MEC 306 AUTOMOBILE ENGINEERING

Unit I

Dr.T Ashok Kumar ME., Ph.D.,

SAP/SoME
SASTRA University

17-09-2021 Progress Through

Through Quality 1
Progress Quality
Education
Educat
UNIT I ENGINE AND AUXILIARY SYSTEMS 12 Hours

Introduction, Vehicle classifications; Engine components-

details; Performance Enhancement – turbocharger; Engine
Auxiliary System: Fuel supply system (SI engine) – SU electrical
fuel feed pump, carburetion - principle, Solex carburetor,
gasoline injection (single point, multipoint ); Fuel supply
system (CI engine): fuel feed pump, injection pump, injection
nozzle, injection system - inline, distributor, Common Rail
Direct Injection (CRDI), Governor in diesel engine; Lubrication
System – pressurized lubrication system, lubricants properties,
oil cooler; Cooling System – types, pressurized cooling system,
coolants, antifreeze agent.
GOVERNOR
Method governing-Hit and miss governed engines, quantitatively
governed engines and qualitatively governed engine

Governor is mechanical device, designed to control the soeed of

the engine with in specified limit., used on tractor or stationary
engine for

1. Maintaining a nearly constant speed of engine under different

load conditions

2. Protecting the engine and attached equipment against high

speeds, when the load is removed or reduced
Types of governors
1. Centrifugal governor
2. Pneumatic governor
3. Hydraulic governor
Hit & Miss Governing
• This method is suitable for small gas engines.
• In this system, the rotational motion of the cam actuates the rocker
through the roller.
• The rocker carries a pecker, which strikes against the pecker block and
lifts the valve against the pressure of the spring.
• At very high speed, the pecker block is lifted by the rod due to rise up
of governor sleeve resulting the engine performs an idle cycle because
no fuel is now being supplied.
• This method of governing is quite simple but owing to the violent
explosions.
• This usually occurs as a result of extra scavenging which takes place
immediately after “missed explosion’.
• It produces uneven turning moment necessitating the use of heavy
flywheel which increases the friction at the bearing.
• Hence it lowers the mechanical efficiency of the engines.
• Qualitative Governing
• This method is widely used in all heavy oil engines.
• Besides being always used on two-stroke cycle engines in
which the air-fuel mixture has to be admitted to the engine
cylinder to drive out the burnt charge of the previous cycle.
• In this governing method, under the action of the
centrifugal governor, the amount of fuel entering the
cylinder is varied.
• This is done by altering the stroke of the Oil Pump or by
passing a part of fuel.
• This would have otherwise been injected into the engine
cylinder back to the oil tank or by delaying the closing of the
suction valve in the fuel pump.
• Quantitative Governing
• In this governing method, the quantity of air-fuel
mixture flowing into the cylinder is varied accordingly.
• This may be done by decreasing the lift of the inlet
valve.
• Secondly, by throttling the mixture before it is made to
enter the engine cylinder.
• This method is largely used for governing petrol and
big gas engines.
• Besides this information, you are suggested to read
something more from below engineering books
• Governor regulation

The governor is fited on an engine for maintaining a constant

speeed , even then some variation in speed is observed at full
load and no load conditions. In normal working , a variation of
about 100 rev/min is observed between full load and noload
conditions for a good governor.

Hence it is possible to regulate the governor to maintain a

higher or lower speed by changing the tention of the spring .
The extent of regulatyion done , is expressed inbterms of
percentage called percentage regulation. This is also called
speed drop. It is the variation in the engine speed between full
load and no load condition. It is usually expressed as percentage
of rated
speed. This is given by
Learning Objectives
As a result of this chapter, you will be able to:
1. Describe the functional relationship between the engine
control governor and the fuel injection system.
2. Explain how the engine control governor senses changes in
the generator load or demand and compensates by
regulating the fuel delivery to the diesel engine.
3. Describe the primary components of the governing
systems used on EDG units.
4. Explain how the terms isochronous and droop apply to
EDG units.
5. Explain the use of other (digital) governor systems.
Purpose of Governor

The governor’s purpose is to control the fuel to

the engine cylinders so as to control the speed
of the unit, holding the speed constant for all
conditions of load imposed on the generator
being driven by the engine.

In order to maintain the frequency of the

generator output, the engine speed must be
held constant.
 Purpose of Governor
(continued)
The relationship between the generator output
frequency and the engine speed is expressed by the
formula:
F = N * P / 120
Where F is frequency, N the engine speed in RPM, and
P is the number of poles on the generator.
A 900 rpm engine requires an 8 pole generator to
produce 60 Hz power.
(For 60 Hz operation, N = 7200/P or P = 7200/N)
Basic Governor Elements
Every engine governing system must contain certain basic
elements, whether the simple mechanical type or an
electrical/electronic type. They include:

A speed sensing element

A speed setting (reference) element
An error sensing/correcting element
A power element sufficient to manage engine fuel controls
A compensation/resetting/stabilizing element
A means of determining the method of operation…droop
or isochronous mode (operating in parallel or alone)
 Droop - Isochronous
Relationship
Droop is defined as the percent change in speed as a unit goes
from no-load to rated load condition. It can be expressed as:
Droop (%) = Speed Change * 100 / Rated Speed
Speed Change = no-load speed – full-load speed

Isochronous means iso (same) chronous (time). Each

engine revolution takes the same time… speed is constant.

Unit must be in Droop mode when paralleled to the

offsite power system. Unit is most desirably in
Isochronous when carrying loads on emergency bus
during the emergency situation.
Figure 8-1 Droop-Isochronous Relationship
Basic Governor with Hydraulic Power Piston
COOLING SYSTEM
LUBRICATING SYSTEM
 Lubrication System Types
1. Splash system
2. Pressure Fed or Force Feed system
3. Combination Pressure Fed and Splash system
4. Gasoline Oil Premix type
The followings are the major components for
lubricating system
i. Oil Pressure gauge,
ii. Oil Filter
iii. Oil Pressure Regulator
iv. Oil Strainer
v. Oil Jet
vi. Oil Pump & vii Oil Pressure Switch.
MAJOR COMPONENTS FOR COOLING SYSTEM
1. Radiator
2. Radiator Reservoir Tank
3. Radiator Cap
4. Water Hose
5. Cooling Fan
6. Thermostat
7. Temperature Sensor
Cooling system
• Necessity
• Heat produced in the cylinders are not converted
in to useful mechanical work.
• Useful work at the crankshaft- 20%
• Loss through the cylinder ---------------35%
• Loss through exhaust gases------------ 35%
• Loss in friction----------------------10%
• Quantity of heat given to the cylinders is
maximum .This heat is to be removed from the
cylinder .otherwise it will lead to pre ignition of
the charge
 Contd.
• Excess heat will damage the cylinder wall
• Lubricant also will get burned leads to seizure
• Dissipating the excess heat from the cylinder
walls to maintain the temperature below
certain limits.
• Optimum cooling is important.
 Effect of excess cooling
• Low thermal efficiency
• Low vaporization of the fuel
• Increases the viscosity of the lubricant that
increases piston friction results in loss of
mechanical efficiency
• improves volumetric efficiency
• Total overall efficiency is reduced.
Effect of less cooling
• Thermal efficiency is high
• Volumetric efficiency is low
• Over heating of components leads to seizure
of piston
• Cracks in the cylinder walls may be formed
because of over heating.
• Power out put is improved.
• Vaporization of lubricant oil leads to loss.
Air cooling

• The heat, which is conducted to the outer parts of

the engine, is radiated and convected away by the
stream of air, which is obtained from the
atmosphere.
• In order to have efficient cooling by means of air,
providing fins around the cylinder and cylinder
head increases the contact area.
• The fins are metallic ridges, which are formed
during the casting of the cylinder and cylinder
head
 Contd.
• The amount of heat carried off by the air-cooling
depends upon the following factors:
• (i) The total area of the fin surfaces
• (ii) The velocity and amount of the cooling air and
direction of air
• (iii) The temperature of the fins and of the cooling air.
• (iv) conductivity of material
• Used in tractors of less horsepower, motorcycles,
scooters, small cars and small aircraft engines where
the forward motion of the machine gives good velocity
to cool the engine.
• Provided in some small industrial engines. In this
system, individual cylinders are generally employed to
provide ample cooling area by providing fins. A blower
is used to provide air.
Contd.
Advantages

• Light in weight
• Extreme climate usage (freezing)
• Water scarcity
• No leakage.no maintenance
• Easy starting
Disadvantages
• No uniform cooling (distortion of cylinders)
• Can be maintained with fins parallel to the
axis.
• Coefficient of heat transfer of air is less and
inefficient cooling
Water cooling
• The engine cylinders are surrounded by water
jackets for cooling water circulation
• The hot water goes to the radiator where it
loses heat with air.
• Types
• Thermosyphon system
• Pump circulation system
Thermosyphon system

Courtesy: research gate

 Contd.
• Circulation is by difference in densities of hot
and cold water
• Heat dissipation by conduction and natural
convection
• Rate of heat transfer depends on heat out put
and load on the engine and not on speed of
the engine
Water cooling system

Courtesy: research gate

 Lay out

Courtesy: research gate

Pump circulation system

• One pump is used for circulation driven by belt

from the engine
• Proportional to both load and speed of the engine
• Positive circulation, more efficient ,smaller water
jackets reduces engine size
• Height of the radiator can be minimized
• Can be placed in rear or side of the engine
• Complicated and costly.
 advantages
• Circulation of cooling water is proportional to
both speed and load.
• Radiator header tank can be placed at above
the engine level
• Cooling is efficient when compared with air.
 disadvantages
• Leakage of water through hoses.
• Corrosion problem
• Costly and complicated
• Consumes engine power and increase in
weight.
 Components
• Radiator
Radiator core

With serpentine
Spiral, plane fins
 thermostat
To maintain optimum cooling and over cooling
leads deterioration of engine efficiency
automatically Keeps the temperature of cooling
water to a predetermined value
Bellow type thermostat

Filled with volatile liquid acetone

 Wax type
Copper loaded wax having higher thermal
coefficient is used.
Bellow and wax types
Water pump
 Radiator cap

Source: Mech diesel blogger

 Coolants and anti freeze agents
• Efficient heat transfer and overall corrosion
protection have always been the key criteria
for engine coolants
• To avoid freezing and corrosion of cooling
water
• Additives should
• Miscible with water
• No corrosive action
• Boiling point should be high
• No deposit in water jackets and radiator
 requirements
• basic requirement of an engine coolant is
to transfer heat from the internal combustion
engine to the radiator, where the fluid is cooled by
means of airflow.
• Furthermore, the coolant needs to provide
year-round protection against freezing and boiling.
• materials are used in the modern cooling system
including steel, copper, aluminium, solder, cast
iron, brass, plastics and numerous types of
elastomers. Engine coolants must contain specific
additives (such as corrosion inhibitors) to prevent
damage to all these material
 requirements
• low freezing temperature. It must be below the
evaporation temperature of the coolants in the
evaporator at 5-8 degrees;
• a large heat capacity and thermal conductivity;
• low viscosity and density;
• chemical neutrality to construction materials;
• chemical resistance and harmless;
• low cost and availability
 Contd.
• engine coolant typically consists of a base fluid
and an additive package made up of mostly
corrosion inhibitor additives. The base fluid mainly
determines heat transfer properties, freezing
protection and boiling protection.
• Corrosion protection is mainly determined by the
type and level of corrosion inhibition additives. A
distinction is made between organic inhibitors and
mineral (also called inorganic) inhibitors such as
silicates, borates, nitrites and phosphates
 Contd.
• A traditional coolant contains
mineral/inorganic inhibitors, such as
phosphate, borate, silicate, nitrite and nitrate,
with some regional preference with regard to
different combinations.
• An organic additive technology (OAT) coolant
contains only organic corrosion inhibitors,
such as carboxylates
 types
• Wood alcohol(methyl alcohol)
• Denatured alcohol(ethyl alcohol)
• Glycerine
• Ethylene glycol
 Lubrication system

Purpose:
• Reducing the friction:
• The primary function of the lubrication is to reduce the
friction and wear and tear of two rubbing parts.
• rubbing parts produce friction and continuous friction
generates heat, lead to wear and power loss. This friction
can be reduced by proper lubrication.
• The lubricating oil forms a thin oil film between moving
surface and avoids direct contact and also act as sealing
agent.
• reduces noise produced by the movement of two metal
surfaces.
 Contd.
• Cooling effect: The heat is generated by
piston, cylinder and bearings is removed by
lubricant to a great extent. Lubrication creates
cooling effect on the engine parts and acts as
coolant.
• Sealing effect: The lubricant enters into the
gap between the cylinder liner, piston and
piston rings. Thus it acts as a seal preventing
the leakage of the gas.
• Cleaning effect: Lubrication keeps the
engine parts clean by removing dirt or carbon
from inside the engine.
• Cushioning effect: to reduce vibration and
noise
 Contd.
• Keep surfaces separate under all loads, temperatures
and speeds, thus minimizing friction and wear.
•
Act as a cooling fluid removing the heat produced by
friction or from external sources
•
Remain adequately stable in order to guarantee
constant behavior over the forecasted useful life
Protect surfaces from the attack of aggressive
products formed during operation
•
Show cleaning capability and dirt holding capacity in
order to remove residue and debris that may form
during operation
 Requirements of lubricants
• Viscosity
• Physical stability
• Chemical stability
• Resistance to corrosion
• Pour point
• Flash point
• cleanliness
 Types of lubricants

• Animal oil
• Vegetable oils
• Mineral oil
• Synthetic lubricants
• Greases
• Solid lubricants
 Types of lubrication systems
• Petroil
• Splash
• Pressure
• Pre lubrication
• Dry sump
Wet sump lubrication system
 Splash

Source: automobile engineering by Kirpal singh

Pre
Pressure lubrication

source: The engineers post

 Contd.

Source: learn mechanical

Source: slide share
Wet sump lubrication

Source: slide share