This document presents a project on designing and building a spark plug testing machine. A group of 5 students designed the machine under the guidance of Mr. V. Ganesh. The machine tests spark plugs by checking if they are accepting current and firing properly. It can also clean and repair spark plugs. The design includes specifications like a working air pressure of 5-16 kg/cm2 and a power supply of 220V AC with an output voltage of 12-19kv. Regular testing and replacement of underperforming spark plugs provides benefits like lower emissions, better fuel economy, and trouble-free engine operation. The machine allows for efficient testing of spark plugs.

1. Major Project
on
Spark Plug Testing Machine
By
• B.Shravan(11PQ1A0310)
• M.Prabhakar Reddy(11PQ1A0323)
• R.Sridhar(11PA1A0333)
• B.Ashok(11PQ1A0307)
• Under esteemed guidance of Mr.V.Ganesh

2. Contents
•Introduction
•Working plan
•Working design
•Specifications
•Defects in spark plug
•Working operation
•Benefits of testing
•Conclusion

3. Introduction about Spark plug
• A spark plug is a device for delivering electric current
from an ignition system to the combustion chamber of a
spark-ignition engine to ignite the compressed fuel/air
mixture by an electric spark.
• Spark plugs usually require voltage of 12,000–25,000
volts or more to 'fire' properly, although it can go up to
45,000 volts.

4. Spark plug anatomy

5. What does the tester do!!
•The Spark plug tester performs the following functions to
check the proper working of the Spark plug.
• Checks if the Spark plug is accepting current from the
wires that go to the spark plug.
•Proper firing of the Spark plug.
•Repairing/cleaning the spark plug.

6. Block Diagram of Work Plan
Study on Spark Plug
and its Efficiency with
respect to usage and life
Design Solution for
performance
improvement and
efficiency losses
Fabricating the
machine
Designing the machine Operation of the
machine

7. Working Design

8. Specifications
• Working Air Pressure : 5kg/cm2 – 16kg/cm2
o For Cleaning the Plug - 5kg/cm2 – 16kg/cm2
o For Electrical Testing of the Plug - 10 kg/cm2 – 16kg/cm2
• Power Supply : Input Voltage 220V AC with earth
o Output Voltage 12kv – 19kv (HT voltage)
• Electronic Vibrator : 220V/12V

9. Appearance Symptoms Remedy
 Carbon
deposits
• Dry sooty deposit on
plug.
• Causes misfiring.
• Use a spark plug with
longer core nose.
 Detonation
• Insulators may be
cracked or chipped.
• Leads to piston damage.
• Make sure fuel antiknock
values meet engine
requirements.
 Mechanical
Damage
• Caused by foreign object
in combustion chamber.
• Causes a dead cylinder
or damages piston.
• Remove the foreign object
from the engine.
Defects in spark plug and their remedies

10.  Splash
deposits • Causes misfiring
• Replace the plugs with new
ones or clean and reinstall
the originals.
 Gap
bridging
• Combustion deposits
lodge between electrodes
and bridge the gap
between them.
• Locate the faulty plug and
remove and remove the
deposits between the
electrodes.
 Ash deposits • Light brown deposits
encrusted on the centre
electrodes or both which
may mask the spark
causing misfiring
• Install new valve guides to
prevent seepage of oil into
combustion chamber.
• Also try changing gasoline
brands.
 High speed
gazing
• Insulator has yellowish
glazed appearance.
• Causes misfiring at high
speeds.
• Install new plug.

11. Working operation
• The project which is the modified version of the conventional
method.
• A 230 voltage electric current is supplied and it is stepped down
to 12 voltages which only is compatible with the design of contact
breaker point and it is primary winding.
• Parallelly a motor is connected to a CAM. When the motor rotates
the connected CAM also rotates. The CAM and the contact
breaker point are connected together by an adjusting screw.

12. • The motor and the rotates and so the electric current is
supplied to the contact breaker point and the contact breaker
point opens and the electric current passes on through
winding.
• Now the 12 voltage is stepped up to 12000 voltages using a
High tension coiled (Secondary winding). Now we could test
the spark plug which is our ultimate objective.

13. Testing
• In conventional tester there are three ranges.
• If the violet spark appears it is in the good condition.
• If it is appeared in the “Yellow” range, the spark plug
is fair.
• If it appears in the no spark range the spark plug is
poor and is to be discharged.

14. Cleaning process

15. Spark plug repair or replacement conditions
STARTINGTROUBLE LACK OF ACCELERATION

16. POOR FUEL ECONOMY ENGINE MISFIRING

17. Benefits of Testing Spark Plugs
& Replacing if underperforming
•Low harmful emissions.
•Better fuel economy.
•Orderly making of optional combustions.
•Trouble free and dynamic start.
• Keeps engine healthy.

18. How often should it be replaced
When a routine change persists then do it for every 10,000
kilometers.

19. Conclusion
Operation of an IC Engine requires 3 pivotal elements.
FUELAIR SPARK
Spark plug plays the major role in the working of IC engine ,so it
should be checked in order to the engine healthy

20. Thank you