INTERNAL COMBUSTION ENGINES
Addis Ababa University
Institute of Technology
School of Mechanical and Industrial Engineering
Division of Thermal and Energy Conversion
Starting Systems
2
Starting Systems
3
Starter motor
4
Ignition Systems
5
Ignition Systems
6
Ignition Systems
7
IGNITION SYSTEM
( SI engines -
Conventional)
• Battery
• Cables
• Ignition switch
• Ignition coil
• High tension cable
• Distributor
• High tension cable
• Spark plug
Ignition Systems
8
Ignition
coil
Ignition Systems
9
Ignition Systems
10
Ignition Systems
11
Ignition Systems
12
Ignition Systems
13
Ignition Systems
14
Ignition Systems
15
Ignition Systems
16
Ignition Systems
17
Induction System
18
Composition
Materials
Cast Iron
Aluminum
Plastic
Manifold Types
Single Plane
Dual Plane
Induction System
19
The air induction system Air delivered to the engine is
consists of the air cleaner, a function of driver demand.
air flow meter, throttle valve,
air intake chamber, intake As the throttle valve is
manifold runner, and intake opened further, more air is
valve. allowed to enter the engine
cylinders.
When the throttle valve is
opened, air flows through the Intake air volume is
air cleaner, through the air measured by using an air
flow meter, past the throttle flow meter directly or air flow
indirectly by monitoring the
valve, and through a well
pressure in the intake
tuned intake manifold runner
manifold
to the intake valve.
Induction System
Main Function
The main function of an engine
intake system is to deliver
combustion air to the engine.
To condition the air, just
particulate removal, to protect
engine parts from airborne
impurities (dirt and other
particulate matter)
Downward movement of the
To reduce noise transmitted piston lowers the air pressure
from the engine intake inside the combustion chamber.
The pressure differential
between the atmosphere and
To give a positive contribution to the inside of the engine forces
the engine performance air into the engine.
Air Cleaner
21
The operating efficiency, good performance and durability of
an engine depend mainly upon its air cleaner.
Air cleaner is a device, which remove harmful particles from
the air, Reduce intake noise, Control backfires (petrol engines)
An IC engine uses large quantities of air for combustion, the
ratio being 14-15 kg of air for every Kg of fuel.
Unfiltered air may contain millions of particles of abrasive
dust and other matter, which could cause rapid wear.
Air Cleaner
22
Air cleaner
Air cleaner used suppress
backfire
Air Cleaner
23
DRY AIR TYPE
There are many types of air Dry Air cleaner the most common type.
cleaners but the types commonly This type of air cleaners contains three
used in tractors are: main parts, such as pre-cleaner, main
housing and cleaning element. All are
sealed into one unit. The air from the
1. Oil wetted mesh type, atmosphere enters from the pre-
cleaner, passes through the cleaning
2. Dry air type and element and goes to the inlet manifold.
3. Wet type or oil bath air cleaners. The paper filter element is cleaned
after 50-100 hours of service.
The following are the advantages of the
OIL WETTED MESH AIR CLEANER dry air cleaner:
1. Easy to service.
It consists of a copper mesh or 2. Good performance in gradient and in
nylon wire wetted with oil to catch rough fields.
the dust particles from the air 3. More efficient at high speeds.
which are made to pass through it.
4. less restriction to air passage.
This type, however, gets clogged
with dust quickly, thus, seriously Its main disadvantages are:
affecting the air flow through it and 5. It is costlier to maintain than an oil
rendering it inefficient in removing bath because the filter elements
the fine particles of dust from the require replacements very often.
air. 6. Sometimes, dust particles enter the
Air Cleaners- Dry type and wet
24 type
Dry type Oil Bath type
Intake manifolds
25
Turbocharger Principles
26
Turbocharger Principles
27
Exhaust System
28
Purpose Components
Reduce the combustion
Exhaust valve
noise
Take the combustion
Exhaust manifold
gases away from the Turbocharger /optional
engine Muffler
Reduce harmful emissions Tail pipe
Removes Heat
Reduce noise levels with a
minimum restriction to
flow
Exhaust System
Exhaust System
30
(Heavy Vehicle)
Absorption type (sound absorbing
material).
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust Systems- Muffler
Reduces the level of exhaust noise
When gas flows through a muffler:
Velocity decreases
Pressure increases
The more effective the silencing – the greater the back-pressure
Muffler selection by manufacturer:
Compromise between noise reduction and back – pressure increase
Straight-through Muffler Reverse-flow Muffler
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust system
Cooling System
45
COOLING SYSTEM
( Liquid cooled )
• Radiator
• Lower hose
• Water pump
• Cooling fan
• Water jacket or
passages
• Thermostat
• Upper hose
Cooling System
46
Cooling System
47
Cooling System
48
Cooling System
49
Cooling System
50
Cooling System
51
Cooling system
52
Water pump
Purpose
Supply coolant from radiator to an engine
Driving mechanism
Belt driven
Gear driven
Materials
Cast iron
Cast alloy
Cooling system
54
Cooling system
55
Cooling system
56
Cooling system
57
58
Cooling system
59
180 F = 82 C
Cooling system
60
Cooling system
61
Cooling system
62
Cooling system
63
Cooling system
64
Cooling system
65
Cooling system
66
Coolant from the thermostat enters the top tank.
Coolant flows down the tube to the lower tank.
Air flow through the fins cools water flowing through the tubes by
way of radiation.
The radiator capacity is determined by horse power & vehicle
design.
Cooling system
67
Cooling system
68
Cooling system
69
Lubrication systems
70
LUBRICATION
SYSTEM
• Oil sump
• Strainer
• Oil pump
• Oil filter
• Gallery or oil
passages
• Lubrication points
Lubrication systems
71
Lubrication systems
72
Lubrication systems
73
Oil Filter
74
If properly maintained, oil filters assure the engine's longevity
and operating reliability.
They have the function of removing mechanical impurities
such as soot, metal abrasion and dust from the oil, in order to
maintain its lubricating properties for as long as possible.
Lubrication systems
75
Lubrication systems
76
Lubrication systems
77
Lubrication systems
78
Lubrication systems
79
Lubrication systems
80
Lubrication systems
81
Oil Pressure gauge & Light
Oil Pressure Gauge
Oil Pressure Light
Oil cooler
83
In addition to lubrication, the engine oil also performs the function of
cooling the engine.
The oil must dissipate the heat as rapidly as possible, so that it does not
become too hot itself. If the oil temperature is excessive, the oil becomes
very mobile and loses its lubricating properties. If the oil film ceases to
adhere to surfaces, considerable damage to the engine may ensue. For
optimum cooling of the oil, oil coolers (heat exchangers) are incorporated
into the oil circuit.
Liquid cooled engine oil
Lubrication System…
84
For optimum heat transfer, the coolant must flow through the
cooling system at as high a speed as possible. The water pump
circulates the coolant rapidly in a closed coolant circuit. It is
driven from the crankshaft via a V-belt.
Centrifugal pumps are used in most cases.
To avoid temperature fluctuations as far as possible, liquid-cooled
engines are fitted with a thermostat.
This device has the important function of keeping the engine at as
constant an operating temperature as possible.
The thermostat switches from the small to the full-flow circuit
when the engine
reaches a given temperature and raises or reduces the amount of
heat being dissipated.
Generally only expansion-element thermostats are used in the
commercial vehicle sector.
Gasoline Fuel system
85
Purpose
To supply clean fuel to the
engine
Components
Fuel tank
Furl filter
Fuel line
Fuel pump
Carburator
Intake manifold
Fuel System for Gasoline Engine
86
FUEL SYSTEM
( Gasoline –
Carburetted)
• Fuel tank with strainer
• Fuel line or pipe
• Fuel pump
• Fuel filter
• Carburettor
Air Carburettor
Filter
1/2
E F
Cockpit
Gauge
Inlet Exhaust
Tank
Pump
Carburettor Fuel System
Injection
Control
Unit ‘Common Rail’
Engine Temp
Engine RPM/TDC
Engine Exhaust Temp Fuel
ECU Throttle Position Injectors
Forward Speed
Air Temps – Inlet & Ambient
Air Filter
Cockpit Throttle
1/2
Gauge E F
Pressure
Regulator
Tank
Pump
Electronic Fuel Injection System
Fuel Tank
Must safely hold an adequate supply of fuel for prolonged engine
operation
Normally mounted in the rear of the vehicle
under the trunk or back seat in a passenger car
Fuel tank capacity varies from about 12 to 25 U.S. gallons (45-95 liters)
Fuel tanks are made of either thin sheet metal or plastic
Metal tanks are made by soldering or welding two formed pieces of
sheet metal together
a zinc alloy is plated to the sheet metal to keep the tank from
rusting
Several components go together to make up the fuel tank assembly:
Fuel Tank
90
Fuel tank filler neck
extension tube on the tank for filling the tank with fuel
Spillback ball
large ball in the fuel tank filler neck to prevent fuel from leaking out of
the vehicle during fillups
Filler cap
sealed to prevent the escape of fuel and fuel vapors from the tank
cap is not vented to atmosphere
Fuel tank baffles
placed inside the tank to keep fuel from sloshing
Fuel tank straps
used to secure the tank to the vehicle
Fuel Tank Assembly
Fuel Pumps
There are two basic types of
fuel pumps:
Mechanical fuel pump
Electric fuel pump
Mechanical fuel pump
Powered by an eccentric on
the engine camshaft
Bolts to the side of the
engine block
Used on carbureted gasoline
engines
Mechanical Fuel pump
93
Purpose
To suck fuel from fuel tank and deliver it to carburetor
One-way One-way
Inlet Valve Outlet Valve
Diaphragm
Driving Cam
PISTON ENGINE – Mechanical Diaphragm Pump
Mechanical Pump
Construction
Rocker arm
metal arm that pivots in the middle
the outer end of the rocker arm rides on the eccentric; the inner end of the arm
operates the diaphragm
Return spring
keeps the rocker arm in contact with the eccentric
Diaphragm
synthetic rubber disc clamped between the halves of the pump body
metal pull rod connects the diaphragm to the rocker arm
Diaphragm spring
when compressed, the spring pushes on the diaphragm to produce fuel
pressure and flow
Check valves
fuel flows easily through the valves in one direction but cannot flow
through in the other direction
valves are situated so that fuel can enter through one valve and exit
through the other
Pump Operation (Intake
Stroke)
Eccentric lobe pushes on the rocker arm
Diaphragm is pulled down, compressing the diaphragm spring
Pumping chamber volume increases
Vacuum created allows atmospheric pressure to force fuel
through the inlet check valve
Pump Operation (Output
Stroke)
Eccentric lobe rotates away from the rocker arm
Diaphragm spring pushes on the diaphragm and pressurizes the fuel in
the pumping chamber
Spring tension controls fuel pressure
Fuel flows out through the outlet check valve
Pump Operation (Idling)
Occurs when the engine is running at slow speeds
The rocker arm is free to slide through the pull rod when fuel
pressure compresses the diaphragm spring
The rocker arm moves up and down while the diaphragm
remains stationary
Fuel filters
99
Designed to protect precision components of the fuel
system
and prevent very fine particles from damaging or
blocking
the fuel system.
Types.
Strainers - course
Filters - fine
Fuel Filters
Used to stop contaminants such as rust, water, and dirt from entering the fuel
lines, hoses, throttle body, injectors, pressure regulator or an other part that
could be damaged
“Sock” filter on the tank pickup tube is used to filter out debris
Second filter is usually located in the main fuel line
Carburetor
101
A carburetor is basically a device for mixing air and fuel in the
correct amounts for efficient combustion.
The carburetor bolts to the engine intake manifold. The air
cleaner fits over the top
of the carburetor to trap dust and dirt. The basic carburetor
consists of the following parts:
Carburetor body. The carburetor body is a cast metal
housing for the carburetor
components.
Usually the main body houses the fuel bowl, main jets, air bleeds,
power valve, pump checks, diaphragm type accelerator pump,
venturis, circuit passages, and float mechanism. The body is
flanged on the bottom to allow the carburetor to be bolted to the
Air horn. The air horn is also called the throat or barrel. It routes
outside air into the engine intake manifold
Diesel Fuel system - Inline
10
Injection Pump
2
P S
Diesel Fuel system
(Ex. unit pump)
103
Fuel Filters
10
4
Water Trap or sedimentor
Filters
10
5
• Most filters have an efficiency rate of over 95%.
• Majority have a cut off size of less than 10 microns.
• Final filters of 4 -5 microns are not uncommon.
• Final filters of 2 microns are also used.
1 micron = 0.001mm
Series Filter
Fuel feed pump and priming
106
Priming
Fuel feed pump
Plunger Type Fuel Feed
Pump
10
7
Fuel Injection Pump
10
8
Main Purpose:
Raise the fuel pressure high enough to inject into the engine
combustion chamber.
Accurately meter the quantity of fuel required.
Accurately time the fuel injection for each cylinder.
Fuel System for Diesel Engine
109
FUEL SYSTEM
(Diesel Engine)
• Fuel tank with
strainer
• Fuel line or pipe
• Fuel feed pump
• Fuel filter(s)
• Injection pump
• Fuel lines
• Injection nozzles
Governor &Delivery valve.
11
0
Function of Governor:
prevents stalling and over-
speeding; and/or
maintain engine speed relatively
constant regardless of load
variations.
The governor increases or
decreases fuel
Prevents drain back.
delivery to maintain engine speed.
reduces dribble
Governors
11
1
Function of Governor:
prevents stalling and over-speeding; and/or
maintain engine speed relatively constant regardless of load variations.
The governor increases or decreases fuel delivery to maintain engine speed.
Classification by Function:
constant-speed governors;
variable or all-speed governors;
limiting or idle and maximum speed governors.
Classification by operating principal:
mechanical (centrifugal);
pneumatic;
hydraulic;
electronic;
or combination of two of the above.
Constant Speed Governor
11
2
Variable Speed Governor
11
.
3
Fuel Injector
11
4
Inject fuel into the cylinder in an atomised state.
Correct spray pattern.
Penetration of cylinder gas.
Caterpillar ECU Fuel Injector
11
5
Direct injection
11
6
Charging Systems
117
CHARGING SYSTEM
COMPONENTS
• Battery
• Cables
• Ignition switch
• Alternator
• Regulator
Functions of Alternators
118
To charge the battery.
Supply the electrical demands of the vehicle once
the battery is fully charged.
Why is alternating converted to direct current? To allow the battery to charge
The diode, both positive and negative: converts AC to DC
The Rotor becomes a electro magnet as it moves cutting the stator
windings producing a EMF the diodes converts it to a DC current.
Components of alternator
119
Components of Alternator
120
ROTOR: Rotating electromagnetic field that cuts the
stationary conductors.
STATOR: A set of stationary conductors that the EMF is
induced into when cut by the rotating magnetic field.
DIODE RECTIFIER: Converts AC produced in the stator to DC
to charge the battery and supply the vehicle’s electrical
requirements.
HEAT SINK: Keep the diodes cool.
SLIP RINGS: The rotary contacts that allows current to be
supplied to the rotor.