MODULE-III

Introduction to IC Engines
Insight into Future Mobility

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 INTRODOCTION TO SYLLABUS

UNIT- III (8 hours)

 Introduction to IC Engines: Components and Working Principles, 4-Strokes Petrol

and Diesel Engines, Application of IC Engines.

 Insight into Future Mobility: Electric and Hybrid Vehicles, Components of Electric

and Hybrid Vehicles. Advantages and disadvantages of EVs and Hybrid vehicles.

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Any type of engine which derives heat energy from the combustion of fuel and converts it in to

mechanical work is termed as a heat engine.

Heat engines may be classified in to two main types;

1)External Combustion engines (EC engines)

2)Internal combustion engines (IC engines)

In an external combustion engine, the combustion of fuel takes place outside the engine cylinder.

Ex: Steam engines

In an internal combustion engine, the combustion of fuel takes place inside the engine cylinder.

Ex: Petrol engines, Diesel engines.

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ADVANTAGES OF I.C ENGINES OVER E.C ENGINES

 High efficiency

 Simplicity

 Compactness

 Light weight

 Easy starting

 Comparatively low cost

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CLASSIFICATION OF IC ENGINES: 2. Type of the Fuel used

I.C. Engines are classified according to:  Petrol engine.

1. Nature of thermodynamic cycle  Diesel engine.

 Otto cycle engine.  Gas engine.

 Diesel engine.  Bi-fuel engine.

 Dual combustion cycle engine. 3. Number of strokes

 Two stroke engine.

 Four stroke engine.

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 6. Position of the Cylinder
4. Type of Ignition
 Horizontal engine.
 Spark ignition engine, known as S.I. Engine.
 Vertical engine.
 Compression ignition engine, known as C.I
 Radial engines
engine.

 In-line engines
5. Number of Cylinder as

7. Method of Cooling
 Single cylinder engine.

 Air cooled engine.

 Multi cylinder engine.

 Water cooled engine.

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PARTS OF I C ENGINE

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 IC ENGINES
PARTS OF I C ENGINE
 Cylinder

 Piston

 Piston rings

 Connecting rod

 Crank and crankshaft

 Valves

 Flywheel

 crankcase
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[Link]:

 It is made of grey cast iron.

 Fuel is burnt inside the cylinder and power is developed by action of hot gases on the piston.

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[Link] head:

 One end of the cylinder is closed by means of are movable cylinder head which is made of

cast iron with alloying elements such as nickel, chromium, molybdenum, etc.

 Cylinder head houses the inlet & exhaust valves.

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[Link]:

It is a close fitting hollow cylindrical plunger moving to & fro inside the cylinder.

It is made of aluminium alloys for light weight.

The power developed by the combustion of fuel is transmitted by the piston to the

crankshaft through the connecting rod.

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4. Piston rings:

These are metallic rings made of cast iron. They are inserted in to the circumferential grooves

provided at the top end of the piston. Piston rings maintain a gas tight seal between the cylinder

& the piston. They also help in conducting the heat from piston to cylinder.

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[Link] rod:

 It is the link that connects the piston and the crankshaft by means of pinjoints.

 It converts the linear motion of the piston in to rotary motion of the crankshaft.

 Connecting rods are made of alloy steels.

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[Link] & Crankshaft:

 Crank is a lever (made of carbon steel) that is connected to the end of the connecting rod by a

pin joint.

 The other end of the crank is rigidly connected to a shaft known as ‘crankshaft’.

 As the connecting rod oscillates, the crank and hence the crankshaft rotate about an axis.

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[Link]:

 Valves are devices which control the flow of in take an exhaust gases to & from the cylinder.

 They are also called as ‘Poppet Valves’ and are operated by means of cams driven by the

crankshaft through belt or gears

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[Link]:

 It is a heavy wheel mounted on the crankshaft of the engine to maintain uniform rotation of

the crankshaft.

 It absorbs kinetic energy during power stroke & delivers energy during other strokes.

 Fly wheel is made of cast iron.

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9. Crankcase:

It is the lower part of the engine serving as an enclosure for the crankshaft.

It also serves as a sump (reservoir) for lubricating oil.

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I.C ENGINE TERMINOLOGY

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I.C ENGINE TERMINOLOGY
 Bore- inside diameter of the cylinder

 crank radius- Rc it is the linear distance between the shaft centre and crank pin centre. It is equal to

half the stroke length

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I.C ENGINE TERMINOLOGY
Top Dead centre / inner dead centre - it is the extreme position of the piston towards cover
end side of the cylinder.

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I.C ENGINE TERMINOLOGY
Bottom dead centre / outer Dead centre: It is the extreme position of the piston towards the

crank end side of the cylinder.

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I.C ENGINE TERMINOLOGY
Stroke- (L=2rc) It is the linear distance travelled by the piston from one dead centre position to

the another dead centre position. It is equal to twice the crank radius.

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I.C ENGINE TERMINOLOGY
Clearance volume Vc- It is the volume included between the top of the piston and the cylinder head

when the piston is at TDC . It is expressed as a percentage of the swept volume . The piston never

touches the cylinder head

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I.C ENGINE TERMINOLOGY
Swept volume : It is the volume through which the piston sweeps during a stroke.

It is equal to the product of surface area of piston and its stroke length.

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I.C ENGINE TERMINOLOGY
Compression Ratio: It is the ratio of the total cylinder volume to the clearance volume

For petrol engine CR varies from 4:1 to 10:1

For diesel engine CR varies from 12:1 to 22:1

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I.C ENGINE TERMINOLOGY
Piston Speed: It is the distance travelled by the piston per unit time.

Cycle of Operation: It is complete series of events

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 FOUR STROKE CYCLE PETROL ENGINE

Petrol engines work on the principle of theoretical Otto cycle.

 It is also known as constant volume cycle, shown in fig.

 The piston performs four strokes (one each in half revolution of crankshaft) to complete the

working cycle. (in 2 revolutions of crank shaft)

 The four strokes are:

(i) Suction

(ii) Compression

(iii) Working (or) Power stroke

(iv) Exhaust stroke

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FOUR STROKE CYCLE PETROL ENGINE

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FOUR STROKE CYCLE PETROL ENGINE

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SUCTION STROKE  During suction stroke, the inlet valve is open and exhaust

valve is closed.

 The piston moves from cover end to crank end during half

revolution of crankshaft.

 The air-petrol mixture is drawn into the cylinder and

completely fills the cylinder.

 Suction takes place at atmospheric pressure and is

indicated by horizontal line AB in the p-v diagram.

 The process is initiated by ‘cranking’ using external

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COMPRESSION STROKE  During this stroke, both inlet & exhaust valves are

closed. The piston moves from crank end to cover end

during half revolution of crankshaft.

 The air fuel mixture in the cylinder will be compressed

adiabatically as shown by curve BC in the p-v diagram.

 At the end of compression stroke, the air-petrol

mixture is ignited by an electric spark given out by the

spark plug.

 The combustion of the mixture causes increase in

pressure as shown by line CD in P-V diagram. 32

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 During this stroke, both inlet & exhaust valves are
POWER STROKE closed.

 The expansion of gases due to heat of combustion

exerts a pressure on the piston forcing it to move

towards the crank end.

 The expansion of gases is indicated by adiabatic

process DE in the P-V diagram.

 At the end of this stroke, the exhaust valve will

open release the burnt gases to the atmosphere thus

bringing down the pressure as indicated by vertical

line EB in the P-V diagram 33

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EXHAUST STROKE During this stroke, the inlet valve remains closed & the

exhaust valve remains open.

 The piston moves from crank end to cover end

forcing exhaust gases out of the cylinder.

 The process is indicated by the horizontal line BA in

the P-V diagram, thus completing the cycle.

 Thus the cycle is completed in four strokes of the

piston or two revolutions of the crankshaft.

 Thereafter, the entire process repeats itself.

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FOUR STROKE CYCLE DIESEL ENGINE

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FOUR STROKE CYCLE DIESEL ENGINE

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SUCTION STROKE During suction stroke, the inlet valve is open and

exhaust valve is closed.

 The piston moves from cover end to crank end

during half revolution of crankshaft, and draws only

air into the cylinder.

 The energy required for this stroke is obtained by

‘cranking’ only at the time of starting & by the

flywheel while running.

 Suction takes place at atmospheric pressure and is

indicated by horizontal line AB in the p-v diagram.37Dr. Bharath V

COMPRESSION STROKE
 During this stroke, both inlet & exhaust valves are

closed. The piston moves from crank end to cover end

during half revolution of crankshaft.

 The air in the cylinder will be compressed adiabatically

as shown by curve BC in the p-v diagram.

 At the end of compression stroke, diesel is injected

into the hot compressed air as a fine spray by the fuel

injector.

 The fuel will be burnt at constant pressure as shown by

line CD. 38
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POWER STROKE During this stroke, both inlet & exhaust valves are closed.

 The expansion of gases due to heat of combustion

exerts a pressure on the piston forcing it to move

towards the crank end.

 The expansion of gases is indicated by adiabatic process

DE in the P-V diagram.

 At the end of this stroke, the exhaust valve will open

release the burnt gases to the atmosphere thus bringing

down the pressure as indicated by vertical line EB in the

P-V diagram 39
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EXHAUST STROKE During this stroke, the inlet valve remains closed & the

exhaust valve remains open.

 The piston moves from crank end to cover end forcing

exhaust gases out of the cylinder.

 The process is indicated by the horizontal line BA in

the P-V diagram, thus completing the cycle.

 Thus the cycle is completed in four strokes of the

piston or two revolutions of the crankshaft.

 Thereafter, the entire process repeats itself.

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 COMPARISON BETWEEN PETROL ENGINE & DIESEL ENGINE

Petrol Engine Diesel Engine

It works on Otto cycle. It works on diesel cycle.

Air & petrol are mixed in the carburettor before Air only enters the cylinder & diesel is sprayed

they enter into the cylinder. into the hot air.

Cylinder is fitted with a spark plug. Cylinder is fitted with a fuel injector.

Less thermal efficiency and more fuel More thermal efficiency and less fuel

consumption. consumption.
Low compression ratio ranging from 7:1 to 12:1 High compression ratio ranging from 16:1 to 20:1

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 Petrol Engine Diesel Engine

Less initial cost & more running cost. More initial cost & less running cost.
Light weight & occupies less space. Heavy & occupies more space.
Easy to start even in cold weather. Difficult to start even in weather

Used in light vehicles like cars, motor Used in heavy duty vehicles like trucks,
cycles, Scoters, etc. buses, locomotives, etc.

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 COMPARISON BETWEEN FOUR STORKE ENGINE & TWO STROKE ENGINE

Four Stroke cycle Engine Two Stroke cycle Engine

One working cycle for every two revolutions of One working stroke for each revolution of the

the crank shaft. crankshaft.

Requires heavy flywheel because of high torque Requires light flywheel because of more or less

fluctuations. uniform torque on crankshaft.

It has inlet & exhaust valves. It has inlet, exhaust & transfer ports.

Less fuel consumption & high thermal More fuel consumption & lower thermal

efficiency. efficiency.

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 Four Stroke cycle Engine Two Stroke cycle Engine

Requires lesser cooling & lubrication. Requires greater cooling & lubrication.

Less noise while running as the exhaust valves More noise due to sudden opening of exhaust

open gradually. port & release of gases.

Mechanical efficiency is less because of more Mechanical efficiency is less because of less

moving parts. moving parts such as valves, cams.

Used in cars, buses, trucks, etc. Used in motorcycles, scooters, etc.

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 IC ENGINES

IC ENGINE CALCULATION

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BRAKE POWER (BP):

It is the net power available calculated at the crank shaft is called Brake Power.

BP=2πNT/60 KW

Where: N= Rpm of crank shaft

T= Engine torque (in KN-m) =(W -S) R

Where: W= Load on brake drum

S=Spring balance reading

R=Radius of the brake drum

Also FP =(IP - BP) KW

Where: FP= Loss of power due to friction 47

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EFFICIENCIES OF ENGINE :

(i) Mechanical Efficiency

ŋmech= BP/IP*100

(ii) Thermal Efficiency

a. Indicated thermal efficiency

ŋ indicated-thermal = IP/mf*Cv *100

Where: mf =Mass of fuel burnt in Kg/Sec

Cv= Calorific value of the fuel in KJ/Kg

b. Brake thermal efficiency

ŋ Brake-thermal = BP/mf*Cv *100, Where: mf =Mass of fuel burnt in Kg/Sec

Cv= Calorific value of the fuel in KJ/Kg 48

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NOTE:

a. The mean effective pressure is given by

Pm = sa / l N/m2

Where: a=Area of the indicator diagram, cm

l=Base width of indicator diagram, cm

s= spring constant or spring value, N/m2/cm

b. If a brake load is in Kg, Torque on brake drum

T=(9.81*W*R) /1000 KN-m

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 ELECTRIC AND HYBRID VEHICLES

Overview
• What is an EV?
• Components of EV
• Advantages of EV
• Limitations of EV
• What is an HEV?
• Components of EV
• Advantages of EV
• Limitations of EV

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 ELECTRIC VEHICLES

 EV are powered by Electric motors and batteries.

 Existence-Mid 19th Century

 EV have low running cost- Less moving parts for Maintenance

 Propulsion- One or more electric motors

 Energy- Solar panel/battery-Generators

 Eg. Road & Rail Vehicles, Electric aircraft, Spacecraft

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Components of EV
 Traction Battery Pack

 Power Inverter

 Controller

 Electric Traction
Motor

 Charger

 Transmission

 DC/AC Converter

 Battery

 Cooling System

 Charge Port
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 ELECTRIC VEHICLES
Traction Battery Pack
 Storage System-Electrical Energy-DC

 Signal received from controller, Battery-DC electrical energy-Inverter to drive the

motor

 Type of Battery used: Rechargeable battery: Li-Ion batteries

Power Inverter
 DC- AC_ Battery

 AC_used by electric Motor

 Inverter-Recharge the battery

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 ELECTRIC VEHICLES
Controller
 Regulate energy from the battery and Inverter- Electric Motors

 I/P from the Car Pedal- Determines the frequency variation or voltage variation which
enters into motor and determines the car speed

Electric Traction Motor

 Controller provides electrical power from the traction battery

 Electric traction motors will work turning the transmission and wheel.

Charger
 Battery Charging device

 Charger get electricity from outside sources- Utility grid , Solar power plants
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 ELECTRIC VEHICLES
Transmission
 Transfer mechanical power from electric traction motor to drive the wheels

DC/AC converter
 Convert higher-voltage DC power from the traction battery pack to the lower-voltage DC
power needed to run the vehicle accessories and recharge the battery

Battery
 The auxiliary batteries provide electricity to power vehicle accessories

Thermal cooling system

 Maintains the temp range of the engine, electric motor, power electronics, and other
components.
Charge Port
 It allows the vehicle to connect an external power supply in order to charge the traction battery
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 ELECTRIC VEHICLES
Working Principle
 Controller takes and regulates electrical energy from the battery and inverter

 Inverter sends a certain amount of energy to the motor (Depth of the pressure on the
pedal)

 Electric motor converts electric energy onto mechanical energy

 Rotation of the motor rotates the transmission so the wheels turn and then the car
moves.

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Advantages of EV ELECTRIC VEHICLES
 No fossil fuel is required

 EV are energy efficient

 EV are more convenient

 Eco-friendly

 Low maintenance due to an efficient electric motor

Limitations of EV
 Recharge points

 Electricity is not free

 Silence is a disadvantage

 Battery replacement

 Short driving range and speed

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 HYBRID ELECTRIC VEHICLES (HEV)

What is an HEV?
HEV – Hybrid Electric Vehicle
A vehicle that has two or more energy conversion technologies combined
with one or more energy storage units.

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 HEV Objectives
Objectives the HEV wants to obtain:
• Maximize fuel economy
• Minimize emissions
• Minimize propulsion system cost to keep affordable
• Maintain acceptable performance with a reasonable cost
• Reduce the conventional car weight

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 HEV: Hybrid electric vehicles are powered by an internal
combustion engine and an electric motor, which uses
energy stored in batteries

 A hybrid electric vehicle cannot be plugged in to charge

the battery. Instead, the battery is charged through
regenerative braking and by the internal combustion
engine.

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Working of a Hybrid Electric Car

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Key Components of a Hybrid Electric Car

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 Key Components of a Hybrid Electric Car
 Battery (auxiliary)
 DC/DC converter
 Electric generator
 Electric Traction Motor
 Exhaust system
 Fuel filler
 Fuel tank (gasoline)
 Internal combustion engine (spark-ignited)
 Power electronics controller
 Cooling System
 Charge Port
 Traction battery pack
 Transmission
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Battery (auxiliary): In an electric drive vehicle, the low-voltage auxiliary battery provides
electricity to start the car before the traction battery is engaged; it also powers vehicle
accessories.

DC/DC converter: This device converts higher-voltage DC power from the traction
battery pack to the lower-voltage DC power needed to run vehicle accessories and
recharge the auxiliary battery.

Electric generator: Generates electricity from the rotating wheels while braking,
transferring that energy back to the traction battery pack. Some vehicles use motor
generators that perform both the drive and regeneration functions

Electric traction motor: Using power from the traction battery pack, this motor drives
the vehicle's wheels. Some vehicles use motor generators that perform both the drive
and regeneration functions.

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Exhaust system: The exhaust system channels the exhaust gases from the engine
out through the tailpipe. A three-way catalyst is designed to reduce engine-out
emissions within the exhaust system.

Fuel filler: A nozzle from a fuel dispenser attaches to the receptacle on the vehicle
to fill the tank.

Fuel tank (gasoline): This tank stores gasoline on board the vehicle until it's needed
by the engine.

Internal combustion engine (spark-ignited): In this configuration, fuel is injected

into either the intake manifold or the combustion chamber, where it is combined
with air, and the air/fuel mixture is ignited by the spark from a spark plug.

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Power electronics controller: This unit manages the flow of electrical energy
delivered by the traction battery, controlling the speed of the electric traction
motor and the torque it produces.

Thermal system (cooling): This system maintains a proper operating temperature

range of the engine, electric motor, power electronics, and other components.

Traction battery pack: Stores electricity for use by the electric traction motor.

Transmission: The transmission transfers mechanical power from the engine

and/or electric traction motor to drive the wheels.

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Advantages of HEV
Fuel economy

Environmentally friendly

Performance

Higher resale value

Lighter cars

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Limitations of HEV
Cost

Less Power

Rare-earth metals and mining

 Batteries die

Plug-in hybrids require a plug

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