2. Engine
What is an āEngineā?
ā¢ An āEngineā is a device which converts one form of energy into
another form. But usually the word engine is associated with a device
that converts Heat energy into mechanical work and are called as
āHeat Enginesā
Definition of āHeat Engineā
ā¢ Heat engine is a device which transforms the chemical energy of a
fuel into thermal energy and utilizes this Mechanical energy into
useful work.
ā¢ Heat engines can be classified into two broad types
1. External Combustion Engines : The combustion takes place
outside the engines . The products of combustion transfer heat to a
secondary fluid which is the working fluid of the cycle.
Example: Steam engines, where steam is the working fluid
2. Internal Combustion Engines : In Internal combustion engines the
products of combustion are directly the motive fluid.
Example: Petrol engines
3. Historical Development of Engines
Lenoir engine (1860)
Free Piston Otto Langen Engine
(1866)
Otto Engine based on Beau De
Rochas Paper (1876)
Brayton engine Atkinson Engine 2 stroke Clerkās Engine (1881)
5. Advantages and
Disadvantages
of Reciprocating
IC engines
Advantages of Reciprocating IC Engines over other engines
ā¢ Absence of heat exchangers, thus improved efficiency
ā¢ Work at an average temperature which is much lower than the
maximum temperature . Thus very high working fluid
temperatures can be employed , resulting in higher efficiency.
ā¢ Can obtain higher thermal efficiency with moderate maximum
working pressure, thus reducing the weight/power ratio.
Disadvantages of Reciprocating Engines
ā¢ Vibration
ā¢ Only certain fuels can be used and fuels used are costly
6. Types of IC
Engines
Cycle of Operation
ā¢ Constant Volume Heat addition Engine or Otto Engine (also called by
the name Spark Ignition Engine/petrol engine)
ā¢ Constant Pressure Heat addition Engine or Diesel Engine (also called by
the name Compression Ignition engine)
Types of fuel Used
ā¢ Engine using liquid fuels like Kerosene, petrol, Diesel, Alcohol
ā¢ Engines using gaseous fuels like CNG, LPG, Bio gas etc.
ā¢ Engines using solid fuels like Charcoal powdered coal etc
ā¢ Engines using two fuels
Method of Charging
ā¢ Naturally aspirated Engines
ā¢ Supercharged Engine
Number of stroke
ā¢ 2 stroke engines
ā¢ 4 stroke engines
7. Engine design
Considerations
Load Factor
ā¢ The first step in designing a new engine is to choose the desired
rated power output and rated speed.The load factor must be
considered in choosing the speed. ā
8. Wankel Engine
ā¢ Designed by German engineer FelixWankel in 1954
ā¢ Extremely lightweight and small when compared to engines with
similar power output.
ā¢ Works on the same principle as the 4 stroke engine . In Wankel engine
the term Phase is used to describe a stroke to avoid confusion.
ā¢ Wankel Engine has 2 moving parts. One rotor and one eccentric Shaft.
ā¢ Internal and external timing gears are provided on the rotor and the
eccentric shaft and are designed to maintain a constant phase relation
between the two.
ā¢ Each phase takes place after 90Ā° movement of the rotor. Usually
eccentric shaft rotates at 3times the speed of rotor and thus for every
270 Ā° movement phase changes
Cycle of Operation of Wankel Engine
9. Cylinder vs.
Rotary Engines
Reciprocating Cylinders
ā¢ Uses pistons to regulate intake and exhaust of fuel
and gas.
ā¢ All four strokes, intake compression, combustion
and exhaust occur in same cylinder.
ā¢ Pistons continually reverse direction
ā¢ Lower rev limit
Rotary Wankel Engine
ā¢ Has a spinning rotor that creates three separate
chambers and regulates the inflow and outflow of
gasses.
ā¢ Each chamber draws in air and fuel, is
compressed, ignited and combusted then
expelled creating power while at the same time
forcing the other two chambers to do the same.
ā¢ Rotors move in a continuous direction making it
smoother
10. Advantages over reciprocating engine
ā¢ The piston in a four stroke-cycle reciprocating engine
must momentarily come to rest four times per cycle as its
direction of motion changes. In contrast, the moving parts
in a rotary engine are in continuous unidirectional motion.
ā¢ Higher operating speeds. Thus twice as much power
output as a reciprocating engine of same weight.
ā¢ Ease of balancing, and absence of vibration
Disdvantages over reciprocating engine
ā¢ Sealing, leaks from the apex seals greatly reduces
efficiency of the engine.
ā¢ High Operating Temperature, the housing operates at
steady state with constant heating in each chamber.
ā¢ Low fuel efficiency and shorter engine life due to
damaged seals.
11. Geometry
of Wankel Engine ā¢ The housing inner surface has a mathematical form
known as a Trochoid or Epitrochoid
ā¢ The ratio of radius of fixed rotor to radius of rotating
rotor is 2:3
ā¢ The centre of the rotating rotor follows a circle . The
distance between the centre of fixed rotor and the
centre of rotating rotor is called Eccentricity.
ā¢ The ratio of the radius of the rotor divided by the
eccentricity of the engine is called K factor
ā¢ K factor for a Wankel engine is usually maintained
between 6-10
12.
13. Engine Block
ā¢Foundation of the engine and contains pistons, crank
shaft, cylinders, timing sprockets and sometimes the cam
shaft.
ā¢The cylinder head is mounted on cylinder block .Water
jackets or air fins are provide on the engine block for
cooling.
ā¢Material-Cast Iron / Aluminium (Grade 319 (7% Si, 1%
Fe, 3.5% Cu, 0.5% Mn, 0.35% Ni, 1% Zn, 0.25%Ti)
ā¢Manufactured by Casting
Components of an reciprocating Engine
14. Components of an reciprocating Engine
Piston
ā¢Cylindrical component fitted into the cylinder
forming the moving boundary of combustion
system
ā¢With the help of lubricant and piston rings it
provides a gas tight space between cylinder
ā¢Through connecting rod, forces
the crank shaft to rotate.
ā¢Materials-Cast Iron/Aluminium alloy
(hypereutectic alloys)
ā¢Manufactured by casting/ forging
15. Piston Rings
ā¢Piston rings are fitted into the slots around the
piston. They provide tight seal between piston and
cylinder, thus preventing leakage and gases
ā¢Four stroke: Three rings Top two are compression
rings (sealing the compression pressure in the
cylinder) and the third is an oil ring (scrapes excessive
oil from the cylinder walls)
ā¢Two Stroke: Two Rings Both the rings are
Compression rings
ā¢Material- Cast Iron
ā¢Manufactured by Forging
Components of an reciprocating Engine
16. Crank Shaft
ā¢Converts reciprocating motion of
piston
ā¢into rotary motion of the output
shaft
ā¢Crankshaft of single cylinder
engine contains a pair of crank arms
and balancing weights, which are
provided for static and dynamic
balancing of the system
ā¢Materials- Alloy steels/ Cast Iron
(alloying elements are manganese
,chromium, Molybdenum, Nickel,
Cobalt,Vanadium
ā¢Manufacturing Method- Forging
Components of an reciprocating Engine
17. Connecting Rod
ā¢Interconnects the piston and the crankshaft and
transmits the gas forces from piston to crankshaft
ā¢Two ends of Connecting rod are called small end and
big end
ā¢Small end is connected to Piston by Gudgeon Pin
ā¢Big end is connected to crankshaft by Crank Pin
ā¢Material- Alloy Steel (42CrMo4, 43CrMo4, 44csr4,
C-70, EN-8D, SAE1141)
ā¢Manufactured by Forging
Components of an reciprocating Engine
18. Flywheel
ā¢Attached to the crankshaft
ā¢The net torque applied on the crankshaft
during one complete cycle of operation of the
engine fluctuates . In order to achieve a
uniform torque, flywheel is used
ā¢Transfers power from engine to Drive train
ā¢Material- Cast Iron
ā¢Manufactured by- Forging
Components of an reciprocating
Engine
19. Hybrid Vehicles
ā¢ Hybrid vehicles are the vehicles, which run on at-least one
alternate source of energy and gasoline. Most of the time that
other alternate source of energy for hybrid cars is electricity
(rechargeable batteries) hence those are called electric hybrid
cars. These new hybrid cars are innovative, efficient and
affordable
Example: TVS Luna, a moped is type of hybrid because it
combines the power or a gasoline engine with the pedal
power of its raider
ā¢ Hybrid electric vehicles (HEVs) are powered by two energy
sources An energy conversion unit such as a combustion engine
or fuel cell. And energy storage device such as batteries ,ultras
capacitors, fly wheels. A gasoline, methanol, compressed natural
gas, hydrogen, or other alternative fuels may power the energy
conversion unit.
Advantages over Common IC engines
ā¢The nature of HEV configuration enables
several important advantages over pure
electric vehicles (EVs).
ā¢ Because the HEV engine shares the
workload with the electric motor, it can be
constructed smaller. This reduction in size
call for weight reductions, leading to
greater fuel economy
ā¢HEV engines can be optimized to operate
within a specific speed range characterized
by better fuel economy and reduced
emissions
20. Levels of Hybrid Vehicles
ā¢ There are two types of hybrid vehicles.
ā¢ In one type, the electric motor acts as a side-kick to the gas
engine, assisting it whenever surplus power is needed. The
electric motor alone is incapable of independently operating the
vehicle. Honda's Power Assist technology in its hybrids, Civic
and Insight is an example. Such vehicles are termed as Mild
Hybrids. In mild hybrids, the gasoline engine provides the main
source of power, and the electric motor provides additional
power whenever needed.
ā¢ The second type of hybrid can be termed as a Full Hybrid, where
the gasoline engine and the electric motor can operate the
vehicle separately. In this type, the electric motor can drive the
vehicle at lower speeds. In need of more speed, the gasoline
engine kicks in. Toyota Prius and the Ford Escape implement
the same technology.
Honda Insight
Toyota Prius
21. Components of HV
Engine
ā¢ The hybrid car has a gasoline engine much like the one
you will find on most cars. However, the engine on a
hybrid is smaller and uses advanced technologies to
reduce emissions and increase efficiency
Hybrid battery
ā¢ The batteries in a hybrid car are the energy storage
device for the electric motor. Unlike the gasoline in the
fuel tank, which can only power the gasoline engine,
the electric motor on a hybrid car can put energy into
the batteries as well as draw energy from them.
ā¢ The batteries perform 2 functions: they send energy to
the electric motor and store energy that is being
captured by the generator.
Honda Insight IMA
Toyota 1NZ-FXE engine (left) with early
HS
22. The electric drive, a powerful 96 kW (131 hp) motor, is located on the front
axle. In contrast, the rear axle is driven by a powerful BMWTwin PowerTurbo
1.5-litre 3-cylinder petrol engine with 170 kW (231 hp) of peak performance
and up to 320 Nm of torque; .These two drive systems combine to accelerate
the BMW i8 from 0 to 100 km/h in 4.4 seconds ā with fuel consumption of just
2.1 l per 100 km CO2 emissions of 49 g/km
23. Types of Hybrid Cars
Parallel hybrid car
ā¢ Parallel hybrid systems, which are most commonly produced at present, have both an internal
combustion engine (ICE) and an electric motor connected to a mechanical transmission.
ā¢ Most designs combine a large electrical generator and a motor into one unit, often located between the
combustion engine and the transmission, replacing both the conventional starter motor and the
alternator. To store power, a hybrid uses a large battery pack with a higher voltage than the normal
automotive 12 volts.
ā¢Honda's Insight, Civic, and Accord hybrids are
examples of production parallel hybrids
24. Types of Hybrid Cars
ā¢ Series hybrid car
ā¢ In a series-hybrid system, the combustion engine drives an electric generator instead of directly
driving the wheels.The generator provides power for the driving electric motors. In short, a series-
hybrid is simple, the vehicle is driven by electric motors with a generator set providing the electric
power.
25. Types of Hybrid Cars
Series Parallel hybrid car
ā¢ They incorporate power-split devices allowing for power paths from the engine to the wheels that can be
either mechanical or electrical. The main principle behind this system is the decoupling of the power
supplied by the engine (or other primary source) from the power demanded by the driver.
ā¢ A combustion engine's torque output is minimal at lower RPMs and, in a conventional vehicle, a larger
engine is necessary for acceptable acceleration from standstill. The larger engine, however, has more power
than needed for steady speed cruising. An electric motor, on the other hand, exhibits maximum torque at
standstill and is well-suited to complement the engine's torque deficiency at low RPMs. In a power-split
hybrid, a smaller, less flexible, and highly efficient engine can be used.
29. Fuel Cell Vehicles
ā¢ A fuel cell vehicle (FCV) or fuel cell electric vehicle (FCEV) is a
type of vehicle which uses a fuel cell to power its on-board
electric motor. Fuel cells in vehicles create electricity to power an
electric motor, generally using oxygen from the air and
compressed hydrogen. A fuel cell vehicle that is fueled with
hydrogen emits only water and heat, but no tailpipe pollutants,
therefore it is considered a zero-emissions vehicle.
ā¢ Fuel cells are like batteries but instead of the chemicals being
inside the battery, we get the chemicals from outside. We feed
hydrogen gas into one side. Then an electrochemical reaction
occurs on the electrode to split the hydrogen into hydrogen ions
and electrons. Only the hydrogen ions can transfer through the
cell through the electrolyte. The electrons canāt and have to go
through a different path. At the other electrode, the hydrgoen
ions and electrons combine with oxygen from the air and makes
water, and nothing else like carbon dioxide. The alternative path
of the electrons is an electric current..i.e. electricity.
Toyota Mirai
Honda FCX Clarity
30. How fuel Cells
Work
Types of Fuel Cells
Molten carbonate cells
Solid oxide cells
Direct methanol and other non-hydrogen
cells
Biofuel cells
PhosphoricAcid
Proton Exchange Membrane
Acid and alkaline cells
31. Historical background
ā¢ Electric cars were present in early 20th century, when
electricity was preferred in automobile propulsion.
ā¢ Advances in internal combustion technology, especially
the electric starter, the greater range of gasoline cars,
quicker refueling times, and growing petroleum
infrastructure, along with the mass production of
gasoline vehicles reduced prices of gasoline cars to less
than half that of equivalent electric cars, which led to
the decline of electric propulsion.
ā¢ The energy crisis of 1970s and 1980s brought a
renewed interest in electric vehicles. Further the
global economic recession of late 2000s called to
abandon the fuel inefficient SUVs, in favor of small
cars, hybrid cars and electric cars.
Tribelhorn
32. Electric Vehicles ā¢ A battery electric vehicle (BEV) is a vehicle that is powered by
electricity stored on the vehicle in a battery through the use of one or
more electric motors
ā¢ An Electric car is powered by an Electric Motor rather than a Gasoline
Engine.
ā¢ The Electric Motor gets its power from a controller. The Controller is
powered from an array of rechargeable batteries
Tesla Roadster
Reva
33. Working
ā¢ The heart of an electric car is the combination of the electric
motor ,The motor's controller, The batteries
ā¢ The controller takes power from the batteries and delivers it to
the motor. The accelerator pedal hooks to a pair of
potentiometers (variable resistors), and these potentiometers
provide the signal that tells the controller how much power it
is supposed to deliver. The controller can deliver zero power
(when the car is stopped), full power (when the driver floors
the accelerator pedal), or any power level in between.
ā¢ The signal from the potentiometers tells the controller how
much power to deliver to the electric car's motor. There are
two potentiometers for safety's sake. The controller reads
both potentiometers and makes sure that their signals are
equal. If they are not, then the controller does not operate.
This arrangement guards against a situation where a
potentiometer fails in the full-on position.
PulseWidth Modulation
34. Electric-car Motors
and Batteries
Motors
ā¢ Electric cars can use AC or DC motors:
ā¢ If the motor is a DC motor, then it may run on anything from
96 to 192 volts. Many of the DC motors used in electric cars
come from the electric forklift industry.
ā¢ If it is an AC motor, then it probably is a three-phase AC
motor running at 240 voltsAC with a 300 volt battery pack.
Batteries
ā¢ Electric vehicle batteries differ from starting, lighting, and
ignition (SLI) batteries because they are designed to give
power over sustained periods of time. Deep cycle batteries
are used instead of SLI batteries for these applications.
Traction batteries must be designed with a high ampere-
hour capacity. Batteries for electric vehicles are
characterized by their relatively high power-to-weight ratio,
energy to weight ratio and energy density
ā¢ Rechargeable batteries used in electric vehicles include lead-
acid NiCd, nickel metal hydride, lithium ion, Li-ion polymer
The weak link in any electric car is the batteries. There are
significant problems with current lead-acid battery
technology:
1. They are heavy (a typical lead-acid battery pack
weighs 1,000 pounds or more).
2. They are slow to charge (typical recharge times for a
lead-acid pack range between four to 10 hours for full
charge, depending on the battery technology and the
charger).
3. They have a short life (three to four years, perhaps
200 full charge/discharge cycles).
4. They are expensive
35. Advantages and
Disadvantages
ā¢ Advantages of an Electric Car
1. No Gas Required
2. Savings
3. No Emissions
4. Low Maintenance
5. No Noise Pollution
ā¢ Disadvantages of an Electric Car
1. Short Driving Range and Speed
2. Lack of recharge points
3. Longer RechargeTime
4. Silence as Disadvantage- Can lead to accidents
5. Costly battery Replacement
36. Gas Turbine
ā¢ A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an upstream rotating
compressor coupled to a downstream turbine, and a combustion chamber in between.
GasTurbine components
ā¢ Inlet System Collects and directs air into the gas turbine. Often, an air cleaner and silencer are part of the inlet
system. It is designated for a minimum pressure drop while maximizing clean airflow into the gas turbine.
ā¢ Compressor Provides compression, and, thus, increases the air density for the combustion process.The higher the
compression ratio, the higher the total gas turbine efficiency . Low compressor efficiencies result in high compressor
discharge temperatures, therefore, lower gas turbine output power.
ā¢ CombustorAdds heat energy to the airflow.The output power of the gas turbine is directly proportional to the
combustor firing temperature; i.e., the combustor is designed to increase the air temperature up to the material
limits of the gas turbine while maintaining a reasonable pressure drop.
ā¢ Gas ProducerTurbine Expands the air and absorbs just enough energy from the flow to drive the compressor.The
higher the gas producer discharge temperature and pressure, the more energy is available to drive the power
turbine, therefore, creating shaft work.
37. 37
Simplistic Gas Turbines working principles
1-2 Isentropic compression (in a
compressor)
2-3 Constant pressure heat addition (in a
combustor)
3-4 Isentropic expansion (in a turbine)
4-1 Constant pressure heat rejection
38. Why gas turbines
are not popular? ā¢ Engine clogging problems
ā¢ Very large in size compared to a normal piston engine
ā¢ Very costly to manufacture
ā¢ Exhaust gas posses lot of energy and if not cooled
down might harm the vehicle behind you
ā¢ Very hard to control the speed of the engine
ā¢ High noise pollution
ā¢ Can be used to charge a battery, but highly inefficient.
(this
42. F1 car engines
Air Intake
ā¢ The engine air intake on Formula 1 car is positioned behind
and above the driver's head to capture high-pressure,
relatively undisturbed air. Inside the air intake is an
expansion chamber (diffuser) that slows the air down and
thus increases its pressure ready for its passage into the
engine inlet manifold.
ā¢ The air intake is positioned away from sources of heat,
such as the track and radiators, to minimize the air
temperature. The intake faces the direction of travel to
take advantage of a small ram effect the car induces as it
moves forward through the air.
Mercedes PU106-Type Hybrid
43. F1 car engines
ā¢ F1 cars are usually associated with Pneumatic operated
Valves, where as the normal engines have Spring
operatedValves. The pneumatic operatedValves can
sustain the high RPM of the F1 car engines
ā¢ The F1 cars are fitted with turbo charges which utilizes
the power of exhaust gases to generate electricity ,
which is stored in battery during deceleration.
ā¢ The F1 car engines operate at much higher RPM range
compared to the normal vehicles