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Module-3

Syllabus: Introduction to IC Engines: Components and Working Principles, 4-Strokes

Petrol and Diesel Engines, Application of IC Engines.

VTU Examination Questions:

1. How are IC engines classified?

 Give any four classifications of IC engines.

2. What are the applications of IC engines?

3. Give comparisons between petrol and diesel engines.

 Enumerate the Difference between Petrol engine and Diesel engine.

 List the differences between 4 stroke Petrol and diesel engine.

4. Analyze the construction and working of the 4 stroke Petrol engine with sketches. Plot the PV
diagram.

 With neat sketch explain the working of 4 stroke diesel engine.

 Explain 4-stroke SI engine with a neat sketch and PV diagram.

 Explain with neat sketch a 4 stroke engine where combustion of fuel takes place at
constant pressure.

 With the help of theoretical P-V diagram, explain Otto Cycle four stroke cycle engines.

5. Explain the construction and working of 4-Strokes Diesel Engine with P-V diagram.

 With neat sketch explain the working of 4 stroke diesel engine.

 Explain 4-stroke CI engine with a neat sketch and PV diagram.

 Explain with neat sketch a 4 stroke engine where combustion of fuel takes place at
constant volume.

 With the help of theoretical P-V diagram, explain Diesel Cycle four stroke cycle
engines.

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PRIME MOVER:

Prime mover is a self-moving device which converts the available natural source of energy into
mechanical energy of rnotion to drive the other machines. The various types of prime movers which
convert heat energy produced by the combustion of fuels into mechanical energy.

Example: Turbines, Internal combustion Engines, External combustion Engines, etc......

Natural Prime Mechanical

Source Mover Energy

IC ENGINES:

Heat engines are thermal prime movers which converts the chemical energy contained in the fuel into
heat energy by the combustion, further utilizes this heat energy to produce useful mechanical work.

Heat engines are classified as.

a) Internal combustion Engine (IC Engine):

IC Engine those in which combustion of fuel takes place inside the engine cylinder.

Example: Petrol engines, Diesel engines, Gas engines, etc.

b) External combustion Engine (EC Engine):

EC Engine those in which combustion of fuel takes place outside the engine cylinder.

Example: Steam engines, Steam turbines.

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CLASSIFICATION OF I.C. ENGINES I.C Engines can be classified into the following types:

i) According to the type of fuel used

a) Petrol engines - Fuel used in these engines is petrol.

b) Diesel engines - Fuel used is Diesel.

ii) According to the number of strokes

a) 4-strokeengine - The working cycle is completed in four different strokes.

b) 2-strokeengine - The working cycle is completed in two different strokes.

iii) According to the method of ignition

a) Spark ignition engine (S.I engine) - Fuel is ignited by an electric spark.

b) Compression ignition engine (C.I. engine) – Ignition takes place due to high
compression.

iv) According to the cycle of combustion

a) Otto cycle engine – Combustion of fuel takes place at constant volume.

b) Diesel cycle engine - Combustion of fuel takes place at constant

pressure.

v) (v) According to the number of cylinders

a) Single cylinder engine – These engines consist of only one cylinder.

b) Multi-cylinder engine - It consists of 2,3,4,6 or 8 cylinders.

vi) According to the arrangement of cylinders

a) Inline or parallel engines - Cylinders are arranged in a line.

b) Radial engines – Cylinders are arranged radially.

c) V-engines – The arrangement of two cylinders are at an angle.

d) Opposed type engine - Cylinders are arranged opposite to each other.

vii) According to the method of cooling

a) Air cooled engines – The cooling of the engine is done by air. Example: bike

b) Water cooled engines – The cooling of the engine is done by water, here a
radiator is used for cooling purpose. Example: cars.

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IC ENGINE PARTS:

The following figure illustrate major parts of an IC Engine

The parts of internal combustion engines are Cylinder, head, piston, piston rings (compression rings
and oil control ring), connecting rod and crankshaft.

Functions of IC engine parts:

Cylinder (cylinder block):

The cylinder is the main part of an engine. The combustion takes place in the combustion chamber and
these gases exert pressure on the piston, due to high gas pressures the piston reciprocates in the cylinder
block. The cylinder is designed to with stand high gas pressure and temperature.. The cylinder has to be
cooled properly either by air cooling or water cooling. The cylinder block material is grey cast iron.

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Cylinder head:

The head is fitted on the top of the cylinder block and is provided with the inlet valve, exhaust valve
and spark plug/fuel injector. There is a gasket is provided between cylinder and cylinder head in order
to prevent the leakage of high pressure gases. The material used for cylinder head is grey cast iron and
for gasket is copper and asbestos.

Piston:

The piston is a cylindrical plug, which converts heat energy in to mechanical energy. A two stroke
piston is fitted with only compression ring. In four-stroke engine both compression ring and oil control
rings are fitted. The piston is connecting to the small end of the connecting rod. The piston is made of
aluminium alloy. Functions of piston are i) The piston will act as a seal ii) To provide the passage for
heat flow from piston to cylinder block through rings. iii) It transmits the force of explosion to the
crankshaft through connecting rod.

Connecting rod:

The small end of the connecting rod is connected to the piston and the big end of the connecting rod is
connecting to the crankshaft. The connecting rod converts the reciprocating motion of piston in to
rotary motion of crankshaft. The connecting rod is made of I-beam cross section to provide maximum
rigidity with minimum weight.

Crankshaft: The big end of the connecting rod is connected to the crankshaft. The power transmission
starts from the crankshaft. The crankshaft is rigidly fixed in the crankcase. The other end of the
crankshaft is connected to a clutch.

Crankcase:

Crankcase is fitted at the bottom of the cylinder block. Two-stroke engine crankcase is properly sealed
and made airtight. Four stroke engine crankcase will serve as a reservoir, filled with sufficient quantity
of lubricating oil. This oil lubricates the main bearings of crankshaft, big end bearings of connecting
rod, lubricates the cylinder liner, piston and piston rings.

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IC Engine Terminology:

1) Bore:

The nominal inside diameter of tthe engine cylinder is known as Bore.

2) Stroke:

It is the linear distance, measured parallel to the axis of the cylinder, between extreme upper
and lower positions of the piston.

3) Top Dead Centre (TDC):

TDC in vertical engine is the extreme position of the piston nearer to the cylinder head. The
cylinder volume is minimum at TDC. In case of horizontal engine this position is known as
inner dead center (IDC).

4) Bottom Dead Centre (BDC):

BDC in vertical engine is the extreme position of the piston towards the crank end. The cylinder
volume will be maximum. In case of horizontal engine. This position is known as outer dead
center (ODC).

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5) Clearance volume:

The volume contained in the cylinder above the top of the piston When the piston is at TDC is
known as clearance volume and it is denoted by V

6) Swept volume:

The volume swept by piston while traveling from TDC to BDC in known as swept volume and
is denoted by V .

π
V = L m

7) Compression ratio:

It is the ratio of total volume of cylinder (V + V ) to the clearance volume(V ).

( )
It is denoted ‘r’. r = .

The compression ratio of petrol engine varies from 7:1 to 12:1.

The compression ratio of diesel engine varies from 16:1 to 22:1

4-Stroke Petrol Engine:

The four-stroke petrol engine works on the principle of Otto (constant volume) cycle. As heat addition
takes place at constant volume, this cycle is known as constant volume cycle. The parts of four-stroke
petrol engine are cylinder, piston, head, crankcase, connecting rod, crankshaft, spark plug, and inlet and
exhaust valve. The four-stroke petrol engine may be air-cooled or water-cooled. The piston performs
four strokes to complete one cycle.

The four different strokes are

i) Suction stroke iii) Power or Expansion stroke

ii) Compression stroke iv) Exhaust stroke

Since the ignition in these engines is due to the spark of a spark plug, it is very commonly known as
spark ignition engines (S.I Engines).
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1. Suction stroke:

 The suction stroke is completed by rotating the crankshaft from 0 to 180

18 . During suction
stroke
roke the inlet valve opens and exhaust valve should keep in closed condition.

 When the piston starts moving from TDC to BDC, The volume above the piston increases,
results in decrease in pressure (vacuum), This decrease in pressure draws the petrol and air
mixture from the carburetor and delivered it to the cylinder, this process is continuous till
the pressure inside the cylinder becomes equal to atmosphere.

 At the end of suction stroke the cylinder is completely filled with petrol and air mixture. At
the end of suction stroke the inlet valve closes. The line AB in the PV diagram represents
r
suction stroke (volume of mixture filled in the cylinder).

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2. Compression stroke:

 During the compression stroke both inlet and exhaust valves are closed and the piston
travels from the BDC to TDC & the crankshaft revolves further by half rotation, causing
the compression of air and fuel mixture.

 This stroke is represented by a line BC on the (Pressure -Volume) P-V diagram.

 At the end of this stroke a spark is produced by a sparkplug, resulting in the combustion of
the fuel and air & is represented by a line CD on P-V diagram.

3. Power stroke / Expansion stroke / Working stroke:

 In this stroke the piston travels from TDC to BDC with both the valves remain closed & the
crankshaft revolves half rotation.

 The piston is forced due to the expansion of the burnt gases .This linear motion of the
piston is transmitted to the crankshaft through the connecting rod to produce Mechanical
power. This stroke is called as power stroke as the Mechanical power is produced during
this stroke.

 It is represented by the curve DE on a P-V diagram.

 As the piston moves further, the pressure of the hot gases gradually decreases at constant
volume as represented by the line EB in PV diagram.

4. Exhaust stroke:

 During Exhaust stroke the exhaust valve opens with inlet valve closed and the piston
travels from BDC to TDC, causing the exhaust of burnt gases from the cylinder & the
crankshaft revolves half rotation.

 This stroke is represented by a line BA on the (Pressure -Volume) P-V diagram.

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4-Stroke Diesel Engine:

The working principle of a 4-stroke

stroke Diesel engine is based on Diesel cycle (constant pressure cycle).
Hence, it is also called as constant pressure cycle engine. Since the ignition in these engines is due to
high compression of air, it is very commonly kno
known
wn as Compression Ignition engines (C.I Engines).

The four strokes that are performed are,

1. Suction stroke

2. Compression stroke

3. Working stroke or Power stroke or Expansion stroke

4. Exhaust stroke

The following figure represent working principl

principle of 4-stroke
stroke Diesel engine with Theoretical Diesel-
Diesel
cycle.

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1) Suction stroke:

 During suction stroke the inlet valve opens with outlet valve closed & the piston travels from
(Top Dead Center) TDC to (Bottom Dead Center) BDC & the crankshaft revolves by half
rotation, causing the suction of pure air. The energy required to perform this stroke is
supplied by ‘cranking’ only during the first cycle at the time of starting, while running, the
flywheel supplies the mechanical energy.

 This stroke is represented by a line AB on the (Pressure -Volume) P-V diagram.

2) Compression stroke:

 During the compression stroke both inlet and exhaust valves are closed and the piston travels
from the BDC to TDC & the crankshaft revolves further by half rotation, causing the
compression of air.

 This stroke is represented by a line BC on the (Pressure -Volume) P-V diagram.

 At the end of this stroke a metered quantity of fuel is injected through the fuel injector, the
high temperature of the air ignites the fuel as soon as it is injected. This is called Auto-
ignition or Self-ignition

3) Power stroke / Expansion stroke / Working stroke:

 In this stroke the piston travels from TDC to BDC with both the valves remain closed & the
crankshaft revolves half rotation.

 The burnt gases released by the combustion of the fuel that is continuously injected into the
cylinder, force the piston to perform earlier part of this stroke at constant pressure till the
injection of the fuel is completed. This constant pressure expansion with simultaneous
combustion is represented by the line CD on PV diagram.

 The piston is forced further during the remaining part of this stroke due to the expansion of
the burnt gases .This linear motion of the piston is transmitted to the crankshaft through the
connecting rod to produce Mechanical power. This stroke is called as power stroke as the
Mechanical power is produced during this stroke.

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 It is represented by the curve DE on a P-V diagram.

 As the piston moves further, the pressure of the hot gases gradually decreases at constant
volume as represented by the line EB in PV diagram.

4) Exhaust stroke:

 During Exhaust stroke the exhaust valve opens with inlet valve closed and the piston travels
from BDC to TDC, causing the exhaust of burnt gases from the cylinder & the crankshaft
revolves half rotation.

 This stroke is represented by a line BA on the (Pressure -Volume) P-V diagram.

Applications of IC Engine

Internal combustion engines (IC engines) are widely used in transportation, power generation, and
industrial equipment. They power cars, trucks, boats, motorcycles, and airplanes, as well as generators,
pumps, and compressors. IC engines can run on a variety of fuels including gasoline, diesel, natural
gas, and biofuels. IC engines have a wide range of applications in various industries and sectors. Some
of the common applications of IC engines are:

 Automobiles: IC engines are widely used in automobiles such as cars, buses, trucks,
and motorcycles to power vehicles.

 Aircraft: IC engines are also used in small aircraft and helicopters to provide
propulsion.

 Marine: IC engines are used in marine applications such as ships, boats, and
submarines.

 Agriculture: IC engines are used in agriculture for powering farm machinery such as
tractors, harvesters, and irrigation pumps.

 Power generation: IC engines are used for power generation in applications where grid
power is unavailable or unreliable, such as remote locations, construction sites, and emergency
backup power.
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 Construction: IC engines are used in construction machinery such as excavators,

bulldozers, and cranes.

 Military: IC engines are used in military vehicles, tanks, and aircraft.

 Small equipment: IC engines are used in a variety of small equipment such as lawnmowers,
chainsaws, and generators.

Comparison between Petrol Engine & Diesel Engine:

Sl
Principle SI Engines (Petrol engine) CI Engines (Diesel engine)
No

1 Working cycle Works on Otto cycle Works on diesel cycle

2 Fuel used Petrol Diesel

During the suction stroke itself the At the end of the compression
Admission of the
3 petrol admitted to the cylinder stroke the diesel is injected into the
fuel
with air cylinder

the suction stroke Air and petrol

Charge drawn Only air is drawn during the
4 mixture is drawn during the suction
during suction stroke
stroke

Compression Low compression ratio ranging High compression ratio ranging

5
ratio from 7:1 to l2:l from 16:l to 20:l

Ignition of the Diesel is ignited by compression

6 Petrol is ignited by the sparkplug
fuel ignition or self-ignition

High engine speeds of about 3000 Low engine speeds ranging from
7 Engine speed
rpm 500 to l500 rpm

Because of the low compression Due to high compression ratio the

8 Power output
ratio power developed will be less power developed will be more

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Thermal The thermal efficiency is less due The thermal efficiency is higher
9
efficiency to lower compression ratio due to high compression ratio

Because of lower operating Because of higher operating

Noise and
10 pressure the noise and vibrations pressure the noise and vibrations
vibration
are almost nil are high

Weight of the
11 Weight of the engine is less Weight of the engine is more
engine

12 Initial cost Initial cost of the engine is less Initial cost of the engine is more

Operating fuel Operating fuel cost is more because Operating fuel cost is less because
13
cost petrol is costly diesel is cheap

14 Maintenance cost Less Slightly higher

Used in scooter, motor cycle, cars Used in trucks, tractors, buses,

15 Uses
etc... heavy vehicles, etc.. -.

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Syllabus: Insight into Future Mobility: Electric and Hybrid Vehicles, Components of
Electric and Hybrid Vehicles. Advantages and disadvantages of EVs and Hybrid vehicles.

VTU Examination Questions:

1. Describe the Components of Electric Vehicle with neat sketch.

 List out components of electrical and hybrid vehicles.

2. Describe Electric vehicles. Explain the components and working of electric vehicles.

3. List the advantages, disadvantages and applications of electrical vehicle.

4. Explain a Hybrid vehicle with neat sketch

5. Describe Hybrid vehicles. Explain the components and working of Hybrid vehicles.

6. Describe the Components of Hybrid Vehicle with neat sketch.

7. What are the advantages and disadvantages and applications of Hybrid Vehicles?

Introduction:
What is a hybrid? A hybrid vehicle combines any two power (energy) sources. Possible combinations
include diesel/electric, gasoline/fly wheel, and fuel cell (FC)/battery. Typically, one energy source is
storage, and the other is conversion of a fuel to energy. The combination of two power sources may
support two separate propulsion systems. Thus to be a True hybrid, the vehicle must have at least two
modes of propulsion.
For example, a truck that uses a diesel to drive a generator, which in turn drives several electrical
motors for all-wheel drive, is not a hybrid. But if the truck has electrical energy storage to provide a
second mode, which is electrical assists, then it is a hybrid Vehicle.
These two power sources may be paired in series, meaning that the gas engine charges the batteries of
an electric motor that powers the car, or in parallel, with both mechanisms driving the car directly.

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DriveShaft

Pure
Battery M/G
Electrical
Wheels

Control Battery
System
Electrical Power
Hybrid
Gasoline
Engine M/G Transmission

Wheels

DriveShaft

Pure Gasoline
Transmission
Gasoline Engine
Wheels
Figure: Components of a hybrid vehicle that combines a pure gasoline with a pure EV

Hybrid electric vehicle (HEV)

Consistent with the definition of hybrid above, the hybrid electric vehicle combines a gasoline engine
with an electric motor. An alternate arrangement is a diesel engine and an as shown in Figure 1, a HEV
is formed by merging components from a pure electrical vehicle and a pure gasoline vehicle. The
Electric Vehicle (EV) has an M/G which allows regenerative braking for an EV; the M/G installed in
the HEV enables regenerative braking. For the HEV, the M/G is tucked directly behind the engine. In
Honda hybrids, the M/G is connected directly to the engine. The transmission appears next in line. This
arrangement has two torque producers; the M/G in motor mode, M-mode, and the gasoline engine. The
battery and M/G are connected electrically.

Components of Electric and Hybrid Vehicles:

Hybrid electric vehicles are powered by an internal combustion engine and an electric motor, which
uses energy stored in batteries. A hybrid electric vehicle cannot be plugged in to charge the battery.
Instead, the battery is charged through regenerative braking and by the internal combustion engine. The
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extra power provided by the electric motor can potentially allow for a smaller engine. The battery can
also power auxiliary loads and reduce engine idling when stopped. Together, these features result in
better fuel economy without sacrificing performance.

Charging Port 1. Battery (Auxiliary

8 2. Transmission
5 67
3. Electric Generator
2 4. Electric Traction Motor
4
1 3 5. Thermal System (Cooling)
6. DC Converter
Charging Port
Fuel Filler 7. Controller & Inverter
8 9 10 8. Traction Battery Pack
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11
9. Exhaust System
2
4 10. Internal
1 3 Combustion Engine
11. Fuel Tank

Battery (auxiliary): In an electric drive vehicle, the low-voltage auxiliary battery provides electricity
to start the car before the traction battery is engaged; it also powers vehicle accessories.

DC/DC converter: This device converts higher-voltage DC power from the traction battery pack to the
lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary battery.

Electric generator: Generates electricity from the rotating wheels while braking, transferring that
energy back to the traction battery pack. Some vehicles use motor generators that perform both the
drive and regeneration functions.

Electric traction motor: Using power from the traction battery pack, this motor drives the vehicle's
wheels. Some vehicles use motor generators that perform both the drive and regeneration functions.

Exhaust system: The exhaust system channels the exhaust gases from the engine out through the
tailpipe. A three-way catalyst is designed to reduce engine-out emissions within the exhaust system.

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Fuel filler: A nozzle from a fuel dispenser attaches to the receptacle on the vehicle to fill the tank.

Fuel tank (gasoline): This tank stores gasoline on board the vehicle until it's needed by the engine.

Internal combustion engine (spark-ignited): In this configuration, fuel is injected into either the
intake manifold or the combustion chamber, where it is combined with air, and the air/fuel mixture is
ignited by the spark from a spark plug.

Power electronics controller: This unit manages the flow of electrical energy delivered by the traction
battery, controlling the speed of the electric traction motor and the torque it produces.

Thermal system (cooling): This system maintains a proper operating temperature range of the engine,
electric motor, power electronics, and other components.

Traction battery pack: Stores electricity for use by the electric traction motor.

Transmission: The transmission transfers mechanical power from the engine and/or electric traction
motor to drive the wheels.

Electric Vehicle (EV):

A Electric Vehicle (EV), also called All-Electric Vehicle (AEV) / Battery Electric Vehicle (BEV),
runs entirely on a battery and electric drive train. These types of electric cars do not have an ICE.
Electricity is stored in a large battery pack that is charged by plugging into the electricity grid. The
battery pack, in turn, provides power to one or more electric motors to run the electric car.

Components of EV:

 Electric motor  Battery  Motor/Regenerator

 Inverter  Control Module  Drive train

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Electric Vehicle (EV)

Working Principles of EV:

 Power is converted from the DC battery to AC for the electric motor

 The accelerator pedal sends a signal to the controller which adjusts the vehicle’s speed by
changing the frequency of the AC power from the inverter to the motor

 The motor connects and turns the wheels

 When the brakes are pressed or the electric car is decelerating, the motor becomes an alternator
and produces power, which is sent back to the battery

Hybrid Vehicle (HV):

HV is a type of hybrid vehicle that both an ICE and a motor, often called as series hybrid. This types
of electric cars offers a choice of fuels. This type of electric cars is powered by a conventional fuel
(such as gasoline) or an alternative fuel (such bio-diesel) and by a rechargeable battery pack. The
battery can be charged up with electricity by plugging into an electrical outlet or electric vehicle
charging station (EVCS).

HEV typically can run in at least two modes:

 All-electric Mode, in which the motor and battery provide all the car’s energy

 Hybrid Mode, in which both electricity and gasoline are employed.

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Hybrid Electric Vehicle (HEV)

Components of HV:

 Electric motor  Inverter  Fuel tank

 Engine  Battery  Control module

 Battery Charger (if onboard model)  Motor/Regenerator

Working Principles of HV:

HVs typically start up in all-electric mode and operate on electricity until their battery pack is depleted.
Some models shift to hybrid mode when they reach highway cruising speed, generally above 100 or
120 Km per hour. Once the battery is empty, the engine takes over and the vehicle operates as a
conventional, non-plug-in hybrid.

In addition to plugging into an outside electric power source, HV batteries can be charged by an
internal combustion engine or regenerative braking. During braking, the electric motor acts as a
generator, using the energy to charge the battery. The electric motor supplements the engine’s power;
as a result, smaller engines can be used, increasing the car’s fuel efficiency without compromising
performance.

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Advantages of Electric Vehicle

1. No Gas Required 5. Popularity 9. Reduced Noise

Pollution
2. More Convenient 6. Safe to Drive
10. Battery Life & Cost
3. Savings 7. Cost-Effective
11. Easy Driving
4. No Emissions 8. Low Maintenance

Disadvantages of Electric Vehicle

1. Battery Replacement 3. Electricity isn’t Free

2. The Initial Investment is Steep 4. Electric cars are limited by range and speed

5. An electric Vehicle takes about 4-6 hours and sometimes even a day to get fully charged.

6. Electric fuelling stations are still in the development stages

7. Not Suitable for Cities, Facing Shortage of Power.

Applications of Electric Vehicle

1. Public Transportation. 3. Military.

2. Aviation. 4. Spaceflight.

Advantages of a Hybrid

1. Environmentally Friendly 4. Regenerative Braking System

2. Less Dependence on Fossil Fuels 5. Assistance from Electric Motor

3. Regenerative Braking System 6. Smaller Engines & Compact.

7. The engine is automatically shut off when the vehicle is idle

8. Higher Resale Value

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Disadvantages of a Hybrid

1. Suited for city driving and not for speed and acceleration.

2. Can be Expensive

3. Higher Maintenance Costs

4. Accident from High Voltage in Batteries

5. Battery Replacement is costly

Applications of Hybrid Vehicle

1. Public Transportation. 3. Military.

2. Aviation. 4. Spaceflight.

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