ME-431 IC Engines & Power Plants Lab

IC Engines and Power Plants Lab

Lab Report 01
Introduction to the IC Engine Lab and Demonstration on Complete
Vehicle

8TH SEMESTER

Submitted to: LE Usman Ghani

Session: 2021 Section: ME-13B Group: N/A

SUBMITTED BY
Name CMS Marks

Ahmed Raza 387375

School of Mechanical and Manufacturing Engineering

 ME-431 IC Engines & Power Plants Lab

Objectives:
 Hands-on learning about internal combustion engines.
 Focus on working principles, components, and applications.
 Prepares students for real-world engine operation and maintenance.
Equipment Discussed:
4-stroke, 4-cylinder, EFI (Electronic Fuel Injection) engine system.
Theoretical Background:
Types of Combustion Engines:
Combustion engines are primarily categorized into two types based on
their fuel combustion process:
Internal Combustion Engine (ICE):
 In internal combustion engines, fuel combustion occurs within
the engine's combustion chamber, generating power directly.
 These engines are widely used in applications such as
automobiles (cars, motorcycles), aircraft, and power plants.
External Combustion Engine (ECE):
 In external combustion engines, fuel is burned outside the
engine, and the resulting heat is transferred to a working fluid
(e.g., steam or air) to produce power.
 These engines are less common in modern applications but were
historically used in steam engines and some industrial systems.
Classification of IC Engine:
Internal combustion engines can be classified in a number of different ways.
Types of Ignition:
Spark Ignition(SI):
The engine begins with the combustion process in each cycle
using a spark plug. The spark plug provides a high -load
electrical discharge between two electrodes that light the
mixture air in the combustion chamber surrounding the plug. At
the early development of the engine, many forms of torches
were used before the invention of electrical spark plugs to start
combustion from external flame.
 ME-431 IC Engines & Power Plants Lab

Figure 1: Spark Ignition Engine

Compression Ignition(CI):
The engine combustion process begins when the mixture of the
air and fuel self-ignites due to the high temperature in the
combustion chamber caused by high compression.

Figure 2: CI Engine

Engine Cycle:
Four-stroke cycle:
Four cycle of introduction is experiencing four piston movements
in two engine revolutions for each cycle.
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Figure 3: 4 Stroke Engine

Two-stroke cycle:
The cycle of two-stroke has two movements of pistons after one
revolution for each cycle. Three -stroke cycles and six-strokes
were also tested in the early engine development.

Figure 4: 2 Stroke Engine

Valve Location:
 Valves in the head (upper valve), also called I head engine.
 Valves in the block (flat head), also called L -head engine. Some
historical motors with valves in the block had an intake valve on
one side of the cylinder and exhaust valve on the other side.
They were called T Head engines.
 One valve in the head (usually intake) and one in the block, also
called F-head engines; This is much less common.
Basic Design:
 Reciprocating: The engine has one or more cylinders in which
the pistons will return back and forth. The combustion chamber
is located at the closed end of each cylinder. Power comes to the
rotating output crankshaft by mechanical binding with pistons.
 ME-431 IC Engines & Power Plants Lab

 Rotary: The engine is made of a block (stator) built on a large

non-concentric rotor and crankshaft. The combustion chambers
are built into blocks of non-rotating block.

Figure 5: Rotary Engine

Position and no. Of cylinders of reciprocating engines:

 Single cylinder: Engine has one cylinder and piston connected
to the crankshaft.

Figure 6: Single Cylinder Engine

 In-line: The cylinders are also located in-lines, one by one along
the length of the crankshaft. They can consist of 2 to 11
cylinders or perhaps more. In-line four-cylinder engines are very
common for cars and other applications. In-line Six and eight
cylinders are historically common automobile engines. In-line
engines are sometimes called straight line (e.g. six or eight).
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Figure 7: Inline Cylinder Engine

 V Engine: Two banks of cylinders at an angle to each other

along a single crankshaft. The angle between cylinder banks can
be anywhere from 15 ° to 120 °, with a normal 60 ° -90 °. The
engines have an even number of cylinders from 2 to 20 or more.
V6 and V8 are common car engines, with V12 and V16
(historical) found in some luxury and high -performance vehicles.

Figure 8: V Configuration Engine

 Opposed cylinder engine: Two cylindrical banks against each

other on one crankshaft (and in the engine 180 ° V). They are
common for small aircraft and some cars with an even number of
cylinders from two to eight or more. These engines are often
called flat engines (e.g. flat four).
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Figure 9: Opposed Cylinder Engine

 W-engine: Same as a V engine except with three banks of

cylinders on the same crankshaft. It is not common, but some
have been developed for racing cars, modern and historical.
Between each bank usually 12 cylinders with an angle of about
60 °.

Figure 10: W Configuration Engine

 Opposed piston engine: Two pistons in each cylinder with the

combustion chamber on the center between the pistons. A single
combustion chamber process causes two power strokes at the
same time, each piston is moved away from the center and adds
energy to a separate crankshaft at each end of the cylinder. The
engine output is either on two rotating crankshafts or on one
crankshaft containing a complex mechanical linkage.

 Radial Engine: Engines with pistons located in a circular plane

around the central crankshaft. The piston intoxicating rods are
connected to the main rod, which in turn is connected to the
crankshaft. The cylinder bank on the radial engine always has an
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odd number of cylinders ranging from 3 to 13 or more. In every

other cylinder cycle that works on a four-stroke cycle, it has
smooth traffic when the crankshaft turns. Many medium and
large propellers use radial engines. For large aircraft, two or
more cylinders are mounted, one after another in one crankshaft,
so one powerful and smooth engine. Very large ship engines
exist with up to 54 cylinders, each six banks of 9 cylinders.

Figure 11: Radial Engine

Air Intake Process:

1. Naturally Aspirated:
o No additional system is used to increase air intake pressure. Air
enters the engine solely through atmospheric pressure.
2. Turbocharged (Mechanical):
o Air pressure is increased using a compressor driven by the
engine's crankshaft.
3. Turbocharged (Exhaust-Driven):
o Air pressure is increased using a turbine compressor powered by
the engine's exhaust gases.
4. Crankcase Compression:
o The engine uses the crankcase as an air compressor, typically in
two-stroke engines. Limited development has been done for four-
stroke engines with this design.

Fuel Input Methods for SI (Spark Ignition) Engines:

1. Carburettors:
o Traditional method of mixing air and fuel before entering the
engine.
2. Multipoint Injection:
o One or more fuel injectors are placed at each cylinder's intake
port for precise fuel delivery.
 ME-431 IC Engines & Power Plants Lab

3. Throttle Body Injection:

o Fuel injectors are located upstream in the intake manifold,
supplying fuel to all cylinders.

Types of Fuel Used:

1. Gasoline:
o Commonly used in spark ignition engines.
2. Diesel Oil or Fuel Oil:
o Used in compression ignition engines.
3. Gas (Natural Gas, Methane):
o Alternative fuel for cleaner combustion.
4. LPG (Liquefied Petroleum Gas):
o A portable and efficient fuel option.
5. Alcohol (Ethyl, Methyl):
o Used as an alternative or additive to gasoline.
6. Dual Fuel:
o Engines that use a combination of fuels, such as methane and
diesel, to reduce costs and improve efficiency.
7. Gasohol:
o A blend of 90% gasoline and 10% alcohol, commonly used as an
alternative fuel.
Applications of Engines:
1. Automotive:
o Cars, trucks, and buses.
2. Locomotive:
o Trains and rail vehicles.
3. Stationary:
o Power generators and industrial machinery.
4. Marine:
o Boats and ships.
5. Aircraft:
o Airplanes and helicopters.
6. Small Portable Devices:
o Chain saws, model airplanes, and other handheld equipment.

4-stroke, 4-cylinder, EFI Engine vehicle (vehicle In IC lab):

The four-stroke, four cylinder, EFI engine (electronic fuel injection) is a
common type of engine with internal combustion used in modern vehicles. It
works through four different strokes in the cycle and its EFI system provides
 ME-431 IC Engines & Power Plants Lab

accurate fuel supply for optimal performance, fuel consumption and emission
control.
Electronic Fuel Injection (EFI):
Electronic fuel injection (EFI) is a system that electronically controls the fuel
supply to the engine using sensors and drivers. Unlike EFI carburetors, it
precisely adjusts fuel injection based on real-time engine conditions.
Components Of Engine:
 Intake Manifold:
The intake manifold is a network of tubes that evenly distributes air to
each cylinder in an EFI (Electronic Fuel Injection) engine. Since fuel is
injected separately into each cylinder, the manifold ensures balanced
air distribution for efficient combustion. It works with sensors like the
Mass Airflow Sensor (MAF) or Manifold Absolute Pressure (MAP) to
optimize the air-fuel ratio, enhancing engine performance and fuel
efficiency.
 Exhaust Manifold:
The exhaust manifold collects burnt gases from all cylinders and
channels them into the exhaust system for expulsion. Typically made
of cast iron or stainless steel to endure high temperatures, it minimizes
back pressure, improves engine efficiency, and connects to the
catalytic converter to reduce harmful emissions.
 Engine Head (Cylinder Head):
Mounted on top of the engine block, the cylinder head forms the
combustion chamber and houses critical components like valves, spark
plugs, fuel injectors, and camshafts in OHC (Overhead Camshaft) or
DOHC (Dual Overhead Camshaft) designs. It manages the flow of
intake and exhaust gases, supports ignition in petrol engines, and
provides the upper sealing surface for the combustion chamber.
 Engine Block:
The engine block is the core structure of the engine, containing
cylinders, pistons, the crankshaft, and lubrication passages. Usually
made of cast iron or aluminium alloys, it ensures durability and
effective heat dissipation. It also includes cooling passages for
temperature regulation and oil galleries to support the lubrication
system, ensuring smooth engine operation.
 Dual Overhead Camshafts (DOHC):
A DOHC engine features two camshafts in the cylinder head—one for
intake valves and one for exhaust valves. The intake camshaft controls
the opening of intake valves to allow air into the cylinders, while the
exhaust camshaft manages the expulsion of burnt gases. This design
 ME-431 IC Engines & Power Plants Lab

reduces valve overlap, improves fuel efficiency, and allows higher

RPMs, making it ideal for high-performance engines.
 Timing Belt:
The timing belt is a toothed rubber belt (or chain in some engines) that
synchronizes the crankshaft and camshafts, ensuring precise valve and
piston timing. It plays a crucial role in maintaining combustion
accuracy, improving engine efficiency, and preventing piston-valve
collisions, which could cause severe engine damage.
 Flywheel:
The flywheel is a heavy rotating disk attached to the crankshaft,
storing rotational energy to maintain smooth engine operation. It
reduces vibrations, assists in engine starting via the starter motor, and
facilitates clutch engagement and disengagement in manual
transmissions.
 Fuel Injectors:
Fuel injectors are electronically controlled valves that spray fuel as a
fine mist into the intake manifold (port injection) or directly into the
combustion chamber (direct injection). They work with the Engine
Control Unit (ECU) to deliver precise fuel amounts, enhancing
combustion efficiency, improving fuel economy, and reducing
emissions compared to traditional carburettors.
Lab Safety Precautions:
 Always wear safety goggles, gloves, and ear protection to stay safe.
 Work in a well-ventilated area to avoid harmful fumes.
 Keep loose clothing, hands, and tools clear of moving engine parts.
 Store fuel in approved containers and keep it away from sparks or
flames.
 Use an exhaust extraction system to vent emissions outside.
 Avoid opening the radiator cap on a hot engine to prevent burns.
 Have a fire extinguisher ready and learn how to shut down the engine
in an emergency.
 Disconnect the battery before working on electrical components.
 Clean up spills immediately to prevent slips or fire hazards.
 Inspect tools and equipment for damage before use.