Unit II

IGNITION AND INJECTION SYSTEMS

Ignition systems: Ignition fundamentals – Electronic ignition systems – Programmed Ignition -

Distribution less ignition – Direct ignition – Spark Plugs. Electronic fuel Control: Basics of
combustion – Engine fuelling and exhaust emissions – Electronic control of carburetion – Petrol
fuel injection – Diesel fuel injection.

The function of ignition

system is to deliver spark
1. At correct time
2. For correct duration
3. With correct strength
Types of Ignition System
1. Battery Ignition System
2. Magneto Ignition
System
3. Electronic Ignition
System
4. Capacitor Discharged
Ignition System
5. Computerized Ignition
System
Ignition Fundamentals
The ignition system in an internal combustion engine is a crucial component responsible for
initiating the combustion process that powers the engine. Its primary function is to generate and
deliver a high-voltage spark to ignite the air-fuel mixture within the engine cylinders at the
appropriate moment in the engine's cycle. Here are the fundamentals of an ignition system:

Components:
Battery: Provides electrical power to the ignition system.
Ignition Switch: Activates the ignition system, allowing the flow of electrical current.
Ignition Coil: Converts low voltage from the battery into a high-voltage pulse, typically thousands
of volts, necessary to create a spark.
Distributor (or Ignition Module): In older systems, the distributor routes the high-voltage pulse
from the ignition coil to the appropriate spark plug at the right time. In modern systems, an
ignition module or electronic control unit (ECU) performs this function.
Spark Plugs: Each cylinder has a spark plug, which delivers the high-voltage spark to ignite the
air-fuel mixture.
Operation:
The ignition process begins when the ignition switch is turned on, sending electrical power from
the battery to the ignition coil.
The ignition coil then steps up the voltage and generates a high-voltage pulse.
In older systems with distributors, the distributor rotates and sends the high-voltage pulse to the
appropriate spark plug via the spark plug wires at the precise moment when that cylinder's piston
is near top dead center (TDC) on the compression stroke.
In modern systems, the ignition timing is controlled electronically by the ECU, which determines
the optimal timing based on various engine parameters such as engine speed, load, and
temperature.
When the high-voltage pulse reaches the spark plug, it creates a spark across the spark plug's
electrodes, igniting the compressed air-fuel mixture in the cylinder.
Types of Ignition Systems:
Conventional Ignition System: Found in older vehicles, it typically uses a distributor, ignition
coil, points, and a capacitor (condenser) to control the timing of the spark.
Electronic Ignition System: Common in modern vehicles, it replaces mechanical components like
points with solid-state electronics for more precise timing control and reliability.
Distributorless Ignition System (DIS): Eliminates the distributor entirely, using individual coil
packs or coil-on-plug (COP) units directly attached to each spark plug. This design allows for
even greater timing accuracy and eliminates many moving parts, reducing maintenance.
Timing:
Ignition timing refers to the precise moment when the spark plug fires in relation to the position
of the piston. Proper timing is crucial for engine performance, efficiency, and longevity.
It is typically measured in degrees before top dead center (BTDC) for gasoline engines. The exact
timing is determined by factors such as engine speed, load, throttle position, and temperature.
Maintenance:
Ignition systems require periodic maintenance to ensure proper function. This may include
inspecting and replacing spark plugs, spark plug wires, ignition coils, and other components as
needed.
Regular tune-ups, including checking and adjusting ignition timing, can optimize engine
performance and fuel efficiency.
Electronic Ignition System
An electronic ignition system operates within electronic circuits, typically utilising transistors that
are controlled by sensors to generate electric pulses. These pulses, in turn, produce a high-voltage
spark capable of igniting the lean mixture in the engine, resulting in improved fuel economy and
reduced emissions. Fully controlled electronically, the electronic ignition system finds extensive
application in aircraft engines, motorcycles, bikes, and cars, serving the same purpose as other
ignition systems. Its primary function is to generate a high-voltage spark to ignite the fuel-air
mixture in the combustion chamber. By incorporating sensors, the system enhances reliability,
mileage and reduces harmful emissions, making it a preferred choice in modern automotive and
transportation technology.
Construction of Electronic Ignition System

Battery
The battery serves as the powerhouse of the electronic ignition system, providing the necessary
electrical energy for its operation. A lead-acid battery is typically used, which is rechargeable
through the engine's dynamo.
Ignition Switch
As the main switch of the system, the ignition switch allows users to turn the system on and off.
Its negative side is grounded, while the positive side is connected to the primary winding of the
ignition coil.
Electronic Control Module
Functioning as the brain of the electronic ignition system, the electronic control module contains
pre-programmed instructions and monitors the timing and intensity of the spark. It plays a crucial
role in controlling the entire system.
Armature
The armature incorporates a reluctor, which is its rotating part containing teeth. The armature can
make or break the circuit by receiving a regular supply of voltage from the electronic control
module. When the armature tooth contacts the pickup coil, it generates voltage and stops the flow
of current in the primary circuit.
Ignition Coil
The ignition coil comprises primary and secondary windings and is responsible for producing
high voltage for the spark plug. Equipped with a soft iron core, the primary winding has 200-300
turns, while the secondary winding consists of 21,000 turns and connects to the high-tension wire.
Ignition Distributor
In cases where multiple cylinders or spark plugs are used, the distributor helps distribute current.
It contains metallic electrodes on its periphery and a rotor in the center. The metallic electrodes
are linked to spark plugs, and the rotor, driven by the camshaft, passes high tension current to the
ignition harness, facilitating spark plug activation.
Spark Plug
The spark plug emits sparks to ignite the fuel. It has two wires, one connected to a high-tension
current-carrying wire and the other grounded. The potential difference between these wires
creates sparks, leading to combustion.
Electronic Ignition System Working Principle
The electronic ignition system, like other ignition systems, is relatively less complex and easily
comprehensible. When the engine starts running with the ignition switch on, power is supplied by
the battery, grounding the negative terminal and connecting the positive terminal to the ignition
switch. This power is directed to the ignition coil, consisting of primary and secondary windings.
An iron rod between the windings generates a magnetic field. As the armature rotates, connected
to the electronic module, a magnetic pick-up occurs, creating a voltage signal. The voltage signal
intensifies until a strong one is generated.

Next, the voltage is sent to the distributor, housing a rotor and distributor points set as per ignition
timing. As the rotor aligns with a distributor point, the voltage jumps through the air gap from the
rotor to the distributor point and is then transmitted to the adjacent spark plug terminal via the
high-tension cable. This generates a voltage difference between the central and ground electrodes
of the spark plug, leading to a spark at the tip of the spark plug, initiating combustion.

Application of Electronic Ignition System

The electronic ignition system has gained widespread applications and its usage continues to
expand across various industries and vehicle types.
It finds extensive use in modern and high-performance vehicles, including hypercars, where
precision and efficiency are paramount.
Prominent automotive brands such as Audi, Mahindra, KTM, Ducati, and numerous others rely on
the electronic ignition system to enhance engine performance and optimise fuel efficiency.
Beyond the automotive sector, the electronic ignition system is also extensively employed in
aircraft engines, providing reliable and precise ignition control for aviation purposes.
The system's advanced electronic components and programmable features allow for customisation
and adaptation to specific vehicle requirements, making it an ideal choice for a wide range of
applications.
In addition to its widespread use in passenger vehicles and high-performance machines, the
electronic ignition system also contributes to enhancing the efficiency and performance of
commercial and industrial engines.
Its ability to generate high-voltage sparks efficiently and precisely control ignition timing has
made it a preferred choice in the automotive industry for meeting stringent emission regulations
and improving overall engine performance.
Distribution less ignition
Distributorless ignition systems normally consist of one coil per cylinder or one coil for each pair
of cylinders. By using multiple ignition coils, each spark plug in these cylinders will ignite at the
same time. These types of systems are also known as Direct Ignition Systems (DIS).
Components of Distributorless Ignition System
Distributorless ignition system consists of three main components, are as follows:
 Electronic control Module
 A crankshaft position sensor, and
 Distributoress ignition coil
1. Electronic Control Module
Several types of systems use a manifold absolute pressure sensor that is integrated into the
module. The module works in almost the same way as the electronic Spark Advance system.
2. Crankshaft Position Sensor
The crankshaft position sensor is a reluctance sensor located on a reluctance wheel in front of the
flywheel or just behind the front crankshaft pulley. The tooth pattern uses 36–1 teeth, which are
spaced 10 degrees apart for the 36th tooth.

The missing tooth is found at 90 degrees for the number 1 and 4 cylinders before TDC. This
reference position is located a certain number of degrees before TDC to determine the timing or
ignition point as a fixed angle after the reference mark.
3. Distributorless Ignition Coil
The distributorless ignition coil consists of low tension winding that is supplied with battery
voltage to a central terminal. Half of the winding is then connected to the earth in the module. The
high tension windings are different and particular to cylinders 1 and 4, or 2 and 3.

Working of Distributorless Ignition System

The system is generally used only on four or six-cylinder engines because the control system
becomes highly complex for a higher number of cylinders. Basically, It runs on the principle of
the lost spark. The spark distribution is achieved through two double-ended coils, which are
alternately fired by the ECU.
And the Ignition timing is achieved by crankshaft speed and position sensors, as well as load and
other improvements. If one of the coils is fired, a spark is supplied to two cylinders of the engine,
either it maybe 1 and 4, or 2 and 3.
The spark is delivered to the cylinder on the compression stroke which normally ignites the
mixture. Whereas the spark in the second cylinder has no effect, as this cylinder is still completing
its exhaust stroke.
Due to the low compression and exhaust gases in the lost spark cylinder, a voltage of 3 kV is
needed for the spark to pass over the gap. This is similar to the cap voltage of the more
conventional rotor arm. Therefore, the spark generated in the compression cylinder is not affected.

Advantages of Distributorless Ignition System

 By using a distributorless ignition system, it can eliminate wear on the moving
parts of the distributor.
 They work through an engine computer that receives a top dead center signal from
a sensor on the flywheel, so they can quickly adjust spark timing to suit a wider range of
driving conditions.
 One of the most benefits is that they can easily adjust for the fuel that you are
using. For example, if you use a low octane fuel, the computer can sense any detonation in
the engine, and minimize the time it takes to deal with the low octane fuel.
 Because the RPM reference signal is raised directly from the crankshaft, it does
not change as it wears out.
 This can eliminate the need to adjust the ignition timing from time to time.
 Distributor-less ignition systems are very reliable and require less maintenance
cost.
 There is no distributor to drive, which gives less drag to the engines.
Disadvantages of Distributorless Ignition System
 A distributorless ignition system is more difficult to diagnose solid-state
electronics.
 These types of ignition systems tend to be more expensive than conventional
systems.
  It requires high voltage wiring from the coil to the spark plug as in the traditional
system.
 The main drawback of a distributorless ignition system is its sensitivity to heat
loss.
 Distributorless ignition systems are more dependent on sensors. Because, if one
sensor goes off, the whole system will break.

Applications of Distributorless Ignition System

Following are some applications of distributorless ignition systems:
 Vehicles with 1.8 L, 2.8 L VR6, and 2.8 L V-6 engines are manufactured with this
system and have been in use for over a century.
 Volkswagen Passat is the first car to be built with a distributorless ignition system
and so far, the manufacturers are using it in the automobile sector.
 Furthermore, this distributorless ignition system is adopted by some high-end
bicycles such as Ducati super sports.

Direct Ignition system

The Direct Ignition System (DIS), also known as a Coil-On-Plug (COP) ignition
system, is a type of ignition system commonly used in modern engines. It differs from
traditional distributor-based ignition systems in that it uses individual ignition coils for
each spark plug, eliminating the need for a distributor. Here's a description of its
working principle and benefits:

Working Principle:

Individual Ignition Coils: In a Direct Ignition System, each cylinder is equipped with
its own ignition coil mounted directly on top of the spark plug. This means there is
one ignition coil per cylinder.
Triggering Signal: The engine control unit (ECU) sends signals to the individual
ignition coils, instructing them when to generate high-voltage sparks to ignite the air-
fuel mixture in the combustion chamber.
 High Voltage Generation: When triggered by the ECU, the ignition coil generates a
high- voltage electrical pulse. This pulse is then transferred directly to the
corresponding spark plug, which creates a spark across the spark plug gap to ignite the
air-fuel mixture.

Precision Timing: The ECU precisely controls the timing of the spark, ensuring that it
occurs at the optimal moment in the engine's combustion cycle. This timing is based
on various engine parameters such as engine speed, load, temperature, and throttle
position.

Feedback System: Many modern Direct Ignition Systems incorporate feedback from
various sensors such as crankshaft position sensors, camshaft position sensors, and
knock sensors. This feedback allows the ECU to continuously adjust ignition timing
for optimal engine performance and efficiency.

Benefits of Direct Ignition Systems:

 Precision: Offers precise ignition timing for improved performance and efficiency.
 Individual Control: Allows for individual cylinder control, simplifying
diagnostics.
 Low Maintenance: Eliminates distributor-related maintenance, increasing
reliability.
 Longevity: Provides greater durability, contributing to longer engine life.
 Cold Starting: Enhances cold-start performance, especially in colder climates.
 Integration: Seamlessly integrates with modern engine management
systems for optimized performance and emissions control.

Spark Plugs

Spark plugs play a crucial role in the ignition systems of internal combustion engines by
generating the spark necessary to initiate combustion within the engine's cylinders. Their
significance lies in their ability to reliably ignite the air-fuel mixture, which is essential for the
 engine to operate efficiently. Here's a discussion of the significance of spark plugs in ignition
systems and their role in initiating combustion within the engine:

Ignition Spark Generation: Spark plugs are designed to generate an electrical spark across a
small gap between two electrodes when subjected to high voltage. This spark occurs at the
precise moment determined by the ignition timing and is responsible for igniting the
compressed air-fuel mixture within the combustion chamber.

Efficient Combustion Initiation: The spark produced by the spark plug initiates combustion
by igniting the air-fuel mixture. This ignition process triggers the rapid expansion of gases,
resulting in the power stroke that drives the engine's pistons and generates mechanical energy.

Reliable Performance: Spark plugs are engineered to provide consistent and reliable ignition
performance under various operating conditions, including extreme temperatures, high
pressures, and rapid engine speeds. They must maintain their ability to generate a strong and
consistent spark over their lifespan to ensure smooth engine operation.

Optimized Engine Performance: The performance of spark plugs directly influences the
efficiency, power output, and emissions of the engine. Properly functioning spark plugs
contribute to optimal combustion, leading to improved fuel efficiency, engine power, and
overall performance.

Emissions Control: The ignition process initiated by spark plugs affects the combustion
efficiency and emissions produced by the engine. Efficient combustion facilitated by spark
plugs helps minimize harmful emissions such as unburned hydrocarbons (HC), carbon
monoxide (CO), and nitrogen oxides (NOx), contributing to environmental sustainability.

Engine Smoothness and Stability: Spark plugs play a crucial role in maintaining engine
smoothness and stability by ensuring consistent and timely ignition of the air-fuel mixture in
each cylinder. This contributes to smooth engine operation, reduced vibrations, and enhanced
driving comfort.

Longevity and Durability: Modern spark plugs are designed to withstand the harsh conditions
within the engine's combustion chambers, including high temperatures, pressure, and
chemical
exposure. They are constructed from durable materials that resist wear and degradation over
time, ensuring long-lasting performance.

Petrol fuel Injection systems

Petrol fuel injection systems are designed to precisely meter and deliver fuel to the
engine's combustion chambers for efficient combustion. There are several types of petrol
fuel injection systems, with the most common being the Electronic Fuel Injection (EFI)
system. Here's an overview of the principles of petrol fuel injection systems and their key
components involved in delivering fuel to the engine:
Fuel Supply System in Petrol Engine

Principles of Petrol Fuel Injection Systems:

Fuel Metering: The petrol fuel injection system accurately meters the amount of fuel
required by the engine based on various parameters such as engine speed, load,
temperature, and throttle position. This precise fuel metering ensures optimal air-fuel
mixture ratios for efficient combustion and engine performance.

Injection Timing: The injection system determines the timing of fuel delivery into the
combustion chamber to coincide with the engine's intake stroke. This timing is crucial for
proper mixing of fuel with incoming air and ignition during the compression stroke.

Atomization: The fuel injector atomizes the liquid fuel into fine droplets, allowing for
better mixing with air and faster combustion. This atomization process contributes to
improved fuel efficiency and reduced emissions.

Optimized Combustion: By delivering fuel directly to each cylinder's intake port or

combustion chamber, petrol fuel injection systems enable more precise control over the
air-fuel mixture, resulting in optimized combustion and improved engine performance.

Components Involved in Petrol Fuel Injection Systems:

Fuel Tank: The fuel tank stores petrol and supplies it to the fuel injection system through
a fuel pump.

Fuel Pump: The fuel pump pressurizes petrol from the fuel tank and delivers it to the fuel
injectors at the required pressure.

Fuel Injector: The fuel injector is a precision valve that sprays atomized fuel directly into
the combustion chamber or intake port of each cylinder. It is controlled by the engine
control unit (ECU) and opens and closes rapidly to deliver precise amounts of fuel.

Fuel Rail: The fuel rail is a pipe that distributes pressurized fuel from the fuel pump to
each fuel injector. It ensures equal fuel pressure is maintained across all injectors.

Engine Control Unit (ECU): The ECU is the brain of the fuel injection system. It receives
input from various sensors such as the throttle position sensor, mass airflow sensor,
oxygen sensor, and engine temperature sensor to calculate the optimum fuel injection
timing, duration, and quantity. It then sends signals to the fuel injectors to control fuel
delivery accordingly.

Sensors: Various sensors provide input to the ECU, helping it to determine engine
 operating conditions and adjust fuel delivery accordingly. These sensors include the
throttle position sensor, mass airflow sensor, oxygen sensor, engine temperature sensor,
and crankshaft position sensor.
Fuel Pressure Regulator: The fuel pressure regulator maintains a constant fuel pressure in
the fuel rail by regulating the flow of fuel returning to the fuel tank. This ensures
consistent fuel delivery to the injectors.

Diesel Fuel Injection systems

Fuel Supply: The diesel fuel is drawn from the fuel tank by the fuel pump and
delivered to a common fuel rail under high pressure. This rail acts as a reservoir that
supplies pressurized fuel to all the fuel injectors.

High-Pressure Pump: A high-pressure fuel pump, often driven by the engine's

camshaft or through an electric motor, pressurizes the fuel to extremely high
pressures, typically ranging from 15,000 to 30,000 psi (pounds per square inch) or
even higher in some modern systems.

Fuel Rail: The pressurized fuel is stored in the common fuel rail, which distributes it
to each fuel injector at the required pressure.

Fuel Injectors: Each cylinder has its own fuel injector, typically located near the
combustion chamber. The fuel injector consists of a solenoid or piezoelectric actuator,
a nozzle, and a valve. When activated by the engine's control unit (ECU), the injector
opens, allowing pressurized fuel to be sprayed into the combustion chamber in a
precise pattern and at a specific timing.

Injection Timing: The ECU calculates the optimal timing for fuel injection based on
various engine parameters such as engine speed, load, temperature, and throttle
position. It sends signals to the fuel injectors to open at the precise moment needed to
achieve efficient combustion.

Injection Pressure Control: The ECU also controls the duration and pressure of fuel
injection, adjusting them according to the engine's operating conditions to optimize
fuel combustion, reduce emissions, and improve performance and fuel efficiency.

Multiple Injections: Some modern diesel engines utilize multiple injections during
each combustion cycle to further optimize fuel combustion and reduce emissions.
These injections may include a pilot injection, main injection, and post-injection, each
occurring at different points in the combustion cycle.

Common Rail System Benefits: The Common Rail Injection System offers several
advantages, including precise control over fuel injection timing, quantity, and
pressure, leading to improved engine performance, fuel efficiency, reduced emissions,
and quieter operation compared to older diesel fuel
injection systems.