction
Battery
Container
Vent plugs
allows the gases from within the
cells to escape
Plates
Anode (positive plate group)
Cathode (negative plate group)
Interlaced with a terminal attached
to each plate group
Cells
Connected in series
Terminals
Individual cell terminals connected by link connectors
+ive terminal of one end cell becomes +ive terminal of the
battery
-ive terminal of opposite end cell becomes +ive terminal of
the battery
Source: http:// www.tpub.com/neets/book1/chapter2/1e.htm
http://pvcdrom.pveducation.org/BATT
ERY/operlead.htm
Overall reaction
Undercharging
Liable to freeze in severe winter
Development of lead sulphate over the plates dense, hard &
crystalline, cannot be electrochemically converted to normal active
material again, leads to shorting, distortion of plates
Lack of water
Lead to high concentrations of acid which may charge and
disintegrate the separators, permanently sulphate the plates and
impair the performance
[Sulfuric acid must never be added to a cell unless it has been lost
due to spillage]
Freezing of Electrolyte
Crack the container and damage the positive plates
Battery testing
Battery troubles
1.
2.
3.
4.
5.
6.
7.
8.
Self discharging
Sulphation
Internal short circuiting
Deterioration
Cracking of container
Corrosion of battery terminals and clamps
Loss of water
Variation in specific gravity of electrolyte
Maintenance of Batteries
Electrolyte
Sulphation
Battery size and Design
Performance
Shock and vibration
Charging System
A.C/ D.C system
Charger output
Fast charging
Maintenance of Acid level
Laying up of batteries
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Alternator
Principle
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43
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[4]
44
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45
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46
References
1. Gupta, R. B., Automobile Engineering, Tech
India Publications, 7th edition, New Delhi, 2011.
2. Ganesan, V., Internal Combustion Engines, 2nd
edition, Tata McGraw Hill, New Delhi, 2004.
3. Rajput, R. K., A text book of Automotive
Engineering, Laxmi Publications, New Delhi,
2007.
4. William H. Crouse and Donald L. Anglin,
Automotive Mechanics, 10th edition, Tata
McGraw Hill, New Delhi, 2004.
7/10/2012
47
Transmission Systems
Topics
1.
2.
3.
4.
5.
6.
7.
Clutch
[3]
While engaging
Slip momentarily, for smooth engagement and lessens shock on gears,
shafts and other drive-train parts
While engaged
Transmit engine power to transmission
Clutch - Location
Clutch - Location
Clutch parts
Clutch linkage
Clutch operation
http://www.tpub.com/basae/89.htm
Clutch
http://www.tpub.com/basae/89.htm
Friction Plate
Cushion Springs & Dampening
Springs
Cushion Springs slightly
waved springs attached to plate
(compresses slightly to take up
shock of engagement)
dampening springs torsional
springs drives the hub and
reduces torsional vibrations
caused by engine power
impulses
Facings provided with grooves
to prevent sticking of facings by
breaking vacuum
Facings cotton & asbestos,
woven or moulded, saturated
with resins or binders
Cover assembly
Types of Clutches
Single Plate
Multi Plate
Coil spring
Diaphragm Spring
http://www.tpub.com/basae/89.htm
Gears[5]
Power transmission
Change angular velocity and torque
Teeth provide a positive driving action, no slippage
Many types of gears almost every type used in
automobile
Ratio
1st
2nd
3rd
4th
5th
3.166:1
1.882:1
1.296:1
0.972:1
0.738:1
output shaft
when the engine is
at 3000rpm
947
1594
2314
3086
4065
http://www.mekanizmalar.com/menu
_gear.html
Helical gears:
teeth cut in the form of helix on a cylindrical
surface
engagement contact begins at leading edge,
progresses along tooth face
greatly reduced impact load and noise, but
generates a thrust load that must be absorbed at
the end of shaft with suitable bearing
Hypoid gears:
Helical teeth cut on hyperbolic surface
Final drives to connect non-intersecting, non-parallel
shafts; high tooth loads & greater sliding - specially
lubricated
less efficient than spiral bevel; however allow driveshaft to
be lowered; hence smaller transmission tunnel in body
Power transmission
Gears a review [5]
through
[5]
A gear train
Manually operated
Overdrive
Chrysler semi-automatic
Automatic
Dog Clutch
Gear Boxes[5]
http://www.carbibles.com/transmissio
n_bible.html
http://auto.howstuffworks.com/seque
ntial-gearbox1.htm
Cross-section of a front-wheel
drive manual gear box
Overdrives[4]
Top gear position (generally) direct drive between
clutch shaft and main shaft; gear ratio 1:1
Overdrive
main shaft of gear box revolves faster than clutch shaft
Fitted to rear of the gear box, between gear box and
propeller shaft
Advantages of Overdrive
Permits an engine to run at lower speed while the car is
running at high speed
Engine runs at slower speed, producing less power,
consequently lesser fuel consumption, lesser wear and
tear on the engine and accessories
Sun gear locked to casing becomes stationary, overdrive engaged, o/p shaft speed
increases
Sun gear locked to carrier solid drive through gear train achieved, normal drive
obtained
Sun gear locked to ring same as the previous
http://www.buckeyetriumphs.org/techni
cal/jod/JOD1/JOD1.htm
A: Sun gear
B: Planet gears
C: Outer ring gear or annulus
D Planet gear carrier
Mekanizmalar.com
Deceleration
Power input: ring gear
Power output: planetary carrier
Stationary: sun gear
When the sun gear is held stationary, only the pinion
gear rotates and revolves. Therefore, the output shaft
decelerates in proportion to the input shaft only by
the rotation of the pinion gear.
Direct
Power
Power
Coupling
input:
sun
output:
gear,
ring
gear
planetary
carrier
Reverse Rotation
Power input: sun gear
Power output: ring gear
Stationary: Planetary carrier
When the planetary carrier is fixed in position
and
the sun gear turns, the ring gear turn on its axis
and the rotational direction is reversed.
http://www.servocity.com/html/plane
tary_gearbox.html
References
1.
2.
3.
4.
5.
6.
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105
Topics
1. Wheels
1. Types
2. Alignment Parameters
2. Steering
1. Geometry
2. Types of Steering Gear Box
3. Power Steering
Types of wheels
i.
Wheels [4]
ii.
Wire Wheel
Comprises hub, spoke and rim made of iron
Spokes connected between hub and rim
Tyre-tube rests on rim
Mostly used in motor-cycles
Wire Wheel[4]
Alloy Wheel[4]
[4]
Camber[5]
Angle made by the tire/wheel
with respect to the vertical in
the front view of the vehicle
Approximately 1
Types
Positive top of wheel tilted
away from vehicle; used in
most vehicles
Negative top of wheel tilted
towards the vehicle; used in
off-road vehicles and race
vehicles (which sometimes use
zero camber also)
Toe[5]
Defined as the difference of the
distance between the leading edge
of the wheels and the distance
between the trailing edge of the
wheels when viewed from above
Toe-in front of the wheels are
closer than the rear
Toe-out rear of the wheels are
closer than the front
Rear wheel drive: front wheels
have slight amount of toe-in
Front wheel drive: require slight
toe-out
Toe-in &
[5]
Toe-out
Caster
During turn, cornering force acts to wheel axis through contact patch
Creates torque about the steering axis tending to centre the wheel
Example shopping cart, wheels free to turn around the axis, self-align
Steering
References
1.
2.
3.
4.
5.
6.
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129
Topics
1. Use of the following fuels in automobiles
1.
2.
3.
4.
5.
Natural Gas
LPG
Bio-diesel
Gasohol
Hydrogen
Natural Gas
Constituents 80 to 90% methane; rest higher HCs, primarily
ethane
Advantages
Clean, non-toxic and non-corrosive, safer
produces lesser CO2, CO and volatile than any other fossil fuel
combustion produces no significant aldehydes or other air toxins as petrol
CNG tanks suffer less damage, high self-ignition temperature (540C)
Performance
More efficient than SI engine
Low energy density, compressed to a pressure of 200 to 250 ksc
On energy basis, 1 kg of natural gas is equivalent to
1.349 liters of Petrol
1.18 liters of Diesel
[1]
LPG
Primarily Propane and Butane (more in winter
and more in summer respectively) [6]
Heavier than air
LPG system[1]
Fuel properties[1]
Optimization points
CNG System
LPG System
Emission
Compression ratio
Air-Fuel ratio
ECU
Air-Gas valve
Vehicle drivability
Ignition timing
Vehicle performance
Gasohol[4]
WHY HYDROGEN ?
Potentially an inexhaustible supply of energy
Can be produced from several primary energy sources
Reduced dependence on petroleum imports if produced
from coal or renewables
Potential environmental benefits
High energy conversion efficiency by use of H2 in Fuel
Cells(UPTO 90%) in place of I.C. engines (30-35%)
HYDROGEN GENERATION
PROCESSES
Steam reforming of Natural Gas/Naphtha
Partial oxidation of hydrocarbons
Thermal cracking of Natural Gas
Coal/Bio mass Gasification
Electrolysis Electricity from renewable sources like
solar, wind, hydel etc.
HYDROGEN PRODUCTION
World wide production
From Natural gas (mostly steam reforming) - 48%
Oil (mostly consumed in refineries) 30%
Coal 18%
Electrolysis 4%
Nearly all H2 production is based on fossil fuels at present.
STORAGE OPTIONS
Storage as gas under pressure (250 350 bar)
Cryogenic storage as liquid hydrogen
(Temp. 253 0 C)
Storage as metallic hydrides
Carbon adsorption and glass microsphere
storage techniques (under development)
HEVs are having high efficiency internal combustion engines with batteries.
Batteries supplement power to the engine during acceleration and hill climbing.
Combined electric and mechanical drives make them costly and complex.
Alkaline (AFC)
Phosphoric Acid
(PAFC)
Solid Polymer
(PEMFC)
Moltan Carbonate
(MCFC)
Solid Oxide
(SOFC)
Direct Methanol
(DMFC)
Temp.C
Application
70-90
150-210
Space
Commercially available
70-90
Automotive application
550-650
Power generation
1000-1100
Power generation
70-90
Under development
Proton exchange membrane (PEM) variety has emerged as the best design
GM has obtained nearly 400 patents in PEM technology
SOFC together with and on-board gasoline fuel processor or reformer would be
suited as auxiliary power units (APUs)
Replacement of low efficiency alternator in automobiles
BMW, Renault and Delphi are pursuing this approach
Batteries
Fuel
Fuel
Cell
Power
conditioner
AC/DC
Drive
motor
Accessories
Wheels
Bridging Strategy :
conventional
References
1.
2.
3.
4.
5.
6.
7.
7/10/2012
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