EXPERIMENT:-01

AIM OF THEEXPERIMENT

Study the differential mechanism and determine the differential ratio.

APPARATUS REQUIRED

EQUIPMENT QUANTITY
SL.NO SPECIFICATION
01 MODEL OF A DIFFERENTIAL 01

THEORY

 Generally the two rear wheels turn on the road exactly at the same speed when a vehicle travels in a
straight line. There is no relative movement between the two rear wheels.

 The propeller shaft which is geared rigidly with the rear axle must rotate the rear wheels simultaneously.

 But when vehicle takes a turn, the outer wheel travels a longer radius than the inner wheel. The outer
wheel turns faster than the inner wheel, so that there is a relative movement between the two rear wheels.

 If the two rear wheels are rigidly fixed to a rear axle the inner wheel will slip which will cause rapid tyre
wear, steering difficulties and poor road holding.

 The purpose of the differential is to provide the relative movement to the two rear wheels when the
vehicle is taking a turn. The torque transmitted to each wheel is however always equal.

CONSTRUCTION:-

 A differential consists of a sun gears which are mounted on the inner end of each rear axle.

 A differential cage is assembled on the left axle. A ring gear called crown gear is attached to the cage,
so that the cage rotates with the crown gear.

 The crown gear is driven by the bevel pinion .both the crown wheel and cage are free on the left rear
axle.

 The cage supports two planet pinions on a shaft which mesh with the two sun gears.

 Thus, when the differential cage is rotate and both wheels turn which are attached to the outer end of the
rear axle.
OPERATION
 When the differential cage is rotated, the planet gears will also rotate as they run around on the stationary
axle sun gear.
 While rotating in this manner, the planet pinions carry rotary motion to the other axle sun gear, and
rotate.

 When the vehicle taking a turn, the planet gears spin on its shaft transmitting more rotary motion to one
rear wheel than to other.

 Thus when the car is running in a straight line, the crown wheel, differential cage, planet pinions and
the sun gear are turns as a unit without any relative motion.

 But when the car takes a turn, the planet pinions rotate on their shaft to permit the outer rear wheel to
turn more rapidly than the inner wheel.

CONCLUSION:-

Hence we have successfully studied about the differential mechanism.

 EXPERIMENT:-02

AIM OF THE EXPERIMENT

Checking the spark plug, setting the port and check the ignition in the spark plug.

APPRATUS REQUIRED

SL.NO EQUIPMENTS SPECIFICATION QUANTITY

01 Model of a spark plug 01

02 Condenser 01

03 Distributor 01

04 Battery 12v 01

THEORY:-
 Spark plug is device to produce electric spark to ignite the compressed air-fuel mixture inside
the engine cylinder .The spark plug is screwed in the top of the cylinder, so that its electrodes
projects in the combustion chamber.
 It must produce the spark at the correct movement at the end of the compression stroke.
 A proper gas is to be maintained between the two electrodes of the spark plug, so that the
sparking may takes place.
 When the spark plug is screwed in the cylinder head, the ground electrode is said to be
connected with ground.
 The terminal of the center electrode is directly connected with H.T. lead of the ignition coil in
case of single cylinder engine, or through the distributor in case of multi cylinder engine.
 The secondary circuit of the electrical system is to be completed through the gap between the
electrodes. When the H.T. current passes through the circuit, it jumps the gap producing a
spark, which ignites the compressed air fuel mixture in the cylinder.

CONSTRUCTION:-
A spark plug is a device consists of mainly three parts:-

1. Center electrode or insulated electrode.

2. Ground electrode or insulated electrode.

3. Insulation separating the two electrodes.

 The upper end of the center electrode is connected to the spark plug terminal, where H.T
cable from the ignition coil is connected. It is surrounded by porcelain insulator.
 The lower half portion of the insulator is fastened with a metal shell. The lower portion of the
shell has a short electrode attached to one side and bent in towards the centre electrodes, so
that there is a gap between the two electrodes.
 The two electrodes are thus separated by insulator. The sealing gaskets are provided between
the insulator and the shell to prevent the escape of gases under various temperature and
pressure condition.
 The lower part of the shell has screw threads and the upper part is made in hexagonal shape
like a nut, so that the spark plug may be screwed in or unscrewed from the cylinder head.
 The material used in the construction of a spark plug are as follows:-

1. SHELL:-STEEL

2. INSULATION: - PORCELAIN, MICA (the porcelain has disadvantages of brittleness and

low resistance to thermal shocks .mica is somewhat attacked by fuels, sintered alumina is now
almost extensively used for insulation.).

3. ELECTRODE: - Nickel, alloy of nickel, manganese and silicon, Platinum alloys are better
for electrodes, but their high cost limit their use.
PROCEDURE
 First connect the terminal of the condenser to the terminal of the battery
 Then connect the black terminal to positive and red terminal to negative terminal of
the battery from the condenser.
 Then ON the main switch of the spark plug model.
 When we switch is ON , the ignition system supply high voltage surges of current to
the spark plug .
 The ignition coil steps 12 volts from the battery to the high tension voltage of about
20,000 to 30,000 volts required to jump the spark at the spark plug gap , which ignites
to combustible charge in the engine cylinder .
 The rotor of the distributer revolves and distributes the current to the four segments
which in turn , send it to the spark plugs
 The distributor then directs this high voltage to the proper spark plug when it jumps
the gap , producing a spark which ignites the combustible mixture in the cylinder .

CONCLUSION
From the above experiment we have successfully set the port and check the ignition in
the spark plug.
 EXPERIMENT:-03

AIM OF THE EXPERIMENT

Study of barking system (Hydraulic /Air brake)

APPARATUS REQUIRED:-

SL.NO EQUIPMENT SPECIFICATION QUANTITY

01 MODEL OF A BRAKING HYDRAULIC 01
BSYSTEM

02 HYDRAULIC OIL SAE40

THEORY:-
 A brake is a mechanical device which decreases speed of a vehicle. Its opposite component is a
clutch. The function of the brakes are :--

1. To stop or slow down the vehicle in the shortest possible distance in an emergencies.

2. To control the vehicle to be retained when descending a hill.

 The hydraulic brakes are applied by the liquid pressure .The pedal force is transmitted to the brake
shoe by means of a confined liquid through a system of force transmission.
 The force applied to the pedal is multiplied and transmitted to all the brake shoe by a force
transmission system.
 It essentially consists of two main components i.e., master cylinder and wheel cylinder.
 The master cylinder is connected by tubing to the wheel cylinder at each of the four wheels.
 The system is filled with the liquid under light pressure, when the brakes are not in operation.
 The liquid is known as brake fluid, and is usually a mixture of glycerin and alcohol or castor oil,
denatured alcohol and some additives.

OPERATION:-
a. Within a hydraulic brake system, as the brake pedal is pressed, a push rod exerts force on the piston
in the master cylinder causing fluid from the brake fluid reservoir to flow into a pressure chamber
through a compensating port which results increase in the pressure of entire hydraulic system.
b. This pressure is conducted instantaneously to the wheel cylinder on each of four brakes,where it
forces the wheel cylinder piston out wards.
c. These pistons in turn, force the brake shoes out against the brake drums.
d. When the driver releases the brake pedals, the master cylinder piston returns to its original position
due to the return spring pressure, and thus the fluid pressure in the entire system drops to its original
low valve, which allows retracting spring on wheel brakes to pull the brake shoes out of contact with
the brake drum into their original position. This causes the wheel cylinder pistons also to come back
to their original position. Thus the brakes are released.

CONCLUSION:-
From the above experiment we have successfully studied about hydraulic braking system.
 EXPERIMENT:-03

AIM OF THE EXPERIMENT

Faults and their remedies in battery ignition system.

EQUIPMENT REQUIRED:

1. Motor cycle and a multi- cylinder engine.

2. Total kit consisting of spanner set, set of screw drivers, feeler gauges.

3. Petrol and cotton rag.

THEORY:

The ignition system is designed to produce a spark to each cylinder, at the right time, to ignite the air/fuel mixture
inside. The system has to ensure that the spark timing must change with engine load and speed and a very high
voltage (10,000 to 20,000), is produced to fire the spark plugs.

THE MAIN COMPONENT & THEIR FUNCTIONS ARE AS FOLLOWS:

 The battery supplies the electrical energy.

 The ignition switch controls the battery current for starting or stopping the engine.

 The ignition coil transforms the battery low tension current to high tension current required to produce
a spark by jumping in a spark plug.

 The distributor delivers the spark to the proper cylinder and incorporates the mechanical breaker, which
opens and closes the primary circuit at exact times.

 The various units are connected by electrical wiring.

 The spark plugs provide the spark in engine cylinder.

Working of Battery Ignition System:

In the battery ignition system ignition coil stores the energy in form of magnetic field and deliver it at the instant
of ignition, in form of high voltage current with high tension wire to correct spark plug. The diagram of four
cylinder battery ignition system is as follow.
  First low voltage current flow form battery to the primary coil through ignition switch and ballast
resistor.
 Ballast resistor regulates the temperature of ignition coil by regulating current passing form it.
 The ignition capacitor connected in parallel with contact breaker. One end of secondary winding is also
grounded through contact breaker.
 When the ignition switch is closed, the primary winding of the coil is connected to the positive
terminal, and current flow through it known as primary current.
 The current flows form primary coil produces a magnetic field which induces an EMF in secondary
coil.
 The cam regulate the contact breaker. Wherever the breaker open, current flows into condenser, which
charged the condenser.
 As the condenser become charger the primary current falls and the magnetic field collapses. This will
induces a much higher voltage in condenser.
 Now the condenser discharge into the battery which reverse the direction of both primary current and
magnetic field. This will induce a very high EMF in secondary winding.
 Now this high voltage EMF produce spark at correct spark plug through distributor.

SYMPTOMS:
1. The engine does not start.
2. Engine “plugs” under load and runs roughly.
3. Engine Misses. (No. defect in Fuel or Valve Systems).
4. Engine gets over-heated and there is a loss of power. (No defect in cooling lubrication, braking or fuel
system).
5. Failure of spark plug.
6. Loss of energy in the primary circuit.
7. Energy loss in secondary circuit.
8. Out of time.

CAUSES:
 Discharged battery.
 Wet or dirty spark plug insulators.
 Ignition timing advanced too far.
 Poor connections.
 Defective spark plug
 Late ignition timing
 Burned electrodes due to over heating.
 Incorrect spark plug gap

REMEDIES:
 Recharge it.
 Wipe, clean and dry with cloth.
 Check ignition timing. Retard it.
 Adjust the points to specified gap.
 Test them and replace it necessary.
 Check ignition timing. Advance it if retarted.
 Check cooling systems, ignition timing, use new plugs.
 Adjust plug gap according to specified value. SETTING OF IGNITION SYSTEM
 Disconnect the drive to the contact breaker cover.
 Loosen the clamp of CB casing and distributor unit.
 Set the piston of cylinder NO.2 on TDC against a fixed mark on engine casing.

PRECAUTIONS:
 Use proper tools.
 Apply proper force for tightening or loosening of nuts and screws.
 The feeler gauge for checking the gap should be sliding fit.
 Don’t interfere with the body clamping screw when adjusting the ignition timing with the help of
graduated scale on the distributor securing clamp.