9056

Automobile Engines (9056)
Experiment No.6

EXPERIMENT No.6

1.0 Title:

To Dismantle lubrication system in engine, check components draw the lubrication circuit & assemble.

2.0 Prior Concepts :

Working of engine & its components. Importance of lubrication in Ie engine.

3.0 New Concepts :

Proposition 1 : Engine Lubrication Function:

Primary function of the engine lubrication system is to maintain positive & continuous oil supply to the bearings. Lubrication system performs two more functions l.e. cooling & carrying dirt in to the pump.

Proposition 2 :Properties of Lubricating Oil:

The most important property is viscosity. Viscosity changes with temperature. Lowest temperature at which oil will pour is called its pour point. SAE &API are the two rating which are used in practise.

Proposition 3 : Lubrication System:

Oil, oil filters, oil passages, oil gallery, oil pump, strainer, relief valve, oil cooler, oil pans, oil pressure warning lap.

Concept Structure:

Engine Lubrication

Gear External

Gear Internal

fIIlAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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Automobile Eogines (9056)

Experiment NO.6

4.0 Learning Objective:

Intellectual Skills:

1. To identify & locate lubrication system components.

2. To select proper tools for dismantling & assembling of lubrication system.

3. To draw sketches of lubrication system & its sub system.

4. To understand construction & working of lubrication system, Motor Skills:

1. Ability to dismantle lubrication system.

2. Ability to assemble lubrication system.

3. Ability to draw sketches of lubrication system. 4, Ability to use general & special tools.

5, Ability to check & clean filter.

6. Ability to check lubrication oil.

5.0 Apparatus :

Four stroke diesel! petrol engine, wooden blocks, general & special tools & oil.

VALVE.

MAIN OIL EXCESSIVE

OIL PR'SSSURS OIL ' ORAIN TUBS LINE

, TO FILTER

,f,ig, 6,1. En5illel,!bri~I;(1n !l.!!lgra~\fJat).

6.0 Diagram :

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62

Automobile Engines (9056) Experiment No.6

Lubrication System Operaclcn and Dia,gno'sis J 39

. Camshaft s-urface

. Camshaft journal

t-lyo-autlc lasn adjtfSfG:t

Ottajn tenaloner

6 , Bypass
, verve
(J
a
a ,
, e
.»
, D
,
IJ , ,
, 6
(j Figure 6,2 Oil flow through an engine starts at the oil pump pickup and eventually ends up with the oil dropping back into the oil pan .

7.0 Stepwise Procedure:

Lubrication System Diassembly :

Note: This experiment needs two identical engines, one should be in dismantled condition for another engine follow steps 1 to 5.

1. Run the engine to warm up oil for 15 minutes.

2. Drain oil from pump. Collect it in a glass beaker to inspect.

3. Remove oil pan, oil strainer & filter

4. Remove pump cover

5. Remove pump.

Lubrication System Reassembly:

1. Assemble oil pan, strainer.

2. Assemble oil filter

3. Assemble oil pump.


63


Experiment No.6

Precautions :

1. Use proper tools to avoid damage to parts.

2, Drain oil before starting dismantling of lubrication system.

3. Do not reuse the filter element.

4. Scrap the used gasket

8.0 Observations: Information of Lubrication System

Sr.No. Component Study Key Points to Observe
1. Oil drained Condition of oil -- Check whether this oil can be reused or
needs change?
-- Why engine was warmed up before
draining oil?
-- What is the oil pressure in engine?
-- What grade of oil is used in this engine?
Is this grade is API orSAE? Multigrade or
not?
-- Why oil is changed in new engine
after one month or 1000 kin (so
early)?
-- What is the normal oil change interval.
2. Oil passage Oil passages, route -- How oil reaches farthest end in the
& bypass engine i.e.rocker arm?
-- Where is the maximum oil pressure?
-- How piston & cylinder are lubricated?
-- How oil is returned to the pump?
-- What are the different oil seals?
-- Where oil is given a bypass. Why?
-- Are all oil passages of same diameter?
Explain which is biggest & Why?
3. Oil pump Construction & -- What type of oil pump it is?
working -- How does it get drive?
-- Identify its inlet & Outlet.
-- What parameters are inspected to
check the functions of gear pump?
-- What is the function of pressure
relief valve?
4. Oil pan Construction & -- Why oil pan is given a particular shape?
working -- Why baffles are provided in a oil pan? MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

64


Experiment No.6

5. Oil filter Construction & -- What are various parts of oil filter?
working -- Identify the passage of oil & filteration
process?
-- Are there any seals and by pass vane in a
filter?
-- When engine is shutt off oil may drain out
of filter. Is there any provision to prevent
this to happen?
6. Oil pressure Construction -- Where from the pressure is measured or
guage or & working sensed? Why?
warning lamp 9.0 Conclusion :

1. The lubrication system in all modern car has ..

(gear type pump I rotor type pump I at filter I oil cooler)

2. The approximate oil pressure in the lubrication system in modern cars is .

....................................................... (40-50 kpa /200-400 kpa/1-5 mpa/above 10 mpa)

3. Student shall write conclusion on the basis of passage of lubrication of all components

under the guidance of teacher .

10.0 Questions:

Write answer to Q ... Q ... Q .. Q ... (Teacher shall allot the questions)

1. Why are the extreme pressure additives required?

2. What is the effect of oil dilution on engine performance?

3. Which engine surfaces are most prone to carbon deposit formation? 4. What is the effect of carbon formation?

5. It is said that engine, immediately after starting, should not be raced. Why?

6. Give example of any Indian Car employing positive crankcase ventilation?

7. What are the approximate pressures encountered in a pressure system of lubrication?

8. Where in the engine is the oil pressure switch mounted?

9. What is the approximate period after which oil is changed in the modern cars? 10. What happens if the oil level in the pump is a) too low b) too high?

11.From where is the drive for oil pump obtained?


65


Experiment No.6

12. Why do, we provide relief valve in the lubrication pump?

13, How does an oil pump differ in construction from a coolant pump?

14. Approximately how much resistance to oil flow offered by the oil filter that can be tolerated?

(Space for answers)


66


Experiment No.6

(Space for answers)

Signature of Teacher

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67


Experiment No.7

EXPERIMENT No.7

1.0 Title:

To remove the carburetor from the engine of motor cycle, identify and check the components, draw the circuits and refit.

.2.0 Prior Concepts :

Working of 4 stroke petrol engine of two wheeler and combustion process.

3.0 New Concepts :

Proposition 1 : Carburettor Role in Engine operation

Carburetor is the most important part of the fuel system. It is responsible for fuel economy, emission pick up and starting of engine. It mixes fuel and air in required proportion.

Proposition 2 : Carburettor Assembly :

Carburetor Consists of a float, float chamber, venturi, various jets, choke, carburetor body, needle jet and throttle valve.


68


Experiment No.7

Concept Structure:

Carburetor systemJ
I

Part of Fuel Suitable upto Process of
System EUROI atomisation &
mixing to suit

engine needs

Carburetor Float Throttle Jets
Circuits Hoses
Types Chamber Valve

I I I 1
Fixed Variable Down Up Side
Venture Venture Draft Draft Draft

Starting Idling Prog ressbsn Main MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

69

· Automobile Engines (9056)

Experiment No]

4.0 learning Objective:


1. To identify and locate various carburettor components.

2. To select proper tools for dismantling and assembling of carburettor system.

3. To draw sketches of carburetor system circuits and its components.

4. To understand construction, working and circuits in carburettor. Motor Skills :

1. Ability to dismantle carburettor from vehicle.

2. Ability to dismantle carburettor from vehicle/carburetor.

3. Ability to draw the various circuits.

4. Ability to use general and special tools.

5.0 Apparatus:

Motorcycle engine; general and special tools and vernier, carburetor cleaner chemical.

6.0 Diagram:

NEEDLE JET N-B

Fig.7.1 : Exploded View of Carburettor

"Fuel ~Mixture

.~Air

1- Throttle Valve 2-Jet Needle 3- Needle Valve 4- Main Jet 5- Needle Jet 6- Pilot Jet

Fig. 7.2 : Section View of Carburettor


70


Experiment NO.7


Locate various outer connections and subassemblies of carburettor. Carburetor disassembly:

1. Remove air vent, air drain and "0" ring from frame.

2. Take out spring piston valve.

3. Take out jet needle and washers.

4. Remove chock liver and its valve

5. Remove spring and plunger starter

6. Remove adjuster piston valve and air screw.

7. Remove float bowl, float, its needle valve and valve seats.

8. Remove main jet and jet holder

9. Remove pilot jet

Carburetor assembly:

1. Change damaged gaskets and seals

2. Check jet needle seat.

3. Adjust float level and check its freeness.

4. Reassemble pilot jet and mainjet

5. Assemble needle valve assembly

6. Assemble float assembly

7. Fix the bowl with seal

8. Assemble jet needle observing position of ring

9. Assemble piston valve

10. Tighten air screw

11. Tighten adjuster piston rod.

12. Assemble plunger starter

13. Fix hoses

14. Conduct the tunings

Precautions :

1. Use appropriate tools and torque to prevent damage to aluminiam parts.

2. Do not use compressed air to clean assembled carburetor.

3. Remove rubber parts before using cleaning agent to prevent damage to the rubber parts.

4. Do not use wire to clean holes in carburetor.


71


Experiment No.7

8.0 Observations: Details of Carburettor

Sr. No. Component Study Key Points to Observe
1. Carburetor Type of carburetor 1.What are the specifications of a
carburetor?
2. What are the basic functions of a
carburetor?
3. Up to which emission norms a
carburetor can be used?
2. Float Construction & Does the level of petrol changes in a float
working bowel.
3. Venture Construction & Whether venturi area remains same or
working changes.
4. Throllte valve Construction & Who changes the position of throttle valve.
working
5. Starting circuit Components & 1.What is the air fuel ratio for starting
working 2. What is the position of throttle valve
during, starting circuits.
3. Where from air is given to engine.
4. What happens if choke and accelerator is
given simultaneously?
6. Slow running Components & 1.When it is required?
circuit working 2. What is the position of throttle?
3. How to adjust the idling speed?
7. Progression Components &
Circuit working
8. Main Circuit Components &
working MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

9.0 Conclusion :

1. When the choke is applied the fuel come outfrom the .. " ..

(main jet / idle part / transfer part / progression hole)

2. The venturi in the carburettor causes the .

(increase of air velocity/ decrease of air velocity/decrease of fuel flow / decrease of mainifold vaccum)

72


Experiment NO.7

3. Student shall write conclusion on the basis of opening of throttle valve and control of

air fuel ratio under the guidance of teacher .

10.0 Questions:

Write answer to Q ... Q ... Q .. Q ... (Teacher shall allot the questions)

1. What happens if the mixture supplied to the engine is : (i) weaker (Ii) richer than the optimum in a given condition?

2. Why in the modern carburettors the float chamber is vented to the carburettor air horn

instead of it to the atmosphere?

3. What causes the air to be drawn into the carburettor?

4. What causes the fuel to flow from the main jet in the carbureftor?

5. On what factors does the fuel delivery in a carburettor depend?

6. Why does the air-fuel mixture delivered by a single jet carburettor become richer at

higher spped?

7. What is the function of choke valve in the carburettor?

8. What happens if the choke valve is left closed after the engine is started?

9. Why is the choke valve kept slightly open while cranking the engine?

10. Name any carburettor which uses compensating jet for compensation.

11. How does the weather influence the working of a carburettor?

12. What is the effect of altitude on the mixture strength of a single jet carburettor?

13. What is an anti-dieseling solenoid?

14. What happens if the float of carburettor in a working engine gets punctured? (Space for answers)


73


Experiment No.7

(Space for answers)

• ~ •••••• ," + ••••••• , •••••• - ••• + ••• , .



74


Experiment No.8

EXPERIMENT No.8

1.0 Title:

To open the fuel injection pump and fuel injector, identify components, draw circuits and reassemble.


Difference between petrol injection and diesel injection, petrol and diesel combustion process, properties of diesel and petrol fuels.

3.0 New Concepts :

Proposition 1 : FIP Types and Applications :

Diesel fuel injection pump are basically of three types in line, rotary and unit injector of unit pump. Distributor injection pump or rotary pump is most popular amongst light motor vehicles and heavy commercial vehicles.

Proposition 2 : FIP Sub~Assembles :

There are normally two pumps in any diesel fuel injection system i.e. feed or fuel supply pump (2-3 bar) and high pressure pump (up to 700 bars).

Sub assemblies in Rotary fuel injection pump are vane type fuel supply pump, distributor head with high pressure pump ,pressure control valve, governer assembly, timing device, shutoff valve and injector assembly.

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Experiment NO.8

Concept Structure:

I FIP System I
I

Input Filtered Drive from Mounting & Pressure at Subassemblies
Diesel Engine Location Various Points in Distributor
pump

Vane pump High Governor Fuel I Valves I Timing Injector
(Fuel supply Pressure System Metering Device Assembly
pump) Pump

I Holder I Nozzle

Overflow Pressure Shut Off Delivery Valve
Restriction Control Valve Valve MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

76


Experiment No.8

Proposition 3 : Introduction to flP Faults and Settings:

In FIP faults and setting follOWing are important aspects:

The unfiltered fuel is the single most damaging cause since components as working with a very close tolerance.

Precise calibration of injection pump and governor are must for achieving optimum fuel consumption of low emission.

Injector cleaning and testing need to be performed at some intervals.

Proper fitting of pump on the vehicle is necessary to match with the firing order and injection timing.

4.0 learning Objective:


1. To identify type of FI P.

2. To identify & locate various subassembly & components of distributor type FIP..

3. To draw sketches of components of FI P.

4. To understand construction & working of FIP. Motor Skills:

1. Ability to dismantle the FIP from engine.

2. Ability to dismantle FIP.

3. Ability to assemble FIP.

4. Ability to use general & special tools.

5. Ability to draw sketches of FIP systems & components.

5.0 Apparatus:

Diesel Engine, Distributor type FIP, General & special tools.

6.0 Diagram:

(See next page)


77


Experiment NO.8

9

Fig.8.1 = Fuel Injection Pump Pe Type with GoVernor for 6~ Cylinders

1- Control fork 2- Control rod 3- TappetAssembly 4- Cam Shaft 5- Stop Control Lever 6- Governor Flyweight 7- Governor Sleeve 8- Speed Lever Shaft 9- Crank Lever 10- Governor Main Spring 11- Governor Idling Spring 12- Damper 13-Speed Control Lever 14- Telescopic Link 15- Trip Lever 16 - Bridge Link 17- Excess Fuel Device 18- Maximum Fuel Stop Screw 19- Plunger 20- Delivery Valve 21- Volume Reducer 22- Barrer23- Delivery Valve Holder


78


Experiment NO.8

VENT SCREW

Fig.8.2 : Engine F--'---..I .... ... _u 1:' •• _1 I_: __ &:on for 4 M Cylinder

DELIVER VALVE AND SEAT

DELIVER VALVE AND SEAT

PUMP BARREL PUMP PLUNGER

. .cONTROL ROP. TOOTHED QUADRANT

CdNTROLsLEEVE

fig.8.l : Pump Element in section


79


Experiment No.8


Locate various connections of FIP on vehicle. FIP system disassembly.

1. Remove all the hydraulic connections.

2. Remove unit from the engine.

3. Remove add on equipments like shutt off value, manifold pressure compensetor etc.

4. Remove timing unit.

S. Remove fuel supply pump.

6. Remove distributor head.

7. Remove governor from body.

Assembly.

1. Assemble the governor system.

2. Assemble the timing device.

3. Assemble the distributor head with plunger & barrel.

4. Assemble the add on equipments.

5. Make al the connections.

6. Assemble unit on the vehicle.

7. Remove governor from body.

Precautions :

1. Make sure to drain the fuel before starting dismantling.

2. Make use of proper tools to avoid any damage to the pump.

3. Maintain highest order of cleanliness.


80


Experiment No.8

8.0 Observations: Details of Fuel Injector & Fuel Injection Pump

1. Hydraulic The sealing & types -- How does it seal at such a high pressure?
connections of connections Is there any difference between low
pressure & high pressure lines? How
many return lines are there?
2. Drive to FIP Observe the drive tc -- Is there any difference between drives to
FIP other engine accessories & FIP. Is the FIF
speed is same as engine speed?
3. Vane pump Construction & -- Locate input & output of vane pump.
working What pressure does vane pump
generates? Is this pressure remains
same at all the engine speeds
4. Pressure Type, ConstructionS -- Why it is required & where it is located, on
control valve working low pressure side or high pressure side.
5. Overflow Location, need &
restriction working &
construction
6. High Pressure Construction & -- Which part is most sensitive to the dirt in
delivery working the fuel. What is the lubricant to these
parts.
-- What is the function of the springs?
-- Delect the delivery path.
7. Distributor Construction & - How distributor head is sealed? At what
head working pressure sealing is required?
- What is the function of delivery valve?
& workinq
8. Fuel Metering Construction & - State the arrangement for fuel delivery
working metering
9. Governor Construction & - What is the type of governor normally
working used in vehicles? Why?
- How starting, idle control & operation
under load is achieved in a governor.
10. Timing device Construction & - What is the need of injection timing.
working
11. Add on Construction & - State the need of these add on
working of torque modules
control, shut off
valve MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

81


Experiment NO.8

9.0 Conclusion :

1 . The amount of fuel delivered by the injector depends upon the "" "" .

.................................................... (size of injector nozzle I pressure pushing I fuel through injectorllength of time the injector is open I all factors)

2. The fuel injection timing in a distributor type pump is controlled by .

...................... , , , (changing plunger strokel changing

speed of rotorl rotating the cam ring)

3. Student shall write conclusion on the basis of arrangement for fuel delivery metering under the guidance of teacher.

10.0 Questions:

1. Which component keeps the fuel supply at the specified pressure in the petrol

injection system?

2. What determines the open time of the injector in the electronic injection system?

3. Name the main components of fuel injection system for automotive diesel engines.

4. Where is feed pump usually located?

5. From where does the feed pump get its drive?

6. What is the function of a hand primer? Where is it located?

7. Why the fuel injection pump has to be manufactured with great precision?

8. In a 4 stroke, 4 cylinder diesel engine running at 5000 r.p.m., how many times the fuel

will be injected per second?

9. What is approximately the magnitude of fuel injected per stroke?

10. What is the function of helix in the plump plunger?

11. At some position of the plunger rotation, there is no fuel delivery even when the

injection pump is running? How does that happen?

12. What material is used for the pump housing?

13. How is the injection advanced with increase in speed in an in-line injection pump?

14. What is a distributor type fuel injection pump?

15. How is the amount of fuel entering the rotor of a distributor type injection pump controlled?

MAHARASHTRASTATE BOARD OFTECHNICAL EDUCATION

82


Experiment No.8

(Space for answers)

••• ~ ••••••••••• ~ •••••••••••••••••••••••••••••••••••• ~ • ~ ••••••••••••••••••• T ••••••••••••••••••••••••••••••••• T .


83


Experiment No.8

(Space for answers)

.. ~ .. , ~ ~ ~ ~ , , ~ ~ ~ .. ' , ., ~ , .


84



Experiment No.9

EXPERIMENT No.9

Heat Supplied by Fuel

1.0 Title:

To prepare and understand a heat balance sheet of a single

Heat Lost to

cylinder Diesel Engine by conducting a trail on a test rig. JackelCool!ng

Waler

exhaust gases


Working principles and classification of Internal Combustion (I.C.) Engines. Nomenclature of I. C. Engine.

Indicated Power (I.P), Brake Power (B.P), Frictional Power (F.P), Thermal Efficiency, Mechanical Efficiency and volumetric efficiency.

3.0 New Concepts :

Proposition 1 : Testing of an I.C.Engine :

It is a process in which the engine is tested for various parameters for efficient performance.

The purpose of testing an I.C. Engine is

1. to determine the information, which cannot be calculated by calculations.

2. to confirm validity the data used in design.

3. to satisfy the customer regarding the performance of the engine.

Concept Structure:

Proposition 2 : Classification of testing an l.c, Engine:

There are 3 types of tests.

Commercial Test

Thermodynamic test

P.U.C. test

Concept Structure :


85


Experiment NO.9

Proposition 3 :

Performance parameters of I.C. Engines:

Brake specific fuel consumption, indicated thermal efficiency, Brake thermal efficiency and mechanical efficiency.

Concept Structure:

Performance parameters

4.0 Learning Objectives:

Intellectual skills:

1. To know the importance of testing of I.C. engine.

2. To understand the performance parameters of l.C. engine.

3. To understand the necessity of preparation of heat balance sheet. Motor skills:

1. Ability to start, stop and operate the engine

2. Ability to observe, note and measure fuel consumption, rate of flow of cooing water, various temperatures and engine speed.

3. Ability to adjust fuel supply to keep the engine speed constant at varying load conditions.

6.0 Diagram:

Governor

5.0 Apparatus :

• Complete single diesel engine test rig with brake dynamometer, fuel gauge, temperature gauges, air box, water manometer, water flow meter, etc.

• Tachometer and Stop watch

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86

Fig.9.1 :Diesel Engine Test Rig with Rope Brake Dynamometer


Experiment No.9

Fig.9.2 :Diesel Engine Test Rig with Rope Brake Dynamometer(Side View)

7.0 Specifications:

(Students to see the catalogue and write the specifications and constants)

1. Engine Specifications:

• Type: ..

• Bore: , m ; Stroke : , m

• Power developed : , KW at , rpm

2. Dynamometer specifications:

For Rope brake dynamometer

• Diameter of rope brake drum, D = , m

• Diameter of Rope, d = , m

e Effective radius, r e = (D + d) 12 = = , m

OR

For Hydraulic dynamometer

• Dynamometer constant, K' = .


87


Experiment No.9

3. Orifice Specifications ::

• Diameter of Orifice, d = , m

• Area of Orifice, a = ( 7t 14 ) d 2

a = , m2

• Coefficient of discharge for orifice, Cd = .

4. Properties of Air:

• Characteristic gas constant for air, R, = 0.287 KJ 1 Kg K

• Atmospheric pressure, P = 101.325 , N 1 mm-

• Absolute ambient temperature, tr = , 0 C

5. Properties of Water:

• Specific gravity of water= 1

• Density of Water, Yw = 1000, Kg 1m3

• Specific heat of water, Cp(WI = 4.187 KJ I Kg K

6. Properties of Fuel:

• Specific gravity of Fuel = ..

• Calorific value of fuel, CV:::: , KJ I Kg.


1. Fill up sufficient diesel in diesel tank.

2. check oil level in the engine. It should be up to the top edge of the flat portion provided over the oil dipstick. If oil level is reduced, add up clean SAE - 40 oil to the crank case by opening the valve cover at the top of the engine. Replace the cover after filling the oil.

3. FiJI up water in Manometer up to half of the manometer height.

4. Start the water supply and see that water is flowing through engine jacket, brake drum and exhaust gas calorimeter. Put off the water in brake drum.

5. If diesel tank was empty before filling the diesel, remove air bubbles in fuel pipe, by opening the vent screw provided at the right side, top of the fuel pump.

6. Adjust the load on the dynamometer to zero, by releasing the loading screw, so that there is no tension in the rope.

7. Start the engine. For starting, lift up decompression lever, at the side of the valve cover. Put the handle over the starting shaft and rotate the shaft. As engine picks up sufficient speed, drop the decompression lever. The engine will start. Remove the handle immediately. Allow the engine to get stabilized.

8. As engine picks up speed, start water to the brake drum.

9. Adjust the fuel supply in order to bring the engine to the required speed at which trial is to be conducted (trial is to be conducted at constant speed).


88


Experiment No.9

10. Open burette filling cock, take sufficient diesel in burette and close the cock.

11. Now, turn selector cock to ' BURETTE' position and note down time required to consume certain amount of fuel ( 10 rnl or 20 ml etc) with the help of fuel gauge and stop watch i.e ~ t ' seconds

12. Note down brake drum speed with tachometer.

13. Take manometer reading h, and h2•

14. Measure cooling water inlet temperature ( t10C) and cooling water outlet temperature( ~OC).

15. Measure engine room temperature ( trOC)

16. a) Measure temperature of exhaust gases from the engine ( tg ° C). or

b) If exhaust gas calorimeter is used, then measure,

1. Quantity of water supplied to the exhaust gas calorimeter in lit. I min.

2. Temperature of water inlet to calorimeter ( tc10C).

3. Temperature of water outlet from the calorimeter ( te20C).

4. Temperature of exhaust gas entering the calorimeter ( tg10C).

5. Temperature of exhaust gas leaving the calorimeter ( tg20C).

17. All the readings taken in step no 11,12,13,14,15 and 16 are for zero load. Note these readings in the observation table in the column of zero load.

18. Calculate full load capacity of the engine.

19. Apply certain load (say 1/4th of full load) 0 the dynamometer and adjust the fuel supply to bring the engine to the required speed at which test is to be conducted. Note this load in the observation table and take all readings as in step no. ii, 12, 13, 14, 15 and 16. Note these readings in the observation table in the column for this load.

20. Repeat the same procedure for different loads (say 3.14th of full load, full load and 10 % overload).

21. Determine Frictional Power (F.P) as follows-

On graph paper mark X and Y axis. On X axis take Brake Power (BP) in KW to some scale. On Y axis take mass of fuel consumed in Kg I min (m) to some scale. Mark the points showing X and Y co-ordinates i.e respective BP and m, on graph. Draw straight line passing through maximum no. of points on graph, as shown in the following figure. The plot is known as William's line.

22. Distance OA represents FP to some scale. As the trial is conducted at constant speed, FP is assumed to be same for all loads. Enter FP obtained as above, in the tabular form of calculation (5.0) in the Sr, no. 11 for all loads.

23. Prepare heat balance sheet on minute and percentage basis for anyone brake load other than zero.


89


Experiment No.9

y

SCALE Xaxis Yaxis

x

Fig.9.3 :William 's line method

Precautions:

1. Before starting the engine, oil level in sump and jacket cooling water supply must be checked.

2. Never stop the engine on load and never use decompression lever for stopping.

3. Do not tamper with any of engine setting, like governor, fuel injector etc.

9.0 Observations:

Readings for calculation of various parameter of Heat Balance Sheet.

Sr. Load c::> 4)
1216 _"0 &; "0 ~~ >
Particulars JJ &; "0 0
No. ~~ -(0 ~~ ::§!"O
~_g (0 0 o (\1
~ _J I-I C")_J 00
..... ...J
01 Weight (W) Kg
02 Spring (S) Kg (in case of rope brake dynamometer)
03 Speed (N), RPM
04 Time taken to consume specific quantity of fuel
(10 ml, 20 ml as sultable)i.e 'f sec
05 Cooling water inlet temp. ( tl ° C)
06 Cooling water outlet temp. ( SOC)
07 Quantity of jacket cooling water (mwJ in lit Imin
08 Exhaust gas temp (tQ°C)
09 Engine room temp. (tr°C)
10 Water manometer reading h.cm
h2cm
11 Quantity of water supplied to exhaust gas calorimeter
(m, e) in lit I min
12 Temp. of water inletfrom calorimeter( telOC)
13 Temp. of water outlet from calorimeter( tc2 0C)
14 Temp. of exhaust gases entering calorimeter( tgl°C)
15 Temp. of exhaust gases leaving the calorimeter( to20C) MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

90

Note: Sr.No.11 to 15 of observation table is applicable when exhaust gas calorimeter is used.


Experiment No.9

10.0 Calculations:

Calculation table for Effciencies and Heat Balance Sheet.

Sr. Load q Q)
e16 !t::"O I§.. "0 >
0; "0 "0 0
No. Particulars Formulae D. :::t~ 00 00 -.;tOO = 00 ;,R"O
r!S.3 :r:.3 __ 0 :l 0 " ro
..- ....J M....J u.......J 00
~....l
01 Weight (W) in N W x9.81
02 Spring (S) Kg (in case of rope brake S x 9.81
dynamometer)
03 Speed (N), RPM -
04 Brake Power For rope brake [{2nN(W-S) x rJ
(BP) in KW dynamometer /(60x100)]
For hydraulic Wx NJ K'
dynamometer
For Eddy Curren
dynamometer
05 Quantity of fuel consumed ( mrJ Specific Quantity
of fuel( 1 Oml,20ml
in lit/sec / (100 x tsec)
06 Mass of Fuel Consumed (m) (Sp.gr.offuel)
in kg/min x (mfC)
07 Mass of jacket cooling water (mw) (Sp.gr.ofwater)
in kg/min x (mwe)
08 Manometer difference or water h2- h,
head (mw) in meters
Refer step no 21
09 Frictional Power (FP) in KW for determination
ofFP
10 Indicated Power (IP) in KW BP + IP
11 Mechanical EfficiencY(Tlmecn)in % (BP liP) x 100
[(BP in KW)/
12 Brake Thermal EfficiencY(11meCh)in % (rrun kg/sec x
CV)1x100
13 I ndicated Thermal Efficiency [(IP in KW)/ (min
(11!)in % kg/sec xCV)]
x100
14 Brake specific fuel consumption [(mrin kg/min)/
(BSFC) in kg/KW-hr (BP in KW)]x60
15 Mass of water supplied to exhaust (Sp.gr.ofwater)
gas calorimeter (me) in kg/min x (mcc) MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

91


Experiment No.9

Prepare heat balance sheet on minute and percentage basis for anyone - brake load other than zero.

For load on engine = , N

HEAT SUPPLIED BY FUEL

HEAT LOST TO JACKET COOLING WATER

HEAT LOST TO EXHAUST GASES

HEAT EQUIVALENT TO HEAT UNACCOUNTED

BRAKE POWER

Fig 2.4 Engine showing the details of Heat supplied and Heat rejected

1. Heat Supplied:

Heat supplied by combustion of fuel = (m) xCV

= X .

= , KJ/min

2. Heat Expenditure :

• Heat equivalent to brake power

Brake power, BP = , KW (KJ I Sec)

Heat equivalent to brake power = BP x 60

= x60

= , KJ I min

• Heat carried away by Jacket cooling water

Heat carried away by Jacket cooling water = (mw) x Cp(w) x (t2 - t.)

=( )x4.187x( - )

= , KJ I min

• Heat carried away by exhaust gases It can be determined by two methods,

1. By using Air box,

First determine the mass of exhaust gas as follows

Density of air, Pa = PI (0.287 x Ta) = 101.3251 (0.287 x ) , Kg 1m3

Where T, = Absolute temperature of air in Kelvin

= ( t/ C + 273) = ( + 273)


92

= ."' 111 K

Therefore, Pa = 101.325 I ( 0.287 x ) = , Kg 1m3


Experiment No.9

Area of Orifice, a = ( 1[ 14 ) d 2 = ( 1[ 14 ) x ( ) 2

a = t m2

But, Pa h a= Pwh w.

h a = (p w h w) I Pa

where, h a = air head in meters hw = water head in meters

P w = Density of water = 1000, Kg 1m3

Therefore, h a = (1000 x ) I ( )

Then,

Quantity of air supplied, Q = Cd x a x 2 g ha m3 I sec

Q = .

Q = , m31 sec

Mass of air supplied in kg I sec = Pa X Q

=

= ."" ,,"" , kg Isec

Mass of air consumed in kg per min,

ma = Mass of air supplied in kg I sec x 60

=

= , kg I min

Mass of exhaust gases in kg I min

= Mass of air consumed in kg I min + mass of fuel consumed in kg I min mg = ma + rn,

mg :: ..

mg :: ,kg I min

Then,

Heat carried away by exhaust gases:: mg x Cpg x (tg - t, )

::

:: , KJ I min

2. By using Exhaust gas Calorimeter

Exhaust Gas Inlet

Water Inlet

Water outle

Fig. 2.5 Exhaust Gas Calorimeter

Exhaust gas outlet


93


Experiment No.9

Heat rejected by exhaust gases in the calorimeter = heat gained by the calorimeter water

mg x C pg x (tg 1 - tg 2 ) = m c x C pw x (t c2 - t c1 )

mg x C pg = [ m c x C pw x (t c2 - t <:1 )] I (tg 1 - tg 2 ) Now, Total heat carried away by exhaust gases = mg xC pg x (t 9 ~ t r)

= { [ m c x C pw x (t (:2 - t c1 )] I (tg 1 - tg 2 ) } x (t 9 - t r )

= ,KJ I min

4t Heat unaccounted (Heat Lost due to radiation, errors of observation etc.) by difference

Heat unaccounted (Heat Lost due to radiation, errors of observation etc.)

= (Heat supplied by combustion of fuel) - [(Heat equivalent of BP) + (Heat lost to jacket cooling water) + (Heat lost to exhaust gases)

=

= ... H •• U.H~H •• U I KJ I min

• Heat balance sheet:

CREDIT DEBIT
Heat KJ/min % Heat Expenditure KJ/min %
supplied
100 a) Heat equivalentto BP
Heat supplied b) Heat lost to jacket cooling water
by combustion c) Heat lost to jacket cooling water
of fuel d) Heat lost tdue to radiation, errors of
observation, etc, by difference
Total 100 Total 100 Please note: If the engine test rig available in laboratory is different from the test rig given in the manual, then there will be change in layout diagram, stepwise procedure, observation table and calculation. Then teachers are advised to make the changes and guide the students accordingly.

(Space for Layout, Observation Table & Calculation)


94


Experiment No.9



95


Experiment No.9



96


Experiment NO.9

11.0 Result:

1. Mechanical Efficiency of the Engine = %

2. Brake Thermal Efficiency = %

3. Indicated Thermal Efficiency = %

12.0 Conclusion:

III It is found that the percentages of Heat Expenditure (are I are not)

within the normal range.

e The overall performance of the Engine is (satisfactory I not

satisfactory)

III Student shall write the conclusion on the basis of heat lost to exhaust gases of an Engine on which the experiment is conducted under the guidance of teacher.

13.0 Questions:

Write answers to Q ..... , Q ..... , Q ..... , Q ..... , Q ..... ( Teacher shall allot the question)

1. State two methods for measuring engine speed.

2. State the ignition temperature of diesel fuel.

3. State the reason for higher volumetric efficiency of diesel engines as compared to petrol engines?

4. Which engine is more efficient out of petrol and the diesel engine? Why?


97


Experiment No.9

(Space for answers)


98



Experiment No,9

GraDh


99


Experiment No.lO

EXPERIMENT No. 10

1.0 Title:

To determine a Mechanical efficiency of a Multi-cylinder petrol engine by Morse test.

2.0 Prior concepts :

• Working principle of Multi-cylinder Internal Combustion (I.C.) Engines.

• Indicator diagram, Indicated Power(I.P), Brake Power(B.P), Frictional Power (EP).

• Mechanical Efficiency.

3.0 New concepts:

Proposition 1: Indian standard (I.S.) specification for testing of I.C. Engines. According to Indian standard 1600 - 1960, I.C.Engine is tested at constant speed. It includes three types of engines used for general purposes.

Concept structure:

Proposition 2: Morse Test.

It is Suitable to calculate indicated power of Multi-cylinder high speed I.C. Engine without use of indicator diagram.

Concept structure:

is used


100


Experiment No.lO

Proposition 3: Relation between frictional losses and speed

The frictional losses at constant speed are independent of the load. It is constant for constant speed.

Concept structure:

is at
Frictional Losses "'- Constant .. Constant speed
... ... 4.0 Learning objectives:

Intellectual skills:

1. To know 1.8. specification for testing of l.C, engines.

2. To know the importance of testing of l.C. engine.

3. To understand the performance parameters of l.C. engine. Motor skills:

1. Ability to start, stop and operate the engine

2. Ability to observe, note and measure fuel consumption, rate of flow of cooing water, various temperatures and engine speed.

3. Ability to adjust brake load in order to bring the engine to constant speed, while cutting off different cylinders.

5.0 Apparatus:

Complete multi-cylinder petrol engine test rig with dynamometer, fuel gauge, temperature gauges, air box, water manometer, water flow meter, etc and arrangement of cutting off cylinders one by one, Tachometer, Stop watch

S.O

I

D. I

lagraml

i.lFftN ,LIHilOll\,\E

*~ :!$Iilf4i' $V,,11:::HBS FC,oR. MORSE TEST ~ ... A,"!!~ME,ER

~. M.4N¢f~TER

tt, IiGNlUD>J s'Al'!C.f1 t, TEMP. mDlCATOO a, ActEit£TER

s. FtiELM8A$\,I~I$Mgr;IT 1{L~ TANK

lji.L0A!D1OO ARRA}JGEM~NT 12.·i'VJW ¢,.oH1ROL W,LVE


101


Experiment No.l0

7.0 Specifications:

(Students to see the catalogue and write the specifications and constants)

1. Engine Specifications:

.. Type: .

.. No. of cylinders: ..

• Bore: , m ; Stroke: , m

.. Power developed: , KW at , rpm

2. Dynamometer specifications:

For Rope brake dynamometer

• Diameter of rope brake drum, 0 = , m

.. Diameter of Rope, d = , m

• Effective radius, r e = (0 + d) 12 = :::;: , m

OR

For Hydraulic dynamometer

Dynamometer constant, K' = ..

OR

For Eddy current dynamometer

It Dynamometer constant, K' = .

3. Orifice Specifications:

.. Diameter of Orifice, d = , m

.. Area of Orifice, a = ( 1t 14 ) d 2

a = , m2

..

Coefficient of discharge for orifice, Cd = ..

Properties of Air:

4.

• Characteristic gas constant for air, Ra= 0.287 KJ I Kg K

• Atmospheric pressure, P = 101.325 , N I rnm-

.. Absolute ambient temperature, tr:::;: 0 C

5. Properties of Water:

.. Specific gravity of water = 1

• Density of Water, Yw:::;: 1000, Kg 1m3

• Specific heat of water, Cp(w} :::;: 4.187 KJ I Kg K

6. Properties of Fuel:

.. Specific gravity of Fuel = ..

.. Calorific value of fuel, CV:::;: , KJ I Kg.


102


Experiment No.l0


1. Fill up sufficient Petrol in the petrol tank.

2. Check oil level in the engine with the help of dipstick provided.

3. Ensure water supply through jacket and exhaust gas calorimeter.

4. Insert the key in the ignition switch and start the engine. Allow it to get stabilized.

5. Adjust the fuel supply and the load on the dynamometer to bring the engine to the

required speed at which test is conducted.

6. Check the speed with tachometer and note it.

7. Measure the load on the dynamometer and note it.

8. The speed and load measured in step NO.6 and 7 are for all cylinders developing power. Note these readings in the observation table.

9. Now put off first knife switch to cut off ignition of cylinder 1. Adjust the load on the dynamometer to bring the engine to the initial speed. Allow it to get stabilized. Note this speed and load in the observation table.

10. Make the cylinder No.1 on. All cylinders are now developing power. Allow the engine to run on all cylinders for a short time.

11. Cut off cylinder No.2 Adjust the load on the dynamometer to bring the engine to the initial speed. Allow it to get stabilized. Note this speed and load in the observation table.

12. Similarly cut off remaining cylinders one by one. Adjust the load on the dynamometer to bring the engine to the initial speed. Note this speed and load in the observation table. Note: The cutting off the cylinders can be done by short circuiting the spark plug in spark ignition engines and by cutting off the fuel supply in compression ignition engines.

13. Complete observation table and calculations in the tabular form.

14. Precautions:

1. Before starting the engine, oil level in sump and jacket cooling water supply must

be checked.

2. Check battery water level before commencement of trial.

3. Do not obstruct orifice when engine is in operation.

4. Before cutting off the next cylinder, engine should run on all cylinders for a short

time.

5. Do not disturb any of the engine settings.

6. Run the engine for 5 minutes every week.

7. Turn the oil filter every 40 hours of operation.

8. Replace engine oil every year.


103


Experiment No.10

9.0 Observations :

Speed of the engine, N = , rpm (it will be constant for all sets of reading)

Readings for Brake power calculation.

Sr. Particulars [] Cylinder off q 0 1st 2nd 3rd 41h
No.
01 Weight (W) kg
02 Spring force (S) kg
(in case of rope brake dynamometer) 10.0 Calculations:

Calculation table for Brake power

Sr. Particulars Cylinder off r 0 1st 2nd 3rd 41h
No. Formulae
01 Weight (W) in N Wx9.81
02 Spring force (S) kg S x 9.81
(in case of rope brake dynamometer)
03 Spring (N), RPM
04 Brake Power 8 B1 82; B3 B4
(BP) in I<W For rope brake {2TI N[(W-S) x re]}l
dynamometer (60 x 1000)
For hydraulic WXM/K'
dynamometer
For Eddy Current
dynamometer MAHARASHTRASTATE BOARD OF TECHNICAL EDUCATION

104


Experiment NO.10

I!il Calculation for Indicated power.

1. When all cylinders are developing power, then

IP of all cylinders = BP of all cylinders + FP of all cylinders

11 + i2 + 13 + 14 = 8 + ( F1 + F2 + Fa + F4 ) ( I )

2. When Cylinder No.1 is cut off, then,

12 + 13 + 14 = B1 + ( F1 + F2 + F3 + F4 ) ( II )

3. When Cylinder No.2 is cut off, then,

11 + 13 + 14 = 82 + ( F1 + F2 + F3 + F4 ) ( III )

4. When Cylinder NO.3 is cut off, then,

11 + 12 + 14 = 83 + ( F1 + F2 + Fa + F4 ) ( IV )

5. When Cylinder NO.4 is cut off, then,

11 + 12 + 13 = 84 + ( F1 + F2 + F3 + F4 ) ( III )

Where,

11 ,12 ' 13 and 14 are the indicated power of cylinder no. 1,2,3 and 4 respectively.

F1 ' F2 ' F3 _and F4 are the frictional power of cylinder no. 1,2,3 and 4 respectively.

Equation No. [(I) - (II)] gives IP of 1st Cylinder

=

= , KW

Equation No. [(I) - (III)] gives IP of 2nd Cylinder

:. 12 = 8 - 82 = - .

Equation No. [(I) - (IV)] gives IP of 3m Cylinder

= .. 01.,.l1lil1li11 .... "., KW

Equation No. [(I) - (V)] gives IP of 4tll Cylinder

Then,

IP of all cylinders, I = 11 + 12 + 13 + 14

= + + + .

= ,KW


105


Experiment No.lO

., Mechanical Efficiency of Multi-cylinder l.C. Engine t llMech llMech = (BP of all Cylinders) 1 (IP of all cylinders)

=B/I = 1 .

:.llMech = x 100 = 0/0

Please note: If the engine test rig available in laboratory is different from the test rig given in the manual, then there will be change in layout diagram, stepwise procedure, observation table and calculation. Then teachers are advised to make the changes and guide the students accordingly.



106


Experiment No.lO



107


Experiment NO.l0

11.0 Result:

t. Indicated Power of all cylinders, I = .. ,KW

2. Brake Power of all Cylinders, BP = , KW

3. Mechanical Efficiency of the Engine = %

12.0 Conclusion:

It is concluded that:

1. Morse test can be (used I not be used) for finding indicated power of Multi-

cylinder engine without the use of mechanical indicator diagram.

2. Morse test is (accurate I not accurate) method for finding out the

Indicated power.

3. Student shall write the conclusion on the basis of Frictional Power of an Engine on which the experiment is conducted under the guidance of teacher .

................................................................................................................................... _----

................................................................................................................................... _----

13.0 Questions:

Write answers to Q ...... , Q ..... , Q ..... , Q ..... , Q ...... (Teacher shall allot the question)

1. State the methods for determining the frictional power.

2. Which types of engines are tested according to I.S. 1600 -1960?

3. State the purpose of conducting a Morse test.

4. Why Morse test is not suitable for determination of IP in case of single cylinder l.O.

engine? Give reason.

5. Motoring test is used to find .

6. State the firing order of the engine on which trial is conducted.

7. Why the speed of the engine is kept constant for conducting Morse test?

8. State the ways by which frictional power can be reduced. Can frictional power be

zero? Justify the answer.

9. What is the effect of cutting off one cylinder on speed?

10. How to keep the speed of the engine constant when the cylinder is cut off?

11. List the main variable encountered in engine testing.

12. State the limitations of a mechanical indicator.

MAHARASHTRASTATE BOARD OFTECHNICAL EDUCATION

108


Experiment No.i0

13. State the usual range of brake thermal efficiency for Spark ignition and Compression ignition engine.

14. State the usual range of mechanical efficiency for an engine.

15. If Diesel and Petrol Engine is of same capacity, which engine will have more efficiency? Why?

16. How are the brake thermal efficiency, indicated thermal efficiency and mechanical

efficiency related?

17. What is it that basically causes friction loss in an engine?

18. Write relation between power and mean effective pressure?

19. How does engine power output vary with speed?

20. What is the effect of ambient temperature & pressure on petrol engine performance?

21. How does humidity in the atmosphere affect the performance of carburetted engine?

22. State the effect atmospheric condictions in diesel engine performance.

(Space for answers)


109


Experiment No.lO

(Space for answers)

...... ~ ~,_ "~,~ .. ,.,.""""~,,,,,,.,,~., , , ~ .


110


Experiment NO.10

(Space for answers )



111

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