INTERNAL COMBUSTION ENGINES (IC Engines)

Engine
Device which transforms one form of energy into another form

Heat Engine
Conversion of thermal energy into mechanical work

• External Combustion Engine

Combustion takes place outside the engine

• Internal Combustion Engine

Combustion takes place within the engine

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PARTS/COMPONENTS

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1.Cylinder
- In an IC engine the main part is the engine cylinder in which the piston
moves and the combustion takes place.
- The cylinder has to withstand high temperature and pressure. Normally the
cylinder is made of cast iron or steel alloy and usually in one piece.
2.Cylinder head
- The cylinder head is a block, which closes one end of the cylinder and it is
removable too.
- It contains inlet valve and exhaust valve through which charge is
taken inside the cylinder and burned gases are exhausted to the
atmosphere.
- The main purpose of the cylinder head is to seal the working ends of the
cylinder and not to permit entry and exit of gases.
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3. Piston
- Its function is to transmit the force exerted by the burning of
charge to the connecting rod. The piston must give tight seal
to the cylinder, slide freely, and be light and strong.
- The pistons are usually made of aluminum alloys.

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4. Piston rings
- The piston rings are placed at the circumferential grooves provided on
the outer surface of the piston. These are made of special steel alloys.
- The function of the upper rings is to provide an airtight seal to prevent
the leakage of burnt gases in to the lower portion.
- Similarly the function of the lower rings to provide the effective seal to
prevent the leakage of oil in to the engine cylinder.

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5. Connecting rod
- It is the link between the piston and the crankshaft, whose main
function is to transmit force from piston to crankshaft.
- It converts the reciprocating motion of the piston to circular
motion of the crankshaft.
- The upper end of the connecting rod is connected to piston and the
lower end is connected to crank.
- Special steel alloys or aluminum alloys, nickel are used for the
manufacture of connecting rods.

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6. Crank
- The piston moves in the cylinder in a reciprocating motion and it
must be changed to rotary motion for useful purposes, for that a
crank and connecting rod is used.
- The connecting rod connects the piston to the crank

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7. Crankshaft
- It is considered as the backbone of the engine.
- The shaft contains one or more eccentric portions called cranks and
it’s a part of the crank shaft.
- The power for any useful purpose is taken from the crankshaft
only.
- Special steel alloys are used for the manufacture of crankshaft.
8. Crankcase
- It is a cast iron casing, which holds the cylinder and the
crankshaft of the I.C engine.
- It also serves as a sump for the lubricating oil.
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8. Flywheel
- It is a big wheel mounted on the crankshaft, whose function is to
maintain the speed constant.
- It is done by storing excess energy during power stroke, which is
returned during other strokes.

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 NOMENCLATURE
In this figure, 6 times Clearance Volume = Maximum Volume
Compression ratio = Maximum Volume/ Clearance Volume

Let, 10
 Basic Terms used in I.C. Engines
Bore diameter: It is the inside diameter of the cylinder.

Top dead centre: It is the extreme position of the piston towards

covered end side of the cylinder. The crank pin comes in line with the
piston and the crankshaft.

Bottom dead centre: It is the extreme position of the piston towards the
crank side of the cylinder. The crank pin moves to the farthest distance
from the cylinder.

Stroke: It is the linear distance travelled by the piston from one dead
centre position to the other dead centre position. It is equal to twice the
crank radius
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 Basic Terms used in I.C. Engines
Swept volume (Vs): (Piston displacement)

It is the volume through which the piston sweeps

during a stroke. It is the product of cross sectional
area of piston and its stroke length.

where d=bore diameter and L is the stroke length.

Clearance volume (vc):

It is the volume included between the top of the

piston and the cylinder head, when the piston is at
the TDC . 12
 Basic Terms used in I.C. Engines

Total cylinder volume:

It is the sum of clearance volume and swept volume (vs + vc )

Compression ratio (CR.):

It is the ratio of the total cylinder volume to the clearance volume.

(For petrol engines CR varies from 4:1 to 10:1 and for diesel engine
it ranges from 16:1 to 22:1)

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 Basic Terms used in I.C. Engines

Cubic capacity or engine capacity:

The displacement volume of a cylinder multiplied by the number of

cylinder cc = vs × n

Engine displacement

Example : vehicle has 4 cylinders

Each cylinder has a volume of 700 cc

700 cc × 4 = 2800 cc

2800cc = 2.8 litre

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 Torque:
• Torque is the term used to describe a rotating force.
• Torque is the actual reading of how “hard” and with how much
“force” the engine turns. It is the turning moment that engine
produces which is responsible for pulling power.
• More torque generally means a car can accelerate faster.
Acceleration at low speed is set by torque
• Higher the compression ratio –higher the torque.
• Torque = Force * Radius
• Power = Torque × R.P.M

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Horsepower or output power
• Horsepower: 1 HP = 33,000 lb-ft / min

• One horsepower is the ability to lift 33000 pounds one foot in one minute

• The horsepower specification for an engine tells you how much power the engine
can produce.

• Horsepower is the rate at which the engine does work. At higher

speed more power produces.

• As r.p.m increases then power increases but torque decreases.

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Torque and horsepower think about:
• Torque being how hard you can
pound away on bicycle pedals
• Horsepower being how fast you can
spin the bicycle pedals.
Consider a tractor pulling a load
• Torque developed will determine
whether or not the tractor is capable
of pulling the load. Power
delivered will determine how fast
the load can be pulled.

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4 Stroke Engine
Petrol Engine/Spark ignition/ SI engine
 Principle of a Petrol Engine
• Petrol engines works on Otto cycle in which the working substance
is heated at constant volume.

• Petrol engines are spark ignition engines. The air fuel mixture is
ignited with the help of a spark produced by a spark plug.

• A device called carburetor is used to mix air and fuel in

correct proportions. This air fuel mixture is admitted in to
the engine cylinder during suction stroke.

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WORKING OF A FOUR STROKE PETROL
ENGINE

For every 4-stroke of the piston, the crankshaft rotates 2 revolutions

and one power stroke.

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1. SUCTION STROKE

• The stroke begins when the piston is at top dead center.

• The piston move downwards and the inlet valve opens.

• A mixture of air and fuel mixed proportionately by carburetor enters

the cylinder and fills the space inside in the cylinder.

• The piston reaches its lowest dead center known as bottom dead center
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2. COMPRESSION STROKE

• The piston moves up after the intake stroke.

• The inlet valve close and exhaust valve remain closed. The
piston moves upward.

• The piston compresses the fuel-air mixture by pushing it upward

into clearance space at the top of the cylinder.

• The pressure and temperature of the mixture increases during

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compression stroke.
3. POWER STROKE
• The fuel-air mixture at high pressure and temperature is ignited by
a spark plug.
• The spark ignites the fuel-air mixture. This burning increases the
pressure and temperature of the gases further.
• The gases expand producing an explosive force pushing the piston
down.
• The linear movement of the piston is converted into rotary motion
of the crankshaft. 24
4. EXHAUST STROKE
• The piston reaches the bottom dead center at the
end of the power stroke. The exhaust valve opens.
The burnt gases escape at
greater speed.
• The piston moves up from bottom dead center and pushes out
the remaining burnt gases inside the cylinder.
• At the end of the exhaust stroke, the exhaust valve closes.

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Diesel Engine/Compression ignition/ CI
engine
 4-STROKE COMPRESSION IGNITION
ENGINE (CI Engine)
• Suction/Intake stroke
• Compression stroke
• Expansion/Power stroke
• Exhaust stroke

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SI vs CI

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SI vs CI

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Petrol Engine &
Diesel Engine

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2 Stroke Engine
Petrol Engine/Spark ignition/ SI engine
WORKING OF A TWO STROKE PETROL ENGINE
For every 2-stroke of the piston, the crankshaft rotates ONE
revolution and one power stroke.

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2-Stroke Spark Ignition Engine (SI Engine)

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 FIRST STROKE

• Assume that the piston is at its BDC position.

• During this stroke, the piston moves upwards from bottom dead
center to top dead center.
• It closes the transfer port and the exhaust port. The charged air-
petrol mixture which is already there in the cylinder is compressed.
• Due to upward movement of the piston, a partial vacuum is created in
the crank case and a fresh charge is drawn into the crank case
through the uncovered inlet port.
• At the end of this stroke, the piston reaches the T.D.C position.
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SECOND STROKE
• The compressed charge is ignited in the combustion chamber by
means of an electric spark produced by the spark plug, slightly
before the completion of the compression stroke.
• Due to combustion, piston is moved in downward direction.
• During this stroke, the inlet port is covered by the piston and the
fresh charge is compressed in the crankcase.
• Further downward movement of the piston uncovers the exhaust
port and then the transfer port. 36
• The expanded gases start escaping through the exhaust port and at
the same time fresh charge which is already compressed in the
crankcase, is forced into the cylinder through the transfer port.

• The charge strikes the deflector on the piston crown, rises to the top
of the cylinder and pushes out most of the exhaust gases.

• The piston is now at the bottom dead center position. The

cylinder is completely filled with the charge.

• The cycle of events is then repeated.

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Diesel Engine/Compression ignition/ CI
engine
2-Stroke Compression Ignition Engine (CI
Engine)

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 SCAVENGING
Scavenging is a process of removing the burnt gases from the
combustion chamber of engine cylinder with the help of fresh charge
in a two stroke engine.

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SCAVENGING

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4-stroke vs
2-stroke

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4 Stroke & 2
Stroke Engine

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Knocking in SI Engine and CI engine

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Engine Performance Parameters

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Engine Performance Parameters

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 Engine Performance Parameters

Efficiencies
– Mechanical efficiency
– Thermal efficiency
– Volumetric efficiency
– Relative efficiency
– Air standard efficiency

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Engine Performance Parameters

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Engine Performance Parameters

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Engine Performance Parameters

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 ASSIGNMENT-1
With the help of neat sketches/block diagrams explain the following:
a) Air intake system in IC Engine
b) Fuel system in IC Engine
c) Cooling system in IC Engine
d) Lubricating system in IC Engine

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 ELECTRONIC FUEL INJECTION
SYSTEMS
• CRDi (Diesel Injection)
• MPFI (Gasoline Injection)
– Port injection vs Throttle body injection

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COMMON RAIL DIRECT INJECTION ENGINE (CRDi) for DEISEL ENGINE

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 COMMON RAIL DIRECT INJECTION ENGINE
(CRDi) for DEISEL ENGINE
• CRDI is a modern direct injection system for diesel engines.
• Conventional direct injection diesel engines must repeatedly generate
fuel pressure (35-40 bar) for each injection. But in the CRDI
engines, the pressure is built up independently of the injection
sequence and remains permanently available in the fuel line.
• Common rail distributes the fuel to the computer-controlled injectors
at a constant pressure of up to 1600 bar. The computer also controls the
amount of fuel pumped.
• An Electronic Control Unit (ECU) receives signals from various
sensors and uses those signals to operate injection. (sensors on the cam
and crankshafts)
• More accurately measured and timed mixture spray in the combustion
chamber significantly reduces unburned fuel and gives CRDi the
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potential to meet future emission guidelines such as Euro V.
 COMMON RAIL DIRECT INJECTION ENGINE
(CRDi) for DEISEL ENGINE
Elements of CRDi are:
1. Low-pressure circuit:
- The low-pressure circuit comprises of the Fuel tank, pre-supply pump,
fuel filter, and the respective connection lines. The low-pressure
circuit is responsible for transporting the fuel to the high-pressure
circuit.

2. High-pressure circuit:
- The high-pressure circuit comprises of the high-pressure pump with a
pressure control valve, a common rail (pressure accumulator) with
the rail pressure sensor, injectors, and the respective high-pressure
connection lines. High-pressure circuit to generate a constant high
pressure in the high-pressure accumulator (the rail) and to inject the fuel
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through the injectors into the engine's combustion chambers.
 COMMON RAIL DIRECT INJECTION ENGINE
(CRDi) for DEISEL ENGINE
Elements of CRDi are:

3. ECU and sensors:

- ECU receives and evaluates the signals from the sensors, viz., speed
sensor, air temperature sensor, air mass meter, and rail pressure sensor.
ECU calculates injected fuel quantity, the start of injection,
duration of injection, and rate of the discharge curve, as well as
supervises the correct functioning of the injection system as a whole.

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Advantages
❖ 25% more power and torque than normal direct
injection system
❖ Superior pick up
❖ Lower levels of noise and vibration
❖ Higher mileage
❖ Lower emission
❖ Lower fuel consumption
Disadvantages
❖ Costly than conventional engine
❖ High degree of engine maintenance
❖ Costly spare parts.
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 MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE

• MPFI System is a system that uses a small computer (more like a

microchip) to control the Car’s Engine.

• A Petrol car’s engine usually has three or more cylinders.

• So in the case of an MPFI engine, there is one fuel – injector installed

near each cylinder that is why they call it Multi-point (more than one
point) Fuel Injection.

• Before the MPFI system was discovered, there was a technology called
“Carburetor”.
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 MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE
• Before the MPFI system was discovered, there was
a technology called “Carburetor”.

― Carburetor was one chamber where petrol and

air were mixed in a fixed ratio and then sent
to cylinders to burn to produce power.

― This system is purely a mechanical machine

with little or no intelligence.

― It was not very efficient in burning petrol; it

will burn more petrol than needed at times
and will produce more pollution.

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MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE

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MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE

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 MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE
• In the MPFI system, each cylinder has one injector (which makes it
multi-point).

• Each of these Injectors is controlled by one central car computer.

• This computer is a small microprocessor, which keeps telling each

Injector about how much petrol and at what time it needs to inject
near the cylinder so that only the required amount of petrol goes into the
cylinder at the right moment.

• So the working of MPFI is similar to Carburetor, but in an improved

way, because now each cylinder is treated independently unlike
Carburetor. 62
 MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE
• For the Inputs, the microprocessor (or car’s computer) reads a number
of sensors.

• Through these sensors, the microprocessor knows the temperature of

the Engine, the Speed of the Engine, it knows the load on the Engine, it
knows how hard you have pressed the accelerator, it knows whether the
Engine is idling at a traffic signal or it is actually running the car, it
knows the air-pressure near the cylinders, it knows the amount of
oxygen coming out of the exhaust pipe.

• Based on all these inputs from the sensors, the computer in the MPFI
system decides what amount of fuel to inject.
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 MULTI POINT FUEL INJECTION SYSTEM (MPFI)
FOR PETROL ENGINE
Advantages
❖ Spraying accurate amounts of air-fuel mixtures controlled by ECU
results in fuel economy and lower exhaust emissions as compared to
carburetor-equipped engines.
❖ The power delivered from all cylinders is uniformly balanced as the
supply of fuel to each cylinder is uniform which reduces vibrations
and hence ensures long engine life.
Disadvantages
❖ The MPFI setup is expensive
❖ MPFI installation is complex as compared to its predecessor fuel
injection systems

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 HYBRID VEHICLE
• Any vehicle that combines two or
more sources of power that can
directly or indirectly provide
propulsion power is a hybrid.
• In 1901 Ferdinand Porsche
developed the Lohner-Porsche
Mixte Hybrid, the first gasoline-
electric hybrid automobile in the
world.
• The hybrid-electric vehicle did not
become widely available until the
release of the Toyota Prius in
Japan in 1997, followed by the
Honda Insight in 1999.
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 HYBRID VEHICLE
• In practice, a hybrid will have a traditional internal-combustion engine
and a fuel tank, as well as one or more electric motors and a battery pack.
• A gasoline car produces a relatively large amount of pollution and
generally gets poor gas mileage.
• An electric car, however, produces almost no pollution, but it can only go
50 to 100 miles (80 to 161 km) between charges. And the problem has
been that it is inconvenient to recharge.
• The hybrid is a compromise. It attempts to significantly increase the
mileage and reduce the emissions of a gas-powered car while
overcoming the shortcomings of an electric car.

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Gasoline-electric hybrid

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 Gasoline-electric hybrid
Gasoline-electric hybrid cars contain the following parts:
Gasoline engine - 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.
Fuel tank - The fuel tank in a hybrid is the energy storage device for the
gasoline engine.
Gasoline has a much higher energy density than batteries do. For example, it
takes about 1,000 pounds of batteries to store as much energy as 1 gallon (7
pounds) of gasoline.
Generator - The generator is similar to an electric motor, but it acts only to
produce electrical power.
Batteries - 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.
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 Gasoline-electric hybrid
Electric motor - Advanced electronics allow it to act as a motor as well as a
generator.
If you supply electrical power to it, the shaft starts turning, acting like a motor.
However, if you turn the shaft using external force, the armature will generate
electric power, acting like a generator.
In all the hybrid types, as one starts braking or lets go of the accelerator pedal,
the wheel driving motor becomes a wheel driven generator.
But acting as a generator, it can slow the car down and return energy to the batteries.
Power split device - is the heart of the hybrid. This is a clever gearbox that hooks
the gasoline engine, generator and electric motor together.
It is a set of planetary gear train.
Transmission - The transmission on a hybrid car performs the same basic function as
the transmission on a conventional car.

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 Gasoline-electric hybrid
Startup and low-to mid-speed range
• Motor operation with outstanding energy efficiency and low-speed torque.

• In normal cruising from vehicle start up to the mid-speed range, where

engine efficiency is poor, the engine is shut off and the vehicle operates
with the high-output motor alone using the electricity from the battery.

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 Rapid acceleration
Rapid acceleration
• The engine power is splitted into two portions by the power split
device, one of which is used directly for driving the wheels and the other
is fed to the generator/ motor to supplement the engine power.
• Battery also supplies electricity to drive the motor (a b c).

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 Deceleration and braking
• Deceleration energy is recovered by the battery.
• During deceleration and braking, the wheels drive the motor.
• This means that the high-output motor operates as a high-output generator
to convert the vehicle braking energy into an additional source of electric
power.
• This highly efficient process is known as regenerative braking, with the
recovered electric power used to recharge the high-performance battery
(d).

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 Battery recharging
• Constant battery charge level is maintained.
• When the battery charge level is low, starting the engine switches the
generator on, and recharging begins.
• This system operates to maintain a constant charge level (e).

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Series hybrid
• The engine will only operate the generator, which in turn charges the
battery.
• The transmission is driven by the electric motor, which is powered
entirely by the battery. This is a very simple system, but not the efficient
one.
• Here, the torque generated by the engine always
undergoes two transformations before reaching the
transmission.

• That is, Torque to electricity and electricity to torque. Each

transformation results in some losses.
• The 2014 BMW i3 and the out-of-production 2012 Fisker Karma use
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75
Parallel Hybrid

• The engine as well as the battery can run the motor, which in
turn drives the transmission. When the battery is drained, only
then engine turns the motor.

• Civic Hybrid from Honda, is a parallel hybrid.

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77
Series & Parallel Hybrid

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79
Series-parallel hybrids

• As the name implies, these cars contain elements of both types.

• Conceptually, the engine and the electric motor feed into the
transmission via separate paths, enabling fully independent propulsion
via the engine or electricity.

• In parallel fashion, the motor-generator can either bolster the engine's

output or provide battery charging via regenerative braking.

• Ford's C-Max and Fusion hybrids and all Toyota and Lexus hybrids use
series-parallel systems.

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Plug-in hybrids
• These are not really a fourth type of hybrid because a plug-in could
conceivably be based on any of the above layouts.
• Plug-in hybrids (also called PHEVs) began appearing in the market with
the Chevrolet Volt at the end of 2010.
• It provides a way to plug the battery into an electrical outlet for
recharging while parked.
• The benefit of the plug-in hybrid is its ability to travel in all-electric
mode for most short trips, reserving the gasoline engine for longer
drives.
• In addition to the Volt, plug-in hybrids include the Ford Fusion Energi,
Toyota Prius and a version of the Honda Accord.
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