MCE 115

SPARK IGNITION ENGINES

BY

ENGR. AJETUNMOBI. D. T.

DEPARTMENT OF MECHATRONICS ENGINEERING

TECHNOLOGY,

THE FEDERAL POLYTECHNIC ILARO,

ILARO, OGUN STATE.

JANUARY, 2022.
 UNIT III IGNITION SYSTEMS & FUEL INJECTION SYSTEMS

3. Ignition System:

The ignition system is a system used to generate a very high voltage from the car
battery and to send it to each sparkplug in turn thereby igniting the fuel-air mixture in the
combustion chamber of the engine.

3.1 Types of Ignition System:

1. Magneto ignition systems

2. Battery coil ignition systems
3. Electronic ignition system

3.2 Magneto ignition systems:

This type of ignition system is mostly used in motorcycles, scooters and racing cars. The
magneto Ignition system with main components is shown in Fig.3.2

Fig 3.2 Schematic of rotating magnet type magneto ignition systems

 Magneto ignition system is a special type of ignition system with its own electric
generator to provide the required necessary energy for the vehicle system. It is mounted on the
engine and replaces all components of the coil ignition system except the spark plug. A
magneto when rotated by the engine is capable of producing a very high voltage and doesn’t
need a battery as source of external energy.

The main components of an ignition coil are Distributor, Condenser, Contact Breaker
(CB) points, Ignition Coil.

There are two important types of magneto ignition system. They are 1) Rotating
armature type and 2) Rotating Magnet type.

In the first type, the armature consisting of the primary and secondary windings rotate in
between the poles of a stationary magnet. In the second type the magnet revolves and windings
are kept stationary is shown in the above figure. A third type of magneto called the polar
inductor type magneto, where both the magnet and the windings remain stationary but the
voltage is generated by reversing the flux field with the help of soft iron polar projections called
inductors.

Condensor:

The function of the capacitor is to reduce arcing at the contact breaker (CB) points. Also
when the CB opens the magnetic field in the primary winding begins to collapse. When the
magnetic field is collapsing capacitor gets fully charged and then it starts discharging and helps
in building up of voltage in secondary winding.

Contact Breaker:

It is to be noted that the Contact breaker cam and distributor rotor are mounted on the
same shaft.

Distributor:

Ignition Coil:
 The main advantage of the high tension magneto ignition system is the production of a
very high voltage.Because of the poor starting characteristics of the magneto system invariably
the battery ignition system is preferred to the magneto system in automobile engines. However,
in two wheelers magneto ignition system is preferred due to light weight and less maintenance.

3.3. Battery coil ignition systems:

It is used in passenger cars and light trucks. A Battery Ignition system for four cylinder
engine where the battery supplies the electrical energy. An ignition switch is used to control 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.

The figure shows battery ignition system for a 4-cylinder petrol engine. It mainly consists
of a 6 or 12 volt battery, ammeter, ignition switch, auto-transformer (step up transformer),
contact breaker, capacitor, distributor rotor, distributor contact points, spark plugs, etc.

The ignition system is divided into 2-circuits namely the Primary Circuit and Secondary
Circuit.

(i) Primary Circuit : It consists of 6 or 12 V battery, ammeter, ignition switch, primary

winding it has 200-300 turns of 20 SWG (Sharps Wire Gauge) gauge wire, contact breaker,
capacitor. 53

(ii) Secondary Circuit: It consists of secondary winding. Secondary Ignition Systems winding
consists of about 21000 turns of 40 (S WG) gauge wire. Bottom end of which is connected to
bottom end of primary and top end of secondary winding is connected to centre of distributor
rotor. Distributor rotors rotate and make contacts with contact points and are connected to spark
plugs which are fitted in cylinder heads.

Working:

When the ignition switch is closed and engine in cranked, as soon as the contact breaker
closes, a low voltage current will flow through the primary winding. When the contact breaker
opens the contact, the magnetic field begins to collapse. Because of this collapsing magnetic
field, current will be induced in the secondary winding. And because of more turns of secondary,
the voltage goes upto 20000-35000 volts.
This high voltage current is brought to centre of the distributor rotor. Distributor rotor
rotates and supplies this high voltage current to proper stark plug depending upon the engine
firing order. When the high voltage current jumps the spark plug gap, it produces the spark and
the charge is ignited-combustion starts-products of combustion expand and produce power.

When compared to the magneto ignition system, the battery ignition system is more
expensive but at the same time it is very highly reliable as it aids in reliable sparking..

Fig 3.3 Schematic of battery ignition systems

3.4. Electronic ignition system:

The requirement for higher mileage, reduced emissions and greater reliability has paved
the way for development of the electronic ignition systems.

Fig 3.4 Schematic of electronic ignition systems

3.5 Relative merits

The main advantages of the electronic ignition system are

It provides better emission control.

It provides a reasonable fuel economy.

It provides better engine performance.

3.6 Distributorless Ignition System:

3.7 Centrifugal advance mechanisms:

Centrifugal advance makes the ignition coil and spark plugs fire sooner as engine speed
increases, using spring-loaded weights, centrifugal force, and lever action to rotate the
distributor cam. Spark timing is advanced by rotating the distributor cam against distributor shaft
rotation. This action helps correct ignition timing for maximum engine power. Basically the
centrifugal advance mechanism consists of two advance weights, two springs, and a advance
lever.

Fig 3.7 Centrifugal advance mechanisms

During periods of low engine speed, the springs hold the advance weights inward
towards the distributor cam or trigger wheel. At this time there is not enough centrifugal force to
push the weights outward. Timing stays at its normal initial setting.

As speed increases, centrifugal force on the weights moves them outwards against
spring tension. This movement causes the distributor cam or trigger wheel to move ahead. With
this design, the higher the engine speed, the faster the distributor shaft turns, the farther out the
advance weights move, and the farther ahead the cam is moved forward or advanced. At a
preset engine speed, the lever strikes a stop and centrifugal advance reaches maximum.

The action of the centrifugal advance causes the contact points to open sooner, or the
trigger wheel and pickup coil turn off the ECU sooner. This causes the ignition coil to fire with
the engine pistons not as far up in the cylinders.

3.8 Vacuum Advance mechanisms:

The vacuum advance provides additional spark advance when engine load is low at part
throttle position. It is a method of matching ignition timing with engine load. The vacuum
advance increases fuel economy because it helps maintain idle fuel spark advance at all times.
A vacuum advance consists of a vacuum diaphragm, link, movable distributor plate, and
a vacuum supply hose. At idle, the vacuum port from the carburetor or throttle body to the
distributor advance is covered, thereby NO vacuum is applied to the vacuum diaphragm, and
spark timing is NOT advanced. At part throttle, the throttle valve uncovers the vacuum port and
the port is exposed to engine vacuum. The vacuum pulls the diaphragm outward against spring
force. The diaphragm is linked to a movable distributor plate, which is rotated against distributor
shaft rotation and spark timing is advanced.

Fig 3.8 Vacuum advance mechanism

 The vacuum advance does not produce any advance at full throttle. When the throttle
valve is wide open, vacuum is almost zero. Thus vacuum is not applied to the distributor
diaphragm and the vacuum advance does not operate.

3.9 Spark plug:

The spark plug consists of a porcelain insulator in which there is an insulated electrode
supported by a metal shell with a grounded electrode. They have a simple purpose of
supplying a fixed gap in the cylinder across which the high voltage surges from the coil must
jump after passing through the distributor.
The spark plugs use ignition coil high voltage to ignite the fuel mixture. Somewhere between
4,000 and 10,000 volts are required to make current jump the gap at the plug electrodes.
This is much lower than the output potential of the coil.
Spark plug gap is the distance between the center and side electrodes. Normal gap
specifications range between .030 to .060 inch. Smaller spark plugs gaps are used on older
vehicles equipped with contact point ignition systems.
Spark plugs are either resistor or non-resistor types (fig. 2-46). A resistor spark plug
has internal resistance (approximately 10,000 ohms) designed to reduce the static in
radios. Most new vehicles require resistortype plugs. Non-resistor spark plug has a
solid metal rod forming the center electrode. This type of spark plugs is NOT commonly
used except for racing and off-road vehicles.
3.10 Spark Plug Heat Range and Reach
The heat range of the spark plug determines how hot the plug will get. The length and
diameter of the insulator tip and the ability of the spark plug to transfer heat into the cooling
system determine spark plug heat range.
A hot spark plug has a long insulator tip that prevents heat transfer into the waterjackets.
It will also bum off any oil deposits. This provides a self-cleaning action.
AUTOMOTIVE ELECTRICAL CIRCUITS AND WIRING 58/ 101
A cold spark plug has a shorter insulator tip and operates at a cooler temperature. The
cooler tip helps prevent overheating and preignition. A cold spark plug is used in engines
operated at high speeds.
Vehicle manufacturers recommend a specific spark plug heat range for their engines.
The heat range is coded and given as a number on the spark plug insulator. The larger
the number on the plug, the hotter the spark plug tip will operate. For example, a 54 plug
would be hotter than a 44 or 34 plug.
The only time you should change from spark plug heat range specifications is when abnormal
engine or operating conditions are encountered. For instance, if the plug runs too cool, sooty
carbon will deposit on the insulator around the center electrode. This deposit could soon build
up enough to short out the plug. Then high voltage surges would leak across the carbon
instead of producing a spark across the spark plug gap.
Using a hotter plug will bum this carbon deposit away or prevent it from forming. Spark
plug reach is the distance between the end of the spark plug threads and the seat or
sealing surface of the plug. Plug reach determines how far the plug reaches through the
cylinder head. If spark plug reach is too long, the spark plug will protrude too far into the
combustion chamber and the piston at TDC may strike the electrode. However, if the
reach is too short, the plug electrode may not extend far enough into the cylinder head
and combustion efficiency will be reduced. A spark plug must reach into the combustion
chamber far enough so that the spark gap will be properly positioned in the combustion
chamber without interfering with the turbulence of the air-fuel mixture or reducing
combustion action.

Figure 2-46.- Sectional view of a (A) non-resistor and (B) resistor spark plug.

3.11 Construction of Spark Plug:

3.12 Types of spark plugs:

Introduction to feed back carburetor systems:

Carburetor is a device used for providing proper air/fuel mixture ratio. The carburetor
works on Bernoulli's principle i.e. The faster the air moves, the lower is its static pressure, and
the higher is its dynamic pressure. The throttle or accelerator linkage indirectly controls the flow
of fuel by actuating the carburetor mechanisms which meters the flow of air being pulled into the
engine. The speed of this flow, and therefore its pressure, determines the amount of fuel drawn
into the airstream.

The latest type of carburetor system is the electronic feedback design, which provides
better combustion by improved control of the air/fuel mixture. A three-way converter not only
oxidizes HC and CO but also chemically reduces oxides of nitrogen (NOX).If the air/fuel mixture
is too lean, NOX is not converted efficiently. If the mixture is too rich, HC and CO does not
oxidize efficiently. Monitoring the air/fuel ratio is the job of the exhaust gas oxygen sensor.

An oxygen sensor senses the amount of oxygen present in the exhaust stream. A lean
mixture produces a high level of oxygen in the exhaust. The oxygen sensor, placed in the
exhaust before the catalytic converter, produces a voltage signal that varies with the amount of
oxygen the sensor detects in the exhaust. If the oxygen level is high (a lean mixture), the voltage
output is low. If the oxygen level is low (a rich mixture), the voltage output is high.The electrical
output of the oxygen sensor is monitored by an electronic control unit (ECU). This
microprocessor is programmed to interpret the input signals from the sensor and in turn
generate output signals to a mixture control device that meters more or less fuel into the air
charge as it is needed to maintain the 14.7 to 1 ratio.

Whenever these components are working to control the air/fuel ratio, the carburetor is
said to be operating in closed loop. The oxygen sensor is constantly monitoring the oxygen in
the exhaust, and the control module is constantly making adjustments to the air/fuel mixture
based on the fluctuations in the sensor's voltage output. However, there are certain conditions
under which the control module ignores the signals from the oxygen sensor and does not
regulate the ratio of fuel to air. During these times, the carburetor is functioning in conventional
manner and is said to be operating in open loop. (The control cycle has been broken.)

The carburetor operates in open loop until the oxygen sensor reaches a certain
temperature (approximately 600F). The carburetor also goes into open loop when a richer-
thannormal air/fuel mixture is required, such as during warm-up and heavy throttle application.
Several other sensors are needed to alert the electronic sensor provides input relating to engine
temperature. A vacuum sensor and a throttle position sensor indicate wide open throttle.

Early feedback systems used a vacuum switch to control metering devices on the
carburetor. Closed loop signals from the electronic control module are sent to a vacuum
solenoid regulator, which in turn controls vacuum to a piston and diaphragm assembly in the
carburetor. The vacuum diaphragm and a spring above the diaphragm work together to lift and
lower a tapered fuel metering rod that moves in and out of an auxiliary fuel jet in the bottom of
the fuel bowl. The position of the metering rod in the jet controls the amount of fuel allowed to
flow into the main fuel well.

A less common method to control the air/fuel mixture is with a back suction system
feedback. The back suction system consists of an electric stepper motor, a metering pintle
valve, an internal vent restrictor, and a metering orifice. The stepper motor regulates the pintle
movement in the metering orifice, thereby varying the area of the opening communicating
control vacuum to the fuel bowl. The larger this area, the leaner the air/fuel mixture. Some of the
control vacuum is bled off through the internal vent restrictor. The internal vent restrictor also
serves to vent the fuel bowl when the back suction control pintle is in the closed position.

Throttle Body Injection(TBI):

TBI fuel injection system is a type of system where the fuel is injected into the throttle
body. The throttle body fuel injection system operates by using a single or pair of injectors. The
throttle looks like a carburetor without the fuel bowl, the metering jets or the float.

This type of fuel injection system consists of only two major castings the fuel body and the
throttle body. The fuel body supplies the fuel while the throttle body has a valve that controls the
flow of air. On the throttle, there are ports that gather signals to relay to the manifold absolute
pressure sensor and to the emission control system.

TBI Fuel Injection Advantages:

It is less expensive than using other types of fuel injection systems.

It is easier to clean, maintain and service because there are fewer parts.
It is cheaper to manufacture than a port injection system and simpler to diagnose.
It also does not have the same level of injector balance problems that a port injection system
might have when the injectors are clogged.

It greatly improves the fuel metering compared to a carburetor.

TBI Fuel Injection Disadvantages:

It is almost the same as a TBI carburetor wherein the fuel is not equally distributed to
all the cylinders. This means that the air/fuel mixture injected differs for each
cylinder.

It can cool the manifold much faster causing the fuel to puddle and condense in the
manifold. The possibility of condensation is much higher since the fuel travels
longer from the throttle body to the combustion chamber.

Since the system needs to be mounted on top of the combustion chamber, you're prevented
from modifying the manifold design to improve your car's performance.

It is a wet system and the mixture of fuel is still based per cylinder.

Ref: http://www.carsdirect.com/carmaintenance/
tbifuelinjectionthrottlebodyfuelinjectionsystems10advantagesanddisadvantages

Multi port or point fuel injection,

Fuel injection systems,

Injection system controls.

Advantages of electronic ignition systems:

Types of solid-state ignition systems and their principle of operation,

Contact less electronic ignition system, Electronic

spark timing control:
It is a closed-loop type electronic control device that continuously corrects the ignition
timing and in effect it re-tunes the engine some few times every second. By providing the correct
spark timing all the time, the fuel consumption is reduced considerably.
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.
Secure the CB camshaft in this position. The ignition timing will be set.

Firing Order Setting

Rotate the crankshaft in correct direction.
Note the order in which inlet valves(or exhaust valve) open.
This the firing order of the engine

Gap Adjustment of Contact Breaker

Turn the engine shaft manually until the contacts are freely open.
Move the fixed contact plate with the help of adjustor screw till required gap is achived If
gap is not correct, loosen the screws of fixed contact plate.
Tighten the screw of distributor securing clamp.

References:
1.http://www.seminarsonly.com/mech%20&%20auto/electronicfuelinjectionseminarreportppt.Ph
p – for electronic injection