A-1 (Academic Level Course)
Theoretical Session - 30 Minutes
Online Training Program
Central Farm Machinery Training & Testing Institute
Tractor Nagar, Budni, District – Sehore,
Madhya Pradesh - 466445
Engine
Content
1. About engine
2. Classification of engine
3. General definitions & terminology
4. Working principle of IC engine
5. Different system of engine
6. About tools (General, Special) and Measuring
instruments
7. Measurement of critical component
8. Setting & adjustment
9. Trouble shooting
About Engine
It is a device which converts the thermal
energy of the working substance into useful
mechanical energy
Or
Engine converts chemical energy into
mechanical energy
Or
A machine with moving parts that converts
power into motion.
Classification of engine
On the basis of -
Combustion- Internal , External
Number of cylinder –Single , Multi
Position of cylinder-Vertical, V-type, Opposed, Radial
Arrangements of valve – F, H, T, I, V, L -Head
Fuel used- Solid, Liquid, Gas
Engine cycle- Diesel cycle, Otto cycle
Cooling system- Air, Liquid
Liner –Wet Liner, Dry Liner
Speed –Variable, Constant
Ignition- Spark, Compression
Injection- Direct, Indirect
Piston Motion- Rotary, Reciprocating
Classification of engine
On the basis of number of cylinder
Single cylinder Multi cylinder
Classification of engine
On the basis of disposition of cylinder
Vertical Cylinder, V-Type Cylinder,
Opposed/Horizontal Radial Cylinder
Classification of engine
On the basis of engine cycle
Two stroke cycle engine Four stroke cycle engine
Classification of engine
On the basis of piston motion
Reciprocating piston motion Rotary piston motion
General Definitions
Power
– It is the rate of work done by the machine in
a given period of time.
Horse Power
– It is an international unit of power
measurement years ago, when engines were
being developed, their ability to do work was
compared with the ability of a horse.
– James watt noticed that a horse walks 165
feet in 1 minute lifting the 200 lbs. weight in
the mines. A horse power, therefore, was
considered to be 165 x 200 = 33000 ft.lb.
per minute.
General Definitions
Low Idle Speed
Even to operate a engine without any load, certain HP is
required to run Water pump, Fuel pump, Alternator,
piston, timing gears, crank shaft etc. Low idle is the
RPM at which the engine produces just enough HP to
keep rotating these units & sustain its motion without
vibration.
High Idle Speed
It is maximum speed of engine at no load condition.
Rated Engine Speed
The engine speed specified by the manufacturer for
continues operation at full load.
General Definitions
Top Dead Centre (TDC)
– The position of piston when the piston is in its
topmost position.
Bottom Dead Centre (BDC)
– The position of piston when the piston is in its lowest
position.
Bore
– The inner diameter of the engine cylinder is referred
to as the bore
Stroke
– Distance travelled by the piston in moving from top
dead centre to bottom dead centre or BDC to TDC
General Definitions
Liner Terminology
General Definitions
Clearance Volume
Volume of cylinder (Including the combustion chamber)
above the piston when it is the top dead centre position.
Swept Volume
This is the Volume swept by piston in moving from
bottom dead centre to top dead centre.
vs = /4 x d² x S
Where-
v = Swept Volume (cm³)
d² = Cylinder bore Diameter (mm)
S = Stroke length (mm)
General Definitions
Compression ratio
This is the mixture volume ratio of the volume above
the piston BDC to the volume above the piston at TDC.
Cr = (vs + vc)/ vc
Where-
Cr = Compression ratio A:B
Vs = Swept Volume (cm³)
Vc = Clearance Volume (cm³)
General Definitions
Engine Capacity (cm³)
This is the total piston displacement or the swept
volume of all cylinder.
vd = vs X n
Where-
Vd = Engine capacity (cm³)
Vs = Swept Volume (cm³)
n = Number of cylinder
General Definitions
BMEP-Brake Mean effective pressure
This is the average effective pressure throughout the
whole power stroke, which is necessary to produce BHP
of the engine. It is expressed in Bars or kilo Pascal
(1Bar = 100 kPa )
BMEP = (BHP x 75 x 60/L x A x N) n/2
(Fore four stroke engine)
BMEP = (BHP x 75 x 60/L x A x N) n
(Fore two stroke engine)
Where-
L = Stroke length of piston (m)
A = Cross sectional area of piston (cm²)
N = RPM of engine
n = Number of cylinder
General Definitions
Indicated Horse Power (IHP)
The power developed with in the engine cylinders is
called indicated power. it is usually expressed in kilo
Watts (kW)
IHP = PLAN/4500 x n/2
(for four stroke engine)
IHP = PLAN/4500 x n
(for two stroke engine)
Where :-
P = Mean effective pressure (kg/cm²)
L = Stroke length of piston (m)
A = Cross sectional area of piston (cm²)
N = RPM of engine
n = Number of cylinder
General Definitions
Brake Horse Power (BHP)
– It is the power delivered by the engine and available
at the end of crankshaft.
BHP = IHP-FHP
Frictional Horse Power (FHP)
– It is the power required to run the engine at given
speed without producing any useful work.
FHP = IHP-BHP
General Definitions
Engine torque
– It is the force of rotation acting about the crank shaft
axis at any given instant of time.(It is the rotational
effort)
T=Fxr
Where
T = Engine torque (Nm)
F = Force applied to crankshaft (N)
r = effective crank radius (m)
Backup Torque
– It is the ability of the machine to keep working as the
engine pulls down due to increased load
requirements over and above the maximum power.
General Definitions
Thermal efficiency
– It is the ratio of horse power output of the engine to
fuel horse power.
Thermal efficiency = Output HP/Fuel HP x100
Mechanical efficiency
– It is the ratio of brake horse power to the Indicated
horse power.
Mechanical efficiency = BHP/IHP x 100
Volumetric efficiency
– Ratio of actual volume of air sucked by engine to
theoretical volume.
Working Principle of an engine
Two stroke cycle engine
– In this type of engine one cycle (Suction, Compression,
Power and Exhaust) completed in one revolution of
crankshaft and two time movement of piston (BDC-TDC
and TDC-BDC) and get one power stroke.
Four stroke cycle engine
– In this type of engine one cycle (Suction, Compression,
Power and Exhaust) completed in two revolution of
crankshaft, one revolution of camshaft and four time
movement of piston (TDC- BDC, BDC-TDC and TDC-BDC
& BDC-TDC) and get one power stroke.
Four stroke cycle engine
Four stroke cycle engine
Engine Systems
Air Intake & Exhaust system
– Supply clean air inside the cylinder and
silently emits exhaust gasses outside the
cylinder.
Fuel Supply system
– Supply the clean fuel at fixed time and as
desired pressure and quantity inside the
combustion chamber.
Lubrication system
– Supply the lubricants at all moving parts
and reduce the friction and noise, also
protect against corrosion, extreme pressure.
Engine Systems
Cooling system
– Supply the coolant for heat dissipation and
maintain the optimum working temperature
of engine.
Governing system
– Control the supply of fuel and maintain
speed of engine as required depending upon
varying load and road conditions.
Critical components
Measurements
Following measurements required
Tappet clearance
Oil running clearance
Bumping clearance
Side clearance
Ring groove clearance
Ring end clearance
Valve guide clearance
Liner taperness
Liner ovality
Crankshaft main journal ovality
Crankshaft end float
Crankshaft fillet radius
Tightening torques for different Nuts and Bolts.
Settings and adjustments of single cylinder engine
Tappet setting
Step-1 Rotate the flywheel and bring the rocker arm into dancing position.
Step-2 Rotate the flywheel and bring the valve into fully closed position.
Step-3 Check the gap between the rocker arm and valve tip with the help of
filler gauge. If required, adjust by loosening or tightening the adjusting screw
and tighten the check nut at the set position.
Valve timing setting
Step-1 Rotate the flywheel and bring the piston to top dead centre.
Step-2 Rotate the cam shaft to bring the push rod at dancing position.
Step-3 Mesh the crank gear with the cam gear without any disturbance.
Fuel timing setting
Step-1 Remove the rocker arm cover and high pressure pipe line.
Step-2 Rotate the flywheel and bring the rocker arm into dancing position.
Step-3 Rotate flywheel for one revolution and check the delivery of fuel for
advance or retard, If fuel timing is advanced – add shims and for retarded
timing, remove the shims.
Engine troubleshooting
Problems in engine
Low cranking speed Lack of power
Engine does not start Excessive fuel consumption
Difficult starting Excessive oil consumption
Low engine oil pressure Blue smoke
High engine oil pressure White smoke
Excessive crankcase pressure Black smoke
Poor compression Engine knocks
Misfiring Erratic running
Overheating Vibration
Start and stop
Thank you
PPT- Compiled by
Dev Vrat Kumar
Senior Technical Assistant
