Introduction to Automobile Engineering (CUAE2170) [2-1-0]

Module II: Engine-

Experiment 1: Valve Timing Diagram of SI Engine. (Taha ashraf,)

Experiment 2: Valve Timing Diagram of CI Engine. (Taha ashraf,)

Module III: Fuel Injection-

Experiment 3: Study of Fuel Injection System of a Diesel Engine. (Kuashal kumar, )

Module IV: Transmission System-

Experiment 4: Study of Transmission System of Automobile. (Rahul kumar,)

Experiment 5: Model Study of Differential of Automobile. (Lalan kumar,)

Module V: Couling and Lubrication System-

Experiment 6: Model Study of Air-Cooling System. (Rohan kumar,)

Experiment 7: Model Study of Liquid Cooling System. (Rohan kumar,)

Module VI: Super Charging &Turbo Charging-

Experiment 8: Study of Working Model of Supercharger. (Sonu ram, )

Experiment 9: Study of Working Model of Turbocharger. (Sonu ram, )

Subsystems of Automobile (CUAE2171) [3-2-0]

Module I: Engine Emissions-

Experiment 1: Identification of Different Sub-Systems of Automobile. (Yashwanth,)

Experiment 2: Studies of Exhaust Gas Recirculation System (EGR) in KNOW Vehicle. (Dilip
kumar,)

Experiment Name:- Exhaust Gas Recirculation System (EGR)

Aim/object: Study of Exhaust Gas Recirculation System (EGR) in Know

vehicle.

Sketch:
Material, Tools, & Equipment:
1. EGR cooler
2. EGR vacuum modulator
3. EGR valve
4. Intake manifold
5. EGR Temperature Sensor
6. Control Valve
7. Pipes and Hoses

Theory: Exhaust gas recirculation (EGR) is a system that reduces nitrogen

oxide (NOx) emissions by recirculating exhaust gas into the engine's intake
manifold:
Types of EGR systems
EGR systems can be classified as external, internal, low-pressure, or high- pressure.
EGR in gasoline engines
In gasoline engines, EGR displaces some of the combustible charge in the
cylinder.
This reduces the amount of charge available for combustion, but
doesn't affect the air-fuel ratio.
EGR in diesel engines
In diesel engines, EGR replaces some of the excess oxygen in the pre-
combustion mixture. EGR and fuel type
The chemical properties of different fuels limit how much EGR can be used. For example,
methanol is more tolerant to EGR than gasoline.
Procedure/ working:-

The following procedure are used in the study of EGR System

How it works
EGR dilutes the air-fuel mixture by recirculating a portion of the exhaust gas
back into the engine's intake system

This reduces the oxygen content and lowers the combustion temperature.
The lower temperature means less NOx is formed, resulting in fewer air-
polluting emissions.
EGR valve
The EGR valve is normally closed and connects the exhaust manifold to the intake manifold.
EGR valve operation
The EGR valve opens when the engine is warm but still under load. As the load increases, the
valve opens more and leaks exhaust gas into the intake manifold
Mixing
The EGR is mixed with filtered, high-pressure, fresh combustion air in the throttle valve
assembly.

Application/Inference:

The following application are used in EGR System

Exhaust Gas Recirculation (EGR) systems are used in a variety of applications, including
Vehicles: EGR systems are used in cars, trucks, buses, and other vehicles.
Stationary engines: EGR systems are used in stationary engines like those used in power plants
and factories.
Marine diesel engines: EGR systems are used in marine diesel engines to reduce nitrogen oxide
(NOx) emissions.

Module II: Ignition System-

Experiment 3: Study of Battery Ignition and Magneto Ignition System. (Rohit kumar, )
 Experiment name:- Battery Ignition System

Name of the experiment:- Study of Battery Ignition

Sketch:

Theory:-
In case of petrol engines during suction operations, charge of air and petrol fuel will be
taken in. During compression this charge is compressed by the upward moving pistons. And just
before the end of compression, the charge of air and petrol fuel will be ignited by means of spark
produced by means of spark plug. And the ignition system does the function of producing the
[spark in case of spark ignition engines. When high tension voltage of the order of 30000 volts is
applied across the spark electrodes of a spark plug, current jumps from one electrode to another
electrode producing a spark.
Battery ignition system works on mutual electromagnetic induction principle. Battery ignition
system was generally used in 4-wheelers, but now-a-days it is more commonly used in 2-
wheelers also (i.e. Button start, 2-wheelers like Pulsar, Kinetic Honda, Honda Activa, Scooty,
Fiero, etc.). In this case 6V or 12V batteries will supply necessary current in the primary windin

Material and equipment/Construction

The Battery Ignition System consists of the following Main Parts:

o Battery
o Ballast Resistor
o Ammeter
o Ignition Switch
o Primary Winding
o Contact Breaker
o Capacitor
o Secondary Winding
o Distributor
o Spark Plug

Procedure\Working:-

o When the ignition switch is turned ON, the primary circuit is closed, allowing current to
flow through it.
o The current creates a magnetic field around the soft iron core of the coil.
o As the breaker points open, the current flows through the condenser; when they close, the
current flows through the contact breaker.
o The condenser charges as the current passes through it, causing the primary current to
decrease, and the magnetic field collapses.
o The change in magnetic field induces a current in the primary winding in the same
direction as the primary current.
o This charges the condenser to a much higher voltage than the battery, stopping the
current flow from the battery.
o The condenser discharges into the battery due to these processes.
o Reversing the direction of the primary current and magnetic field induces a high voltage
in the secondary winding.
o The high voltage is sent to the distributor via the high-tension wire.
o The distributor connects to the spark plugs through the ignition harness.
o The current passes through each spark plug one by one, producing sparks for igniting the
air-fuel mixture.

Application and inference

Some of the common applications of Battery Ignition System include

o Used in a wide range of automobiles, including cars, motorcycles, trucks, and buses.
 o Commonly employed in light commercial vehicles and passenger cars for reliable engine
ignition.
o Found in various two-wheeler vehicles, such as motorcycles and scooters, for efficient
spark generation.
o Used in some agricultural machinery and equipment to power small engines.

Conclusion:- The battery ignition system provides good spark intensity but occupies more space
and requires periodic battery maintenance. It is commonly used in cars, buses, trucks and motor.

Experiment name:- Magneto Ignition System.

Name of the experiment:- Magneto Ignition System

Sketch:

Theory:
Magneto is a special type of ignition system with its own electric generator to provide
then ecessary energy for the system. It is mounted on the engine and replaces all the components
of the coil ignition system except the spark plug. A magneto when rotated by the engine is
capable of producing very high voltage and does not need a battery as a source of external
energy.
Construction: -
The high intension magneto incorporates the windings to generate a primary voltage as well as to
set up the voltage and thus does not require a separate coil to boost up the voltage required too
perate the spark plug. Magneto can be either a rotating armature type or rotating magnet typ. In
the rotating armature type, the armature consisting of the primary and secondary windings all
rotates between the poles of a stationary magnet. In rotating magnet type the magnet revolve
sand the windings are kept stationary. Another type called polar inductor type is also use, where
both magnet and windings remain stationary. The voltage generated by reversing the flux field
with the help of soft iron polar projections, called inductors.
The following main parts or components of the Magneto Ignition system are:
 Rotating Magnets
 Primary Winding
 Secondary Winding
 Fixed Armature
 Condenser
 Breaker-points or Contact Breaker
 Distributor
 Ignition Switch and
 Spark plug

Procedure\ Working::-

o Engine Start: When the engine starts, it initiates the rotation of the magneto, generating
energy in the form of high voltage.
o Grounding and Capacitor Connection: One end of the magneto is grounded through a
contact breaker, and the ignition capacitor is connected in parallel to it.
o Contact Breaker Regulation: The contact breaker is regulated by a cam, and when it
opens, current flows through the condenser, charging it.
o Condenser Acting as a Charger: As the condenser functions as a charger, the primary
current flow reduces, leading to a decrease in the overall magnetic field generated in the
system, thereby increasing the voltage in the condenser.
o Spark Production: The increased high voltage in the condenser acts as
an EMF (Electromotive Force), producing the spark at the appropriate spark plug through
the distributor.
o Speed-Dependent Voltage Generation: Initially, with a low engine speed, the voltage
generated by the magneto is low, but as the engine's rotating speed increases, the voltage
generated by the magneto and the current flow also increase.
o Kick Start Option: To facilitate engine kick-starting, an external source such as a
battery can be used to avoid slow engine starts.

Application and inference

The following application of the Magneto Ignition system are:

 In the engine where other electricity means not available such as lawnmowers and
chainsaws.
 Aviation Piston Engine and
 Racing Cars.
 In the engine where other electricity means not available such as lawnmowers and
chainsaws.
  Aviation Piston Engine and
 Racing Cars.

Experiment 4: Disassembly and Assembly of 6-Cylinder Diesel Engine (Rahul kumar, )

Module III: Transmission System & Gear Box-

Experiment 5: Study of Single Plate Friction Clutches (Coil Spring Type and Diaphragm Type).
(Lalan kumar, )

Experiment 6: Study of Synchronizer Mechanism and Synchromesh Gear Box, Continuously

Variable Transmission (CVT). (Kuashal kumar, )

Module IV: Propeller Shaft and Differential & Axles-

Experiment 7: Study of Propeller Shaft, Universal Joints, Slip Joints, Centre Bearing. (Rohan
kumar, )

Experiment 8: Study of Front Axle System. (Yashwanth,)

Experiment 9: Study of Rear Axle System Including Differential Mechanism. (Sonu ram, )

Experiment 10: Disassembly and Assembly of Manual Transaxle of Front Wheel Drive Car.
(Rahul kumar,)
Module V: Steering System & Braking System-

Experiment 11: Study of Steering Gear Box and Hydraulic Power Assisted Steering System.
(Md umar, )

Experiment 12: Identifying the Different Components and Working Of Drum Brake, Disc
Brake, Hydraulic Brake, Air Brake System. (Md umar, )

Experiment 13: Study of Anti-Lock Braking System (ABS) In KNOW Vehicle. (Sonu ram, )

Module VII: Suspension System-

Experiment 14: Identification of Different Types of Suspension Systems: Coil Spring, Tension
and Telescopic Suspension System. (Rohit kumar,)
Experiment name:- suspension system
Aim:- study of suspension system

Sketch
Theory:-
Suspension is the system of tires, tire air, springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two. Suspension systems
serve a dual purpose:
contributing to the vehicle's road holding/handling and braking for good active safety and driving
pleasure and
keeping vehicle occupants comfortable and a ride quality reasonably well isolated from road
noise, bumps, vibrations, etc
Horse-drawn wagons first incorporated crude suspension systems, often consisting of simple leaf
springs. Some of these systems were the first independent suspension systems (ones that let each
wheel rise and fall independent of the three other wheels). Some of today's suspension
components look much like early suspension parts while others take advantage of high-tech
enhancements like computer controlled suspension response and road-surface compensation. The
most advanced systems take advantage of modern computer-control capabilities to adjust the
suspension to match almost any imaginable road and driving conditions.

Types of Suspension Systems

1. Dependent Suspension:
o Beam Axle: Common in trucks and older cars, where wheels on the same axle are
connected.
o Leaf Spring: Often used in heavy-duty vehicles; simple and cost-effective.
2. Independent Suspension:
o MacPherson Strut: Widely used in front suspension of many cars, providing a
compact design.
o Double Wishbone: Offers better handling and wheel alignment, used in
performance vehicles.
o Multi-link: Provides superior handling and comfort, commonly found in luxury
cars.
3. Air Suspension:
o Utilizes air-filled bags instead of traditional springs. Offers adjustable ride height
and enhanced comfort, often used in luxury vehicles and heavy trucks.
4. Hydraulic Suspension:
o Uses hydraulic fluid to provide a smooth ride and can adapt to varying load
conditions.
5. Active Suspension:
o Continuously adjusts to road conditions using sensors and actuators, improving
handling and comfort.
6. Semi-active Suspension:
o Adjusts damping characteristics in real-time based on road conditions, offering a
balance between comfort and performance.

Procedure/Working:-

A suspension consists of springs that can store kinetic energy that is generated from friction
when the vehicle is travelling at high speed on a bumpy road. This energy is transmitted to the
dampers, which in turn convert this energy into heat energy. The fluid present in dampers
dissipates this energy to prevent overheating. The combination of springs and dampers provides
maximum protection and comfort to the passengers.

Applications of Suspension Systems

1. Automobiles: Enhances ride comfort, handling, and safety by absorbing road

irregularities.
 2. Trucks and Heavy Vehicles: Supports heavy loads, improving stability and control
under various conditions.
3. Motorcycles: Provides balance and comfort while maneuvering, crucial for handling.
4. Bicycles: Offers shock absorption to improve ride quality on uneven terrain.
5. Railways: Ensures smooth rides by dampening vibrations in train cars.
6. Aerospace: Used in landing gear systems to absorb impact during takeoff and landing.
7. Industrial Equipment: Found in machines like forklifts to stabilize and absorb shock
during

Conclusion

The choice of suspension system depends on the specific requirements of the vehicle or
machinery, including load capacity, desired ride comfort, handling characteristics, and cost. Each
type has its advantages and is suited to different applications, ensuring safety and performance
across various environments.

Maintenance of Automobile (CUAE2176) [0-3-0]

· Safety Precautions in Automobile Maintenance. (Lalan kumar,)

· Identification and Functions of Various Touls and Equipments used in Automobile

Workshop. (Md umar, )

· Disassembling and Assembling of Engine of a Four Wheeler. (G.dhanraju, )

· Disassembling and Assembling of Engine of a Two Wheeler. (G.dhanraju,)

· Engine Troubleshooting. (G.dhanraju, )

· Nomenclature of a Spark Plug and Spark Plug Reading, Testing and Cleaning of Spark
Plug. (Yashwanth,)
 · Checking and Replenishing Lubricating Oil, Engine Coulant, Power Steering Hydraulic
Oil and Wind Screen Wiper Water. (Dilip kumar,)

Experiment Name:- Lubrication system:

Aim/object:- Checking and Replenishing lubricating oil, engine coolant, power steering
hydraulic oil and wind screen wiper water.

Sketch:

Material, Tools,& Equipment

1. Oil sump
2. Oil pump
3. Oil filter
4. Oil strainer
5. Oil galleries
6. Oil cooler
7. Oil level indicator
8. Oil pressure gauge
9. Oil pressure indicating light

Theory:-

The lubrication system in an automobile is essential for reducing friction and wear between
moving engine components, ensuring smooth operation, and prolonging engine life.

It works by delivering oil to the various parts of the engine that require lubrication.

The lubrication system purposes:

Reducing friction: The lubrication system reduces friction between moving parts, which slows
down the rate of wear and tear.

Cooling: The lubrication system cools vital components.

Lowering noise: The lubrication system lowers noise.

Cushioning, cleaning, and sealing: The lubrication system provides cushioning, cleaning, and
sealing effects.

Types of lubrication system:

1. Splash lubrication system

2. Wet sump lubrication system
3. Dry sump lubrication system
4. Mist lubrication system
5. Pressure lubrication system
6. Semi-pressure lubrication system
7. Gravity lubrication system

Procedure/working:
  The following procedure are used in lubrication system:
Oil pump: Extracts oil from the oil tank and pumps it through a strainer to remove
contaminants
Oil filter: Filters the oil under pressure to remove smaller contaminants
Oil distribution: The oil is distributed to lubrication points in the engine, where it flows
between moving parts
Oil recycling: After forming an oil film, the oil is returned to the oil tank
Monitoring: The system has equipment to monitor oil pressure, temperature, and other
parameters.

Lab command:

 Sop process for lubrication system:

Tap at cover
Tap at cover cap open
Oil pump
Oil strainer
Oil sump
Oil pressure gauge
Part:- Piston, piston ring, cylinder, connecting rod, smaller bearing, and bigger bearing, crank
shaft , push rod, rocker arm, all part are required in lubrication system.

Application/working:

The lubrication system in an automobile is applied in various ways to ensure smooth operation,
durability, and efficiency of the engine and other critical components.

Larger machinery, such as trucks, tractors, buss, cars and diggers, have many moving parts that
require regular lubrication.

Its main application is lubrication of hole engine parts consists of crank shaft , camshaft,
connecting rod, piston, piston ring, valve. Further, it is used as a coolant of the above engine
parts.
 · Overhauling and Servicing of Fuel System including Air Filter. (Dilip kumar, )

Experiment Name:- Fuel System:

Aim/object: Overhauling and Servicing of Fuel System including Air Filter.

Sketch:
Material, Tools, & Equipment:

1. Fuel filter
2. Fuel pump
3. Fuel injection system
4. Fuel management system
5. Fuel tank
6. Diesel fuel
7. Injectors
8. Throttle plate

Theory:

The fuel system in a vehicle is the combination of parts needed to carry fuel into and out of the
engine. Once a fuel system is clean the tank should be completely filled. The main parts of a fuel
system are the fuel tank, fuel lines, fuel pump, fuel filters, and a distribution device.

Fuel delivery: The fuel pump extracts fuel from the tank and sends it to the engine.
Fuel injection: In fuel-injected engines, injectors spray fuel into the combustion chamber.
Fuel combustion: The fuel mixes with air in the combustion chamber and burns to generate
power.

Fuel control: The Engine Control Unit (ECU) manages the fuel injection process by controlling
the injectors and adjusting the fuel-to-air ratio. The ECU uses input from internal sensors to
assess engine conditions and requirements.

Fuel pressure: Fuel pumps pressurize the fuel to ensure it's delivered at the correct pressure for
injection. A fuel pressure regulator maintains the fuel pressure within the optimal range.

Fuel distribution: A fuel rail distributes fuel to the various engine cylinders evenly.

Types of fuel System:

a) Fuel supply systems

b) Fuel injection systems

Procedure/Working:

Following procedure are used in Fuel system:

Fill the tank: Insert the nozzle into the fuel filler inlet and fill the tank.
Send fuel to the engine: The fuel pump sends the fuel to the engine through the fuel lines.
Filter the fuel: The fuel is filtered to protect the engine from debris.
Inject the fuel: The fuel injector injects the fuel into the combustion chamber.
Check for leaks: A fuel system check can identify leaks and ensure that pipes and hoses are in
good condition.
Replace the fuel filter: An old fuel filter can restrict flow and make the fuel pump work
harder. Before replacing the fuel filter, relieve the pressure in the fuel system by removing the
fuel pump fuse or relay.
Inspect and replace worn parts: A fuel system service can include inspecting parts and
replacing worn parts.

Application/Inference:
Following application of fuel system:

Vehicles: Fuel systems are used in most modern vehicles to supply fuel to the engine.

Aircraft: Fuel systems are used in aircraft engines to precisely control fuel.

Industrial machinery: Fuel systems are used in industrial machinery and generators to improve
efficiency.
Marine engines: Fuel systems are used in marine engines to improve fuel management.
Motorcycles and off-road vehicles: Fuel systems are used in some motorcycles and off-road
vehicles to improve performance.

· Disassembling and Assembling Of Clutch, Clutch Troubles And Remedies. (Dilip kumar,)

Experiment Name:- Disassembling and Assembling Of Clutch:

Aim/object: Disassembling & assembling of Clutch, Clutch Troubles and Remedies.

Sketch:
Material ,tools and equipment:

1. Flywheel
2. Clutch Disc (Friction Disc)
 3. Pressure Plate
4. Release Bearing
5. Clutch Fork
6. Pilot Bearing or Bushing
7. Clutch Cable or Hydraulic System
8. Clutch Pedal
9. Diaphragm Spring
10. Return Spring
11. Bell Housing
12. Clutch Alignment Tool
13. Clutch Dampers

Theory:

A clutch is a mechanical device in a car that connects and disconnects the engine's power to the
transmission and wheels.

The clutch allows the driver to change gears smoothly, start the vehicle, accelerate, and decelerate
without damaging the transmission or stalling the engine.

Types of clutch:

1. Friction Clutch:

A friction clutch is a mechanical device that connects and disengages rotating shafts in a
controlled way.

2. Centrifugal Clutch

centrifugal clutch is a mechanical device that uses centrifugal force to connect an engine's drive
shaft to a transmission shaft.

3. Hydraulic Clutch

A hydraulic clutch is a system in vehicles that uses hydraulic fluid to transfer force from the
clutch pedal to the clutch assembly.

4. Dog Clutch (Jaw Clutch)

A dog clutch is a type of clutch that is manually disconnected and used to couple the gear shaft
to the driven pulley shaft.

5. Semi-Centrifugal Clutch
A semi-centrifugal clutch is a type of clutch that uses both springs and centrifugal force to
engage the clutch and transmit power.

6. Positive Displacement Clutch

A positive displacement clutch is a mechanical device that uses a clutch disc and vanes to
transfer power from an output shaft to a load, such as a wheel.

Procedure/working:

 The following procedure are used in clutch.

 It works by using a friction plate and a movable plate to transmit power between two
shafts that are rotating at different speeds.
 When the clutch pedal is pressed:
 The clutch fork moves the release bearing toward the pressure plate.
 This disengages the clutch disc from the flywheel.
 With the clutch disengaged, power from the engine is not transmitted to the transmission.
 This allows the driver to shift gears smoothly

 When the clutch pedal is released:

 The release bearing moves away from the pressure plate.
 The pressure plate pushes the clutch disc against the flywheel.
 The engine and transmission are now connected, allowing power transfer and movement.

Lab Command:

Clutch assembly this mattel for sop process

1. Clutch cable to remove Oil

2. Clutch cover to remove
3. Oil pump
4. Oil pump nut to remove
5. Remove the oil pump
6. Engine circulate plate
7. Clutch plate upper cover to remove
8. Clutch release wearing to remove
9. Clutch assembly nut to remove
10. Multi plate clutch
11. Clutch hub
 12. Clutch bush
13. Clutch hub washer
14. Pressure plate cap
15. Clutch pressure plate
16. Clutch plate

Application/inference:

Clutches are used in many applications, including in vehicles, heavy machinery, and
motorcycles.

Vehicles

Clutches transmit torque from the engine to the drivetrain, and help prevent the vehicle from
jerking.

Heavy machinery
Multi-plate clutches are often used in heavy machinery because they can transmit higher torque
than single-plate clutches.

Motorcycles
Multi-plate clutches are often used in motorcycles because they can transmit higher torque than
single-plate clutches.

· Repairing and Adjustment of Brake System. (Rohit kumar,)

 Experiment Name:-Study of Braking System
Aim:- Study of Braking System

Sketch:-

THEORY:
Functions of Brake:
There are two distinct functions of the brake:
 To stop or slow down the vehicle in the shortest possible distances in emergencies
 To control the vehicle to be retained when descending a hill.
Classification of brakes:
I. From construction point of view
 Drum brakes (b) Disc brakes II. By method of actuation
 Mechanical brakes (b) Hydraulic brakes (c) Electric brakes (d) Vacuum brakes (e) Air
brakes.
These types of brakes consist of master cylinder, which contains hydraulic brake fluid. Master
cylinder is operated by the brake pedal and is further connected to the wheel cylinder in each wheel
through pipelines, unions and flexible lines. The system is so designed that even when the brakes are in
the released position, a small pressure of about 50kpa is maintained in the pipelines to ensure that the
cups of the wheel cylinder are kept expanded. This prevents the air entering the wheel cylinders when the
brakes are released. Besides this pressure also serves the following purposes: 1. It keeps the free travel of
the pedal minimum by opposing the brake shoe retraction springs. 2. During bleeding, it does not allow
the fluid pumped into the line to return, thus quickly purging air from the system.
Material and equipment/ components.
 brake pedal or lever,
 actuating ro
 master cylinder
  assembly containing one or two pistons, a return spring
 gaskets or O-rings, and a fluid reservoir

TYPES OF BRAKES
MECHANICAL BRAKES
• DRUM BRAKES
• DISC BRAKES
HYDRAULIC BRAKES
POWER BRAKES
 AIR BRAKES
 AIR HYDRAULIC BRAKES
 VACCUM BRAKES
 ELECTRIC BRAKES

WORKING OF BRAKES

o While the operation of a brake system may appear intricate, the elucidation of its
components and types likely renders you acquainted with the relevant terminology. Brake
systems come in two primary variants: disc brakes and drum brakes. Disc brakes find
application on the front wheels of vehicles, while drum brakes are typically fitted to the
rear wheels. However, some contemporary high-end vehicles incorporate disc brakes on
all four wheels.
o When the driver presses the brake pedal, a force is generated, subsequently amplified by
the vacuum sourced from the engine. This enhancement ensures a quicker and more
efficient response from the brakes. The force exerted by the vacuum booster propels the
piston within the master cylinder against the spring, inducing the flow of brake fluid
under pressure. This pressurised fluid traverses through the fluid lines to reach the brake
calliper (in the case of disc brakes) or the brake cylinder (for drum brakes).

Applications/inference

1. Automobiles:
o Essential for passenger vehicles, trucks, and buses, with advanced systems
improving safety and performance.
2. Motorcycles:
o Use disc and drum brakes, often incorporating ABS for better handling.
3. Railways:
o Trains use air brake systems and dynamic braking (regenerative) to control speed
effectively.
4. Aerospace:
o Aircraft use specialized braking systems for landing and taxiing, often combining
hydraulic and electronic controls.
5. Industrial Machinery:
 Heavy machinery employs braking systems for safety and operational control,
o
with specialized designs for various applications.
6. Bicycles:
o Use either mechanical (cable-actuated) or hydraulic disc brakes for effective
stopping power.

Conclusion

The study of braking systems encompasses various types, working mechanisms, and applications
across different modes of transportation. Continuous advancements in technology aim to enhance
braking performance, safety, and energy efficiency, making them a crucial area of focus in
automotive engineering and design. Understanding these systems helps in maintaining vehicles,
improving safety standards, and ensuring reliable operation across various applications.

Experiment Name:-Study of Braking System

· Disassembling and Assembling of Propeller Shaft. (Rajkishor singh,)

· Inspection and Servicing of Gear Box. (Rahul kumar,)

· Inspection and Servicing Of CVT. (Kuashal kumar, )

· Tire Change Operation, Wheel Balancing, Wheel Alignment, Tire Inspection (Tubeless
& Tube) and Inflation. (Dilip kumar,)

· Overhauling of Suspension System. (Rohit kumar,)

· Disassembling and Assembling of Steering System and Adjustment of Drag Link. (Md
umar, )

· Preparation of Electrical Circuits using Switches and Fuses. (Rajkishor singh,)

Name of the experiment:-
Preparation of Electrical Circuits using Switches and Fuses.

Sketch:-
Theory:-

Switches:- Devices that open or close an electrical circuit, controlling the flow of current. They
can be single-pole or double-pole, depending on the control requirements.

Fuses:- Protective devices that automatically interrupt the flow of current when it exceeds a safe
limit. Fuses protect the circuit from overcurrent, which could cause damage or fire hazards.

Circuit Layout:-

Series Circuit: All components are connected end-to-end, so current flows through each
component sequentially.

Parallel Circuit: Components are connected across common points, allowing current to
split and flow through multiple paths.
Material & tools required:-

 DC power supply (battery or power adapter)

 Breadboard or circuit board
 Switches (single-pole, double-pole)
 Fuses (rated for circuit protection)
 Resistors (for load simulation)
 Light bulb or LED (as load)
 Connecting wires
 Multimeter (for measuring voltage and current)
 Soldering kit (optional)
 Insulation tape or shrink tubing (for safety)
 Wire strippers

Procedure / Working:-

1. Switches control circuit flow

2. Fuses protect against overcurrent

3. Circuit design ensures safe operation

Application / Conclusion:-

 Residential wiring
 Industrial control panels
 Automotive electrical systems
 Electronic devices (e.g., computers, appliances)
 Power distribution boards

Summarize your findings, including the importance of using fuses for protection in electrical
circuits and how switches provide control over the flow of electricity.
 · Checking of Battery Terminal Vultage, Electrulyte Level and Specific Gravity.
(Rajkishor singh,)
Name of the experiment:-
Checking of Battery Terminal Vultage, Electrulyte Level and Specific Gravity.

Sketch:-
Theory:-

Battery Terminal Voltage:-

Measures the voltage across the positive and negative terminals of the battery. The
voltage indicates the battery's charge level.

For a 12V lead-acid battery:

o Fully charged: ~12.6V to 12.8V

o Partially charged: ~12.4V to 12.6V
o Discharged: ~11.8V to 12.0V

Electrolyte Level:-

The electrolyte in lead-acid batteries is a mixture of sulfuric acid and water. Over
time, water evaporates, reducing the electrolyte level, which needs to be maintained
for proper battery function.

Specific Gravity:-

Specific gravity is a measure of the density of the electrolyte and indicates the
state of charge of the battery. A fully charged battery has a specific gravity between
1.265 and 1.285. Lower values indicate a partially or fully discharged battery.

Material tools & required:-

 Battery (Lead-acid or similar)

 Digital multimeter (for voltage measurement)

 Hydrometer (for specific gravity measurement)

 Distilled water (for topping up electrolyte)

 Protective gloves and goggles (for safety)

 Battery terminal cleaner or wire brush

 Electrolyte level gauge (if available)

Procedure / Working:-

 Battery Terminal Voltage Check

1. Ensure battery is fully charged.

2. Set multimeter to DC voltage (20V range).

3. Connect multimeter leads to battery terminals (red to positive, black to negative).

4. Record voltage reading.

 Electrolyte Level Check

1. Locate electrolyte level indicator (usually on top of battery).

2. Check level against minimum/maximum marks.

3. Add distilled water if level is low.

 Specific Gravity Check

1. Use hydrometer to measure specific gravity.

2. Insert hydrometer into electrolyte.

3. Record specific gravity reading.

Application / Conclusion:-

 Automotive batteries
 Industrial batteries (forklift, UPS)
 Marine batteries
 Renewable energy systems (solar, wind)
 Backup power systems (data centers, hospitals)

Summarize your findings, including the importance of using fuses for protection in electrical
circuits and how switches provide control over the flow of electricity.

· Inspection of Different Electrical Circuits and ECU. (Rajkishor singh,)

Name of the experiment:-

Inspection of Different Electrical Circuits and ECU.

Sketch:-

Theory:-

Electrical Circuits:-

Electrical circuits are pathways for current to flow, typically configured as series,
parallel,or combination circuits.
These circuits are the foundation of electrical systems in vehicles, machines, and
equipment, powering components such as lighting, motors, and sensors.

Electronic Control Unit (ECU):-

The ECU is a microcontroller responsible for managing various electrical and

mechanical subsystems in modern vehicles and machinery.

It receives input signals from sensors and sends commands to actuators and other
control systems.

OBD-II System (in vehicles):-

The On-Board Diagnostics (OBD-II) system provides self-diagnostic and reporting

capabilities, helping to monitor the performance of the vehicle's ECU and related
systems.

Fault codes (DTCs) can be read using a diagnostic tool to understand any issues in the
circuits or ECU.

Material & tools required :-

 Vehicle or machine with ECU and multiple electrical circuits

 Digital multimeter (for voltage, current, and resistance measurement)
 OBD-II scanner or ECU diagnostic tool (if inspecting a vehicle)
 Circuit diagram or wiring schematic (for the system under inspection)
 Test leads and probes
 Fuses and relays
 Screwdrivers and wire strippers
 Battery (if testing circuits independently)

Procedure / Working:-
 1. Input Signals: Receive data from sensors (e.g., temperature, pressure)
 2. Processing: Execute algorithms and calculations
 3. Output Signals: Control devices (e.g., fuel injectors, ignition coils)
 4. Memory: Store data, calibration, and firmware
Conclusion / Application:-
 Automotive electrical systems
 Industrial control systems
 Aerospace electrical systems
 Medical devices
 Consumer electronics
Summarize the condition of the electrical circuits and ECU. Discuss any issues found during the
inspection, such as faulty wiring, damaged components, or ECU errors. Recommend further
action, such as repairs or part replacements, based on the results.

· Checking of Ignition System Circuit & Components. (Taha ashraf)

1. Rajkishor singh-220101160001 ()
2. Dilip kumar-220101160002 ()
3. Rohit kumar-220101160004 ()
4. Rahul kumar-220101160007 ()
5. Lalan kumar-220101160011 ()
6. Kuashal kumar-220101160013 ()
 7. Rohan kumar-220101160024 ()
8. Sonu ram-220101160029 ()
9. Md umar-220101160030 ()
10. G.dhanraju-220101161035 ()
11. Yashwanth-220101161042 ()
12. Taha ashraf-220101161044 ()

Electric Vehicles (CUAE2172) [2-1-0]

Module I: Introduction to Electric Vehicles-

· Study of Different Components of E-Rickshaw and Assembing Methods.

· Working of Circuits in Contrullers with respect to Current and Vultage Rating.

Module III: Energy Sources-

· Maintenance of Lead Acid Batteries.

· Wiring & Harnessing of Battery Circuit.

Module IV: Electric Motors-

· Study of Different Parts of D.C. Motor and Make Connection.

· Performance Characteristics of a Shunt and Series DC Motor.

· Load Test on Three Phase Induction Motor.

 · Speed Contrul of DC Shunt Motor by Armature and Field Contrul.

Module V: Electric Vehicle Maintenance & Safety-

· Maintenance of BLDC Motor.

· Maintenance of Hub Motor.