DIESEL

ENGINE
HEAVY VEHICLES

INTRODUCTION:

Thediesel engine(also known as acompressionignitionor CI engine) is aninternal combustion enginein

whichignitionof thefuel that has been injected into
thecombustion chamberis initiated by the high
temperature which a gas achieves when greatly
compressed (adiabatic compression).

The diesel engine has the highestthermal

efficiency(engine efficiency) of any
practicalinternalorexternal combustionengine due to its
very highexpansion ratioand inherentleanburn which
enables heat dissipation by the excess air.

A small efficiency loss is also avoided compared to twostroke non-direct-injection gasoline engines since unburnt
fuel is not present at valve overlap and therefore no fuel
goes directly from the intake/injection to the exhaust.

DIESEL ENGINE PROTOTYPE:

Working of pistons and

crankshafts:

Initiating the crankshaft tends

to move the pistons in to and fro

motion.

This movement leads to

the compression of the air in

Cylinder.

Fuel injecter expels the diesel

into the cylinder at the end of

Compression stroke.
CRANKSHAFT

PROTOTYPE OF
PISTON AND

FLYWHEEL:

The power produced due to

the main strokes such as

Suction,compression,power
and exhaust strokes is driven
by the flywheel.

This flywheel rotates similar

to the crankshaft[1 rotation of

Crankshaft=1 rotation of
Flywheel].

FLYWHEEL

CLUTCH:

If the engine is running with

clutchengaged the transmission

is in neutral.

The engine spins the input

shaft of the transmission, but

no power is transmitted to the
wheels.

The clutchis located between

the engine and the gearbox, as

disengaging is required to
change gear.Pressure plate is
required to operate the clutch.

GEAR BOX[TRANSMISSION]:

Thegearboxis the second stage in

thetransmissionsystem, after the clutch.

It is usually bolted to the rear of the engine,with the clutch

between them.Modern cars withmanual transmissions
have four or five forward speeds and one reverse, as well
as a neutral position.

The gears transfer the torque

to the output shaft.

Different speeds are achieved

with different gear ratios.

PROPELLER[OUTPUT SHAFT]:

Propeller shaft connects gearbox to the final drive gears of

the vehicle through universal joint and serves as drive shaft.

A universal joint allows the drive to be transmitted through

a variable angle.

The drive system is an arrangement for transmitting the

driving thrust from the road wheels to the vehicle body.

The final drive is the transmission system between propeller

shaft and differential.

The differential mechanism is built into the centre portion of

the final drive.

This permits the wheels to rotate at different speeds without

interfering with the propulsion of the vehicle while taking a
turn.

DETAILED SKETCH OF
PROPELLER SHAFT.

DIFFERENTIAL MECHANISM:

A vehicle with two drive wheels has the problem that when
it turns a corner the drive wheels must rotate at different
speeds to maintain traction.

The automotive differentialis designed to drive a pair of

wheels while allowing them to rotate at different speeds.

Assimilating the differential mechanism is matters,

differential mechanism is simply used to transmit the
torque to two rear wheels in an appropriate manner
especially , when two wheels facing two different
frictional surfaces and while taking turns.

While taking a right/left turn no two wheels should rotate at

same speed, in order to get appropriate transmission of
torque to wheels differential mechanism is used. This tends
to move the wheels at different and appropriate speeds.

Cooling system in diesel engine:

The cooling system is made up of the passages inside the engine

block and heads.

a water pump to circulate the coolant, a thermostat to control

the temperature of the coolant, a radiator to cool the coolant, a
radiator cap to control the pressure in the system.

Plumbing consisting of interconnecting hoses to transfer the

coolant from the engine to radiator and also to the car's heater
system where hot coolant is used to warm up the vehicle's
interior.

A cooling system works by sending a liquid coolant through

passages in the engine block and heads.

As the coolant flows through these passages, it picks up heat

from the engine. The heated fluid then makes its way through a
rubber hose to the radiator in the front of the car.

As it flows through the thin tubes in the radiator, the hot liquid is
cooled by the air stream entering the engine compartment from
the radiator in front of the car .

Once the fluid is cooled, it returns to the engine to absorb

more heat. The water pump has the job of keeping the fluid
moving through this system of plumbing and hidden
passages.

Thermostat valve opens and releases the hot water

to the upper tank.

Hot water is sent through the pipes of radiator to decrease

the temperature of it . Fins plays a crucial
role in decreasing the temperature.

Fan rotates in front of a radiator to increase the cooling

capacity . Air from fan directs through the fins.

FUEL INJECTOR:

In fuel injector , Fuelrail connected to the injectorsthat are

mounted just above the intake manifold on a cylinder
engine . Fuel injection is a system for introducing Fuel into
internal combustion engines, most commonly
automotive engines.

An acceleration trigger is provided to regulate the

flow of fuel into the cylinder . Self
trigger is
used for starting the
fuel injection .

Fuel is sent through the valves and injects into the cylinder
at the suction stroke.

FUEL FILTER:

FUEL FILTER:

A fuel filteris a filterin the fuelline that screens out dirt

and rust particles from the fuel, normally made into
cartridges containing a filterpaper.

They are found in most internal combustion engines.

It consists of both primary and secondary meshes , initially

fuel is sent through the primary mesh where fuel is purified
for a small extent.

Eventually , purified fuel is sent through the secondary

mesh and this tends to separate the very tiny impure
contaminants from fuel.

COMPRESSOR:

Compressor is generally used to

increase pressure in sucked air .

In automobile, compressor s inlet

valve is connected to the turbocharger
which is connected with the
air filter.

Its outlet is connected to the air storage tank and inlet

valve of piston cylinder.

Compressor runs with the help of a engines crankshaft.

It consists of a pulley in front of it , whenever the crankshaft

rotates pulley of a compressor also rotates with the help of
a belt.

Compressor increases the pressure of air up to 8Mpa.AC

compressor also works similar to the normal compressor .

Instead of rotating element, v pistons are installed. Its

input air is also driven from air filter.

AIR FILTER:

Air filter is used to filter

the impurities in sucked
air.

It has two valves and one

open end to take in the
air from atmosphere.

One of the valve is

connected to the inlet of
compressor and another
valve is connected to
turbocharger.

BRAKING SYSTEM:

Braking mechanism:

The compressor is used to store the air with high pressure .

Air with high pressure is filtered initially with the help of a
air filter which is connected to the inlet of compressor.

Compressed air filled in two air tanks one at front air

chamber and another at rear.

Driver brake valve is used to regulate the flow of air into

the air chamber . Whenever the driver applies brake the air
is sent into the air chamber.

This operation tends to operate the s cam to rotate in a

clockwise direction .When cam rotates brake plates situated
above the cam expands and gets in contact with drum .Due
to frictional resistance ,drums gets slower and tends to stop
the vehicle.

The sucked air has some moisture . This moisture content

will be removed with the help of a air drier.

TURBOCHARGER:

Intentionally ,
is used
increase the efficiency
of engine.

This is situated at the

exhaust valve . The
exhaust gases are taken
into the turbo charger
which leads to the
of the blades in
turbocharger.

turbocharger
to

rotation

Whenever , the turbine rotates it tends to rotate the

another turbine too . The second turbine acts a compressor
and sucks the purified air from air filter.

The filtered air is sent into the inlet valve through

turbocharger at suction stroke.

STEERING MECHANISM:

Thesteeringsystem converts the rotation of the steering

wheel into a swiveling movement of the road wheels in
such a way that the steering-wheel rim turns a long way to
move the road wheels a short way.

The hydraulic power for the steering is provided by arotaryvane pump(see diagram ). This pump is driven by the car's
engine via a belt and pulley. It contains a set of retractable
vanes that spin inside an oval chamber.

A power-steering system should assist the driver only when

he is exerting force on the steering wheel (such as when
starting a turn).

When the driver is not exerting force (such as when driving

in a straight line), the system shouldn't provide any assist.
The device that senses the force on the steering wheel is
called therotary valve.

The key to the rotary valve is atorsion bar. The torsion bar
is a thin rod of metal that twists whentorqueis applied to
it. The top of the bar is connected to the steering wheel,
and the bottom of the bar is connected to the pinion or
worm gear (which turns the wheels), so the amount of
torque in the torsion bar is equal to the amount of torque
the driver is using to turn the wheels. The more torque the
driver uses to turn the wheels, the more the bar twists.

The input from the steering shaft forms the inner part of
aspool-valve assembly. It also connects to the top end of
thetorsion bar.

The bottom of the torsion bar connects to the outer part of

the spool valve.

The torsion bar also turns the output of the steering gear,
connecting to either the pinion gear or the worm gear
depending on which type of steering the car has.

Selective Catalytic
Reduction:

What is SCR:

Selective Catalytic Reduction is a technology that

injects urea a liquid-reductant agent through a
catalyst into the exhaust stream of a diesel engine.

The urea sets off a chemical reaction that

converts nitrogen oxides into nitrogen and water,
which is then expelled through the vehicle tailpipe.

While urea is the primary operating fluid presently

used in SCR systems, alternatives to the urea
agent are currently being explored.

One option involves the use of diesel fuel to

transform NOx into harmless gases.

ALTERNATOR:

An alternator supplies the power to run the

vehicle electronics, ignition, lights etc and to
charge the battery.

The battery has to

deal with a huge power
drain when starting.

The alternative is a
generator.

An alternator is a spinning magnet surrounded by a coil of

wire, a generator is usually a magnetic field with a spinning
coil of wire.

It is generally called as a dynamo

Dynamo converts mechanical energy to electrical energy.

A pulley is situated in front of it, which is in contact with the

crankshaft of engine with the help of a belt.

When the crankshaft rotates the pulley of the alternator ,

electricity is generated and stored in battery.