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Automotive Systems course (Module 01) - Internal Combustion Engine (ICE) basics

M
Mário Alves

The document provides an overview of internal combustion engines (ICE), including their definition, operating principle, classification, types based on combustion and ignition methods, engine cycles, valve actuation, and fuel systems. It describes the four strokes of a 4-stroke engine as intake, compression, power, and exhaust. It also summarizes 2-stroke and rotary engine cycles. The document aims to cover basic ICE concepts.

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29 de setembro de 2016 | 1 SistemasAutomóveis Internal Combustion Engine (ICE) basics Mário Alves (mjf@isep.ipp.pt)
29 de setembro de 2016 | 2 SistemasAutomóveis Outline • ICE definition and operating principle • ICE classification examples • ICE types according to the combustion method • Phases of the combustion cycle • Camshaft and valve actuation • ICE types according to the ignition principle • Phases versus strokes (4-stroke and 2-stroke engines) • Fuel types • Mixture formation (direct and indirect injection) • Cylinders configuration • Engine cooling • Engine lubrication
29 de setembro de 2016 | 3 SistemasAutomóveis ICE definition and operating principle • An ICE is a heat engine based on the combustion of a fuel with air • inside a combustion chamber • The combustion triggers an expansion of the high- temperature and high-pressure gases • forcing some components of the engine (e.g. pistons, turbine blades) to move • All this process converts chemical into mechanical energy • very low efficiency ( 30%) even today 
29 de setembro de 2016 | 4 SistemasAutomóveis ICE classification - examples Classification according to Ignition principle Compression Ignition (CI) Heterogeneous Charge (conventional) Homogeneous Charge (HCCI) Spark Ignition Electromechanical Distributor-less (Direct Ignition) http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
29 de setembro de 2016 | 5 SistemasAutomóveis ICE classification - examples Classification according to Combustion principle Intermittent Linear pistons with alternating movement Rotary pistons (Wankel) Continuous Turbine engine Jet engine http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
29 de setembro de 2016 | 6 SistemasAutomóveis ICE classification - examples Classification according to Cylinders number and configuration Single Multiple In-line Horizontally opposed V-shaped W-shaped Radial http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
29 de setembro de 2016 | 7 SistemasAutomóveis ICE classification - examples Classification according to the Working Cycle 2-stroke 4-stroke Classification according to the Number of valves 2 per cylinder 3 per cylinder 4 per cylinder … http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
29 de setembro de 2016 | 8 SistemasAutomóveis ICE types according to how combustion is performed • ICEs engines can be classified according to the way combustion is performed: • Intermittent combustion • linear piston (alternating/reciprocating movement) • rotary piston (Wankel) https://www.citelighter.com/technology/technology/knowled gecards/rotary-engine-vs-four-stroke-engine
29 de setembro de 2016 | 9 SistemasAutomóveis ICE types according to how combustion is performed • ICEs engines can be classified according to the way combustion is performed (cont.): • Continuous combustion • Turbine engine (e.g. jet engine) http://www.navyaircrew.com/blog/2009/07/18/suck-squeeze-bang- and-blow/
29 de setembro de 2016 | 10 SistemasAutomóveis ICE main components (linear pistons) • Piston • transmits movement to the rod • Connecting Rod • transmits the movement to the crankshaft • Crankshaft • transforms reciprocating into circular movement http://direns.mines-paristech.fr/Sites/Thopt/en/co/maci.html
29 de setembro de 2016 | 11 SistemasAutomóveis Phases of the combustion cycle (strokes) • In ICEs, combustion is composed of four phases: • Admission (or Intake, or Induction) Stroke • Air (direct injection) or air/fuel mixture (indirect injection) is admitted into the combustion chamber, by opening the admission valves • Air comes from the intake manifold: atmosphere  air filter  (throttle body)  (turbo-compressor)  admission pipes • Compression Stroke • the air/fuel mixture is compressed • the piston moves upwards from the Bottom Dead Center (BDC) to the Top Dead Center (TDC) http://www.chevelle.fr/chevelle.fr/articles.php?lng=fr&pg=423
29 de setembro de 2016 | 12 SistemasAutomóveis Phases of the combustion cycle (strokes) • In ICEs, combustion is composed of four phases (cont.): • Power (or Expansion) Stroke • Air/fuel mixture ignites, triggering the combustion • The piston is forced to move downwards • Exhaust Stroke • burned gases are expel from the combustion chamber • Air goes out through the exhaust valves  exhaust pipes turbo- compressor  … http://www.chevelle.fr/chevelle.fr/articles.php?lng=fr&pg=423
29 de setembro de 2016 | 13 SistemasAutomóveis Camshaft and valve actuation • Objective • Open/close intake and exhaust valves • Operation • synchronization (aka timing) belt (or chain) drives camshaft • camshaft lobes (called cams) push (intake and/or exhaust) valves to open/close as the camshaft rotates • springs return valves to closed position • Valve (open/close) timings can be • fixed (conventional) • variable, to optimize ICE operation https://xorl.wordpress.com/2011/03/27/valve-timing-and-variable-valve-timing/
29 de setembro de 2016 | 14 SistemasAutomóveis Camshaft and valve actuation • The most common camshaft arrangements are: • OHV (Over-Head Valve) – left • SOHC (Single Over-Head Cam) – middle • DOHC (Double Over-Head Cam) – right http://www.samarins.com/glossary/dohc.html
29 de setembro de 2016 | 15 SistemasAutomóveis ICE types according to ignition principle • The ignition of the fuel mixture is either • natural/gradual (Diesel) • requires high pressure&temp.  Compression Ignition (CI) • Homogeneous Charge technology (HCCI) requires lower temperatures and results in lower NOx emissions • forced/artificial (gasoline, LPG, alcohol, natural gas, hydrogen) • requires an ignition system  Spark Ignition (SI) http://www.ni.com/white-paper/13516/en/
29 de setembro de 2016 | 16 SistemasAutomóveis ICE phases versus piston movements • The four phases of the ICE cycle can be performed in 2 or 4 piston movements • 2 stroke engines • 2 phases per piston movement • 4-stroke engines • 1 phase per piston movement
29 de setembro de 2016 | 17 SistemasAutomóveis • Phases • Admission (Intake) • Compression • Power (Expansion) • Exhaust 4-stroke CI engine (Diesel cycle) Rudolf Diesel (1858 - 1913) https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 18 SistemasAutomóveis 4-stroke CI engine • Admission (Intake) stroke • the piston starts moving down, from the Top Dead Center (TDC) downwards • the intake valve opens (forced by the camshaft), letting fresh air enter the combustion chamber • the piston moves down and reaches the Bottom Dead Center (BDC) • the combustion chamber is now full of air, ready to be compressed (next stroke) http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
29 de setembro de 2016 | 19 SistemasAutomóveis • Compression • the intake valve closes (forced by the camshaft) • the piston starts moving up, from the BDC upwards, to the TDC • the piston moves up, compressing the air, until reaching the TDC • at TDC, air temperature and pressure are maximized, enabling optimized ignition (upon fuel injection) 4-stroke CI engine http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
29 de setembro de 2016 | 20 SistemasAutomóveis 4-stroke CI engine • Power (Expansion) • Fuel is injected into the combustion chamber (at very high pressure) • air-fuel mixture inflames (ignites) and combustion is spread all over the combustion chamber • combustion triggers volume expansion, pushing the piston downwards http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
29 de setembro de 2016 | 21 SistemasAutomóveis • Exhaust • at the end of expansion, once the piston hits the BDC, the exhaust valve opens • piston moves upwards (forced by the mechanical inertial movement) • the burned gases are gradually expel from the cylinder, through the exhaust valve and pipes 4-stroke CI engine http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
29 de setembro de 2016 | 22 SistemasAutomóveis • 4 stroke Otto cycle • Admission (Intake) • Compression • Ignition + Expansion • Exhaust 4-stroke SI engine (Otto cycle) Nicolaus Otto (1852 - 1891) https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 23 SistemasAutomóveis • Admission (Intake) • the piston starts moving down, from the Top Dead Center (TDC) downwards • the intake valve opens (forced by the intake camshaft), letting fresh air enter the combustion chamber • (in Indirect Injection fuel is already mixed with air outside the cylinder) • the piston moves down and reaches the bottom dead center (BDC) • the combustion chamber is now full of air, ready to be compressed (next stroke) 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
29 de setembro de 2016 | 24 SistemasAutomóveis • Compression • the intake valve closes (forced by the camshaft) • the piston starts moving up, from the BDC upwards, to the TDC • (in Direct Injection, fuel is injected into the combustion chamber during Compression) • the piston reaches TDC, where air temperature and pressure are maximized, enabling optimized combustion 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
29 de setembro de 2016 | 25 SistemasAutomóveis • Power (Ignition + Expansion) • when the piston reaches the TDC (actually a few miliseconds before), the spark plug ignites the air-fuel mixture • air-fuel mixture inflames (ignites) and combustion is spread all over the combustion chamber • combustion triggers volume expansion, pushing the piston downwards 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
29 de setembro de 2016 | 26 SistemasAutomóveis • Exhaust • at the end of expansion, once the piston hits the BDC, the exhaust valve opens (forced by the exhaust camshaft) • piston moves upwards (forced by the mechanical inertial movement) • the burned gases are gradually expel from the cylinder, through the exhaust valve and pipes 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
29 de setembro de 2016 | 27 SistemasAutomóveis 2 stroke gasoline engine 2-stroke SI engine • 2 stroke SI cycle: • Compression stroke • Combustion stroke https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 28 SistemasAutomóveis 2-stroke SI engine • Sparks fire • the fuel-air-oil mixture has been fully compressed and the spark plug fires, igniting the mixture in the combustion chamber (red area at the top) • the piston is driven downwards, compressing the air-fuel-oil mixture in the crankcase (blue area at the bottom) • when reaching the BDC, the exhaust port is left opened • the pressure in the cylinder drives most of the exhaust gases out of it https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 29 SistemasAutomóveis 2-stroke SI engine • Fuel intake • when the piston reaches the BDC, the intake port is left opened (pipe/port on the lefthand of the combustion chamber) • The piston's downwards movement has pressurized the mixture in the crankcase, so when the intake port is opened, the air-fuel-oil mixture rushes into the combustion chamber, expelling the remaining exhaust gases https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 30 SistemasAutomóveis 2-stroke SI engine • Compression Stroke • The momentum in the crankshaft starts driving the piston upwards (compression stroke) • as the air-fuel-oil mixture in the piston is compressed, vacuum is created in the crankcase; this vacuum forces the reed valve to open and lets the air-fuel-oil mixture enter the cylinder • once the piston gets to the TDC, the spark plug fires again… https://www.uclm.es/profesorado/porrasysoriano/
29 de setembro de 2016 | 31 SistemasAutomóveis 2-stroke CI engine • Intake + Compression • As the piston reaches BDC, it uncovers the air intake ports, filling the combustion chamber of fresh air and forcing out the remaining exhaust gases • the exhaust valves close • the piston starts moving upwards, covering the intake ports and compressing the air inside the combustion chamber http://railmotorsociety.org.au/images/diesel_page_00.gif
29 de setembro de 2016 | 32 SistemasAutomóveis 2-stroke CI engine • Injection + Expansion • when the piston gets to the TDC, the combustion chamber contains a charge of highly compressed air. • Diesel fuel is sprayed into the cylinder by the injector and immediately ignites due to the heat and pressure inside the cylinder • The pressure created by the combustion of the air-fuel mixture drives the piston downward http://railmotorsociety.org.au/images/diesel_page_00.gif
29 de setembro de 2016 | 33 SistemasAutomóveis 2-stroke CI engine • Exhaust • as the piston moves downwards (towards BDC), the exhaust valves open and exhaust gases rush out of the cylinder, relieving the pressure http://railmotorsociety.org.au/images/diesel_page_00.gif
29 de setembro de 2016 | 34 SistemasAutomóveis • 4-stroke Wankel engine: • Intake • Compression • Combustion • Exhaust 4 stroke Wankel engine 4-stroke Wankel engine http://auto.howstuffworks.com/rotary-engine4.htm
29 de setembro de 2016 | 35 SistemasAutomóveis • Intake • intake starts when the tip of the rotor passes the intake port (clockwise movement) • the intake port is exposed to the chamber, when the volume of the chamber is close to its minimum • as the rotor moves past the intake port, the volume of the chamber expands, drawing air/fuel mixture into the chamber 4-stroke Wankel engine Intake http://auto.howstuffworks.com/rotary-engine4.htm
29 de setembro de 2016 | 36 SistemasAutomóveis • Compression • as the rotor continues its motion around the housing, the volume of the chamber gets smaller and the air/fuel mixture gets compressed • when it reaches the spark plugs, the volume of the chamber is close to its minimum (maximum compression) • this is when sparks ignite the air-fuel mixture and combustion starts 4-stroke Wankel engine Compression http://auto.howstuffworks.com/rotary-engine4.htm
29 de setembro de 2016 | 37 SistemasAutomóveis • Combustion • most rotary engines have two spark plugs; as the combustion chamber is very long, the flame would propagate too slowly if there was just one plug • when the spark plugs ignite the air/fuel mixture, pressure quickly builds, forcing the rotor to move (clockwise) 4-stroke Wankel engine Combustion http://auto.howstuffworks.com/rotary-engine4.htm
29 de setembro de 2016 | 38 SistemasAutomóveis • Exhaust • once the peak of the rotor passes the exhaust port, the high-pressure combustion gases are free to flow out, through the exhaust port • as the rotor continues to move (clockwise), the chamber shrinks, forcing the remaining exhaust gases out 4-stroke Wankel engine Exhaust http://auto.howstuffworks.com/rotary-engine4.htm
29 de setembro de 2016 | 39 SistemasAutomóveis Fuel types • ICEs can run on several types of fuels: • Gasoline* • Diesel* • Liquefied petroleum gas (LPG)* • Alcohol • Natural gas* • Hydrogen • Biodiesel** * Most common in Europe ** Commonly mixed with Diesel, in a low percentage
29 de setembro de 2016 | 40 SistemasAutomóveis Fuel types – gasoline vs. Diesel • Advantages of Diesel engines: • Higher energy efficiency  lower fuel consumption • No spark ignition system (no spark plugs, no igniters, …) • Longer lifetime (several hundreds of thousands km) • Advantages of gasoline engines: • Less acoustic noise and mechanical vibrations • More elasticity (allows higher RPM) • Lighter/smaller engine (less CC) for the same power • No combustion chamber pre-heating system (no glow plugs, no relays,…)
29 de setembro de 2016 | 41 SistemasAutomóveis Mixture formation • ICEs can be distinguished according to where the air/fuel mixture is formed • Indirect Injection (IDI) aka external injection • Inside the combustion chamber • Direct Injection (DI) aka Internal Injection • Outside the combustion chamber • This applies to both Compression Ignition (CI) and Spark Ignition (SI) Engines
29 de setembro de 2016 | 42 SistemasAutomóveis Mixture formation – CI engine • In Compression Ignition engines • Indirect Injection • Injector sprays into a pre-chamber (aka swirl chamber) • Glow-plug heats pre-chamber • Direct Injection • Injector sprays directly into combustion chamber • Glow-plug heats combustion chamber http://www.jensales.com/blog/indirect-injection-vs- direct-injection-diesels/
29 de setembro de 2016 | 43 SistemasAutomóveis Mixture formation – SI engine • In Spark Ignition engines • Indirect Injection • Injector sprays into the intake pipe (before intake valve) • Before Throttle  Single-Point Injection – Figure a) • After Throttle  Multi-Point Injection – Figure b) • Direct Injection • Injector sprays into the combustion chamber – Figure c) http://www.intechopen.com/books/advances-in-internal-combustion-engines-and-fuel- technologies/combustion-process-in-the-spark-ignition-engine-with-dual-injection-system
29 de setembro de 2016 | 44 SistemasAutomóveis Mixture formation • Direct versus indirect injection Direct Injection Indirect Injection Losses Lower thermal losses High thermal losses (between chambers) Performance Higher Lower Speed Lower engine speed Higher engine speed Fuel type Demands higher quality fuels Works with lower quality fuels Injection Multi-jet (higher injection pressure) Single-jet (lower injection pressures) Efficiency More efficient (lower fuel consumption) Less efficient (higher fuel consumption) Emissions Less pollutant More Pollutant
29 de setembro de 2016 | 45 SistemasAutomóveis Cylinders configuration • ICEs can be classified by their cylinders configuration In-line V-shape W-shape Radial Opposed Horizontal Wankel http://auto.howstuffworks.com/
29 de setembro de 2016 | 46 SistemasAutomóveis Cylinders configuration • In-line configuration • most used, simple and inexpensive • single engine block where cylinders are aligned • main disadvantage (against other configurations) is requiring a longer crankshaft http://auto.howstuffworks.com/
29 de setembro de 2016 | 47 SistemasAutomóveis Cylinders configuration • V-shape configuration • cylinders are disposed in two blocks, in a V shape • the two blocks share a common crankshaft • main advantage is having a shorter crankshaft for the same number of cylinders (comparing to the in-line configuration) • most used when the number of cylinders is ≥ 6 http://auto.howstuffworks.com/
29 de setembro de 2016 | 48 SistemasAutomóveis Cylinders configuration • W-shape configuration • similar to V-shape but has 3 blocks of cylinders • This allows to have more cylinders with the same space (comparing to other configurations), i.e. shorter crankshaft • mostly used for 12-cylinder engines http://auto.howstuffworks.com/
29 de setembro de 2016 | 49 SistemasAutomóveis Cylinders configuration • Opposed-Horizontal configuration (aka boxer or flat) • more balanced, because the movement of one piston is compensated by the movement of the other moving in the opposite direction • allows a lower center of gravity for, improving driveability • pistons movement is not affected by gravity (like in other configurations) http://auto.howstuffworks.com/
29 de setembro de 2016 | 50 SistemasAutomóveis Cylinders configuration • Radial configuration • pistons arranged in circle (around the crankshaft) • typically 3-9 cylinders • mostly used in airplanes http://auto.howstuffworks.com/
29 de setembro de 2016 | 51 SistemasAutomóveis Cylinders configuration • Wankel configuration • Piston rotates (instead of linear movement, as in traditional ICEs) • Rarely used, due to inherent technical limitations (e.g. cooling, lubricating) http://auto.howstuffworks.com/
29 de setembro de 2016 | 52 SistemasAutomóveis Cylinders volume vs number • Two approaches (for the same volume – CC): • More cylinders of smaller capacity • Less cylinders of larger capacity • Pros of having more cylinders • Better thermal efficiency • Larger specific power (relation between the engine capacity and power) augmenting the engine´s maximum regime • Greater uniformity of engine torque • Better balance of mass in motion, which results in lower engine vibrations • Cons of having more cylinders • Larger crankshaft length, resulting in torsional vibration problems • Increase in engine volume and weight • Decrease in mechanical efficiency and thus in engine power
29 de setembro de 2016 | 53 SistemasAutomóveis Cooling System • Objectives • Guarantee a suitable engine operating temperature • cooling it down (after reaching a stationary regime) • helping to warm it up (keep fluid inside engine, while cold) • keep the physical and chemical proprieties of the lubricating oil • can deteriorate upon overheating • supply heat to acclimatize the interior of the vehicle • Facts • Most of the heat is dissipated through the exhaust • leading to wasted energy, thus low energy efficiency • Some heat is dissipated via lubricating oil (and oil cooler) • fixed engine parts (e.g. block, head) are cooled by the main cooling system • moving parts (e.g. pistons, crankshaft, rods) are mostly cooled by the lubricating oil
29 de setembro de 2016 | 54 SistemasAutomóveis Cooling System • Liquid-cooled engine • dedicated cooling circuit (pump, thermostat, radiator, fan,…) https://tyeschenbach.files.wordpress.com/2013/06/cooling.jpg
29 de setembro de 2016 | 55 SistemasAutomóveis Cooling System • Air-cooled engine • air circulates over hot parts; extended cylinders radiation area http://www.vdubxs.com/vintage-speed-vw-split-screen-rear-end- transformation/air_cooled_engine/#sthash.k3hPi7nw.dpbs
29 de setembro de 2016 | 56 SistemasAutomóveis Lubricating System • Objective • Mitigate friction and overheating of moving parts http://www.britannica.com/technology/lubrication
29 de setembro de 2016 | 57 SistemasAutomóveis Glossary (English  Portuguese)
29 de setembro de 2016 | 58 SistemasAutomóveis Bibliography [1] Ricardo Marques (1030379), André Soares (1021069), class project under the SIAUT course, ISEP, 2011.

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Automotive Systems course (Module 01) - Internal Combustion Engine (ICE) basics

  • 1. 29 de setembro de 2016 | 1 SistemasAutomóveis Internal Combustion Engine (ICE) basics Mário Alves (mjf@isep.ipp.pt)
  • 2. 29 de setembro de 2016 | 2 SistemasAutomóveis Outline • ICE definition and operating principle • ICE classification examples • ICE types according to the combustion method • Phases of the combustion cycle • Camshaft and valve actuation • ICE types according to the ignition principle • Phases versus strokes (4-stroke and 2-stroke engines) • Fuel types • Mixture formation (direct and indirect injection) • Cylinders configuration • Engine cooling • Engine lubrication
  • 3. 29 de setembro de 2016 | 3 SistemasAutomóveis ICE definition and operating principle • An ICE is a heat engine based on the combustion of a fuel with air • inside a combustion chamber • The combustion triggers an expansion of the high- temperature and high-pressure gases • forcing some components of the engine (e.g. pistons, turbine blades) to move • All this process converts chemical into mechanical energy • very low efficiency ( 30%) even today 
  • 4. 29 de setembro de 2016 | 4 SistemasAutomóveis ICE classification - examples Classification according to Ignition principle Compression Ignition (CI) Heterogeneous Charge (conventional) Homogeneous Charge (HCCI) Spark Ignition Electromechanical Distributor-less (Direct Ignition) http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
  • 5. 29 de setembro de 2016 | 5 SistemasAutomóveis ICE classification - examples Classification according to Combustion principle Intermittent Linear pistons with alternating movement Rotary pistons (Wankel) Continuous Turbine engine Jet engine http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
  • 6. 29 de setembro de 2016 | 6 SistemasAutomóveis ICE classification - examples Classification according to Cylinders number and configuration Single Multiple In-line Horizontally opposed V-shaped W-shaped Radial http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
  • 7. 29 de setembro de 2016 | 7 SistemasAutomóveis ICE classification - examples Classification according to the Working Cycle 2-stroke 4-stroke Classification according to the Number of valves 2 per cylinder 3 per cylinder 4 per cylinder … http://web.iitd.ac.in/~ravimr/courses/mel345/classification.pdf
  • 8. 29 de setembro de 2016 | 8 SistemasAutomóveis ICE types according to how combustion is performed • ICEs engines can be classified according to the way combustion is performed: • Intermittent combustion • linear piston (alternating/reciprocating movement) • rotary piston (Wankel) https://www.citelighter.com/technology/technology/knowled gecards/rotary-engine-vs-four-stroke-engine
  • 9. 29 de setembro de 2016 | 9 SistemasAutomóveis ICE types according to how combustion is performed • ICEs engines can be classified according to the way combustion is performed (cont.): • Continuous combustion • Turbine engine (e.g. jet engine) http://www.navyaircrew.com/blog/2009/07/18/suck-squeeze-bang- and-blow/
  • 10. 29 de setembro de 2016 | 10 SistemasAutomóveis ICE main components (linear pistons) • Piston • transmits movement to the rod • Connecting Rod • transmits the movement to the crankshaft • Crankshaft • transforms reciprocating into circular movement http://direns.mines-paristech.fr/Sites/Thopt/en/co/maci.html
  • 11. 29 de setembro de 2016 | 11 SistemasAutomóveis Phases of the combustion cycle (strokes) • In ICEs, combustion is composed of four phases: • Admission (or Intake, or Induction) Stroke • Air (direct injection) or air/fuel mixture (indirect injection) is admitted into the combustion chamber, by opening the admission valves • Air comes from the intake manifold: atmosphere  air filter  (throttle body)  (turbo-compressor)  admission pipes • Compression Stroke • the air/fuel mixture is compressed • the piston moves upwards from the Bottom Dead Center (BDC) to the Top Dead Center (TDC) http://www.chevelle.fr/chevelle.fr/articles.php?lng=fr&pg=423
  • 12. 29 de setembro de 2016 | 12 SistemasAutomóveis Phases of the combustion cycle (strokes) • In ICEs, combustion is composed of four phases (cont.): • Power (or Expansion) Stroke • Air/fuel mixture ignites, triggering the combustion • The piston is forced to move downwards • Exhaust Stroke • burned gases are expel from the combustion chamber • Air goes out through the exhaust valves  exhaust pipes turbo- compressor  … http://www.chevelle.fr/chevelle.fr/articles.php?lng=fr&pg=423
  • 13. 29 de setembro de 2016 | 13 SistemasAutomóveis Camshaft and valve actuation • Objective • Open/close intake and exhaust valves • Operation • synchronization (aka timing) belt (or chain) drives camshaft • camshaft lobes (called cams) push (intake and/or exhaust) valves to open/close as the camshaft rotates • springs return valves to closed position • Valve (open/close) timings can be • fixed (conventional) • variable, to optimize ICE operation https://xorl.wordpress.com/2011/03/27/valve-timing-and-variable-valve-timing/
  • 14. 29 de setembro de 2016 | 14 SistemasAutomóveis Camshaft and valve actuation • The most common camshaft arrangements are: • OHV (Over-Head Valve) – left • SOHC (Single Over-Head Cam) – middle • DOHC (Double Over-Head Cam) – right http://www.samarins.com/glossary/dohc.html
  • 15. 29 de setembro de 2016 | 15 SistemasAutomóveis ICE types according to ignition principle • The ignition of the fuel mixture is either • natural/gradual (Diesel) • requires high pressure&temp.  Compression Ignition (CI) • Homogeneous Charge technology (HCCI) requires lower temperatures and results in lower NOx emissions • forced/artificial (gasoline, LPG, alcohol, natural gas, hydrogen) • requires an ignition system  Spark Ignition (SI) http://www.ni.com/white-paper/13516/en/
  • 16. 29 de setembro de 2016 | 16 SistemasAutomóveis ICE phases versus piston movements • The four phases of the ICE cycle can be performed in 2 or 4 piston movements • 2 stroke engines • 2 phases per piston movement • 4-stroke engines • 1 phase per piston movement
  • 17. 29 de setembro de 2016 | 17 SistemasAutomóveis • Phases • Admission (Intake) • Compression • Power (Expansion) • Exhaust 4-stroke CI engine (Diesel cycle) Rudolf Diesel (1858 - 1913) https://www.uclm.es/profesorado/porrasysoriano/
  • 18. 29 de setembro de 2016 | 18 SistemasAutomóveis 4-stroke CI engine • Admission (Intake) stroke • the piston starts moving down, from the Top Dead Center (TDC) downwards • the intake valve opens (forced by the camshaft), letting fresh air enter the combustion chamber • the piston moves down and reaches the Bottom Dead Center (BDC) • the combustion chamber is now full of air, ready to be compressed (next stroke) http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
  • 19. 29 de setembro de 2016 | 19 SistemasAutomóveis • Compression • the intake valve closes (forced by the camshaft) • the piston starts moving up, from the BDC upwards, to the TDC • the piston moves up, compressing the air, until reaching the TDC • at TDC, air temperature and pressure are maximized, enabling optimized ignition (upon fuel injection) 4-stroke CI engine http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
  • 20. 29 de setembro de 2016 | 20 SistemasAutomóveis 4-stroke CI engine • Power (Expansion) • Fuel is injected into the combustion chamber (at very high pressure) • air-fuel mixture inflames (ignites) and combustion is spread all over the combustion chamber • combustion triggers volume expansion, pushing the piston downwards http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
  • 21. 29 de setembro de 2016 | 21 SistemasAutomóveis • Exhaust • at the end of expansion, once the piston hits the BDC, the exhaust valve opens • piston moves upwards (forced by the mechanical inertial movement) • the burned gases are gradually expel from the cylinder, through the exhaust valve and pipes 4-stroke CI engine http://beamerguide.blogspot.pt/2010/10/how-diesel-engine-work.html
  • 22. 29 de setembro de 2016 | 22 SistemasAutomóveis • 4 stroke Otto cycle • Admission (Intake) • Compression • Ignition + Expansion • Exhaust 4-stroke SI engine (Otto cycle) Nicolaus Otto (1852 - 1891) https://www.uclm.es/profesorado/porrasysoriano/
  • 23. 29 de setembro de 2016 | 23 SistemasAutomóveis • Admission (Intake) • the piston starts moving down, from the Top Dead Center (TDC) downwards • the intake valve opens (forced by the intake camshaft), letting fresh air enter the combustion chamber • (in Indirect Injection fuel is already mixed with air outside the cylinder) • the piston moves down and reaches the bottom dead center (BDC) • the combustion chamber is now full of air, ready to be compressed (next stroke) 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
  • 24. 29 de setembro de 2016 | 24 SistemasAutomóveis • Compression • the intake valve closes (forced by the camshaft) • the piston starts moving up, from the BDC upwards, to the TDC • (in Direct Injection, fuel is injected into the combustion chamber during Compression) • the piston reaches TDC, where air temperature and pressure are maximized, enabling optimized combustion 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
  • 25. 29 de setembro de 2016 | 25 SistemasAutomóveis • Power (Ignition + Expansion) • when the piston reaches the TDC (actually a few miliseconds before), the spark plug ignites the air-fuel mixture • air-fuel mixture inflames (ignites) and combustion is spread all over the combustion chamber • combustion triggers volume expansion, pushing the piston downwards 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
  • 26. 29 de setembro de 2016 | 26 SistemasAutomóveis • Exhaust • at the end of expansion, once the piston hits the BDC, the exhaust valve opens (forced by the exhaust camshaft) • piston moves upwards (forced by the mechanical inertial movement) • the burned gases are gradually expel from the cylinder, through the exhaust valve and pipes 4-stroke SI engine http://www.indycarz.com/threads/tech-basics-part-2-the-four-stroke-cycle.141585/
  • 27. 29 de setembro de 2016 | 27 SistemasAutomóveis 2 stroke gasoline engine 2-stroke SI engine • 2 stroke SI cycle: • Compression stroke • Combustion stroke https://www.uclm.es/profesorado/porrasysoriano/
  • 28. 29 de setembro de 2016 | 28 SistemasAutomóveis 2-stroke SI engine • Sparks fire • the fuel-air-oil mixture has been fully compressed and the spark plug fires, igniting the mixture in the combustion chamber (red area at the top) • the piston is driven downwards, compressing the air-fuel-oil mixture in the crankcase (blue area at the bottom) • when reaching the BDC, the exhaust port is left opened • the pressure in the cylinder drives most of the exhaust gases out of it https://www.uclm.es/profesorado/porrasysoriano/
  • 29. 29 de setembro de 2016 | 29 SistemasAutomóveis 2-stroke SI engine • Fuel intake • when the piston reaches the BDC, the intake port is left opened (pipe/port on the lefthand of the combustion chamber) • The piston's downwards movement has pressurized the mixture in the crankcase, so when the intake port is opened, the air-fuel-oil mixture rushes into the combustion chamber, expelling the remaining exhaust gases https://www.uclm.es/profesorado/porrasysoriano/
  • 30. 29 de setembro de 2016 | 30 SistemasAutomóveis 2-stroke SI engine • Compression Stroke • The momentum in the crankshaft starts driving the piston upwards (compression stroke) • as the air-fuel-oil mixture in the piston is compressed, vacuum is created in the crankcase; this vacuum forces the reed valve to open and lets the air-fuel-oil mixture enter the cylinder • once the piston gets to the TDC, the spark plug fires again… https://www.uclm.es/profesorado/porrasysoriano/
  • 31. 29 de setembro de 2016 | 31 SistemasAutomóveis 2-stroke CI engine • Intake + Compression • As the piston reaches BDC, it uncovers the air intake ports, filling the combustion chamber of fresh air and forcing out the remaining exhaust gases • the exhaust valves close • the piston starts moving upwards, covering the intake ports and compressing the air inside the combustion chamber http://railmotorsociety.org.au/images/diesel_page_00.gif
  • 32. 29 de setembro de 2016 | 32 SistemasAutomóveis 2-stroke CI engine • Injection + Expansion • when the piston gets to the TDC, the combustion chamber contains a charge of highly compressed air. • Diesel fuel is sprayed into the cylinder by the injector and immediately ignites due to the heat and pressure inside the cylinder • The pressure created by the combustion of the air-fuel mixture drives the piston downward http://railmotorsociety.org.au/images/diesel_page_00.gif
  • 33. 29 de setembro de 2016 | 33 SistemasAutomóveis 2-stroke CI engine • Exhaust • as the piston moves downwards (towards BDC), the exhaust valves open and exhaust gases rush out of the cylinder, relieving the pressure http://railmotorsociety.org.au/images/diesel_page_00.gif
  • 34. 29 de setembro de 2016 | 34 SistemasAutomóveis • 4-stroke Wankel engine: • Intake • Compression • Combustion • Exhaust 4 stroke Wankel engine 4-stroke Wankel engine http://auto.howstuffworks.com/rotary-engine4.htm
  • 35. 29 de setembro de 2016 | 35 SistemasAutomóveis • Intake • intake starts when the tip of the rotor passes the intake port (clockwise movement) • the intake port is exposed to the chamber, when the volume of the chamber is close to its minimum • as the rotor moves past the intake port, the volume of the chamber expands, drawing air/fuel mixture into the chamber 4-stroke Wankel engine Intake http://auto.howstuffworks.com/rotary-engine4.htm
  • 36. 29 de setembro de 2016 | 36 SistemasAutomóveis • Compression • as the rotor continues its motion around the housing, the volume of the chamber gets smaller and the air/fuel mixture gets compressed • when it reaches the spark plugs, the volume of the chamber is close to its minimum (maximum compression) • this is when sparks ignite the air-fuel mixture and combustion starts 4-stroke Wankel engine Compression http://auto.howstuffworks.com/rotary-engine4.htm
  • 37. 29 de setembro de 2016 | 37 SistemasAutomóveis • Combustion • most rotary engines have two spark plugs; as the combustion chamber is very long, the flame would propagate too slowly if there was just one plug • when the spark plugs ignite the air/fuel mixture, pressure quickly builds, forcing the rotor to move (clockwise) 4-stroke Wankel engine Combustion http://auto.howstuffworks.com/rotary-engine4.htm
  • 38. 29 de setembro de 2016 | 38 SistemasAutomóveis • Exhaust • once the peak of the rotor passes the exhaust port, the high-pressure combustion gases are free to flow out, through the exhaust port • as the rotor continues to move (clockwise), the chamber shrinks, forcing the remaining exhaust gases out 4-stroke Wankel engine Exhaust http://auto.howstuffworks.com/rotary-engine4.htm
  • 39. 29 de setembro de 2016 | 39 SistemasAutomóveis Fuel types • ICEs can run on several types of fuels: • Gasoline* • Diesel* • Liquefied petroleum gas (LPG)* • Alcohol • Natural gas* • Hydrogen • Biodiesel** * Most common in Europe ** Commonly mixed with Diesel, in a low percentage
  • 40. 29 de setembro de 2016 | 40 SistemasAutomóveis Fuel types – gasoline vs. Diesel • Advantages of Diesel engines: • Higher energy efficiency  lower fuel consumption • No spark ignition system (no spark plugs, no igniters, …) • Longer lifetime (several hundreds of thousands km) • Advantages of gasoline engines: • Less acoustic noise and mechanical vibrations • More elasticity (allows higher RPM) • Lighter/smaller engine (less CC) for the same power • No combustion chamber pre-heating system (no glow plugs, no relays,…)
  • 41. 29 de setembro de 2016 | 41 SistemasAutomóveis Mixture formation • ICEs can be distinguished according to where the air/fuel mixture is formed • Indirect Injection (IDI) aka external injection • Inside the combustion chamber • Direct Injection (DI) aka Internal Injection • Outside the combustion chamber • This applies to both Compression Ignition (CI) and Spark Ignition (SI) Engines
  • 42. 29 de setembro de 2016 | 42 SistemasAutomóveis Mixture formation – CI engine • In Compression Ignition engines • Indirect Injection • Injector sprays into a pre-chamber (aka swirl chamber) • Glow-plug heats pre-chamber • Direct Injection • Injector sprays directly into combustion chamber • Glow-plug heats combustion chamber http://www.jensales.com/blog/indirect-injection-vs- direct-injection-diesels/
  • 43. 29 de setembro de 2016 | 43 SistemasAutomóveis Mixture formation – SI engine • In Spark Ignition engines • Indirect Injection • Injector sprays into the intake pipe (before intake valve) • Before Throttle  Single-Point Injection – Figure a) • After Throttle  Multi-Point Injection – Figure b) • Direct Injection • Injector sprays into the combustion chamber – Figure c) http://www.intechopen.com/books/advances-in-internal-combustion-engines-and-fuel- technologies/combustion-process-in-the-spark-ignition-engine-with-dual-injection-system
  • 44. 29 de setembro de 2016 | 44 SistemasAutomóveis Mixture formation • Direct versus indirect injection Direct Injection Indirect Injection Losses Lower thermal losses High thermal losses (between chambers) Performance Higher Lower Speed Lower engine speed Higher engine speed Fuel type Demands higher quality fuels Works with lower quality fuels Injection Multi-jet (higher injection pressure) Single-jet (lower injection pressures) Efficiency More efficient (lower fuel consumption) Less efficient (higher fuel consumption) Emissions Less pollutant More Pollutant
  • 45. 29 de setembro de 2016 | 45 SistemasAutomóveis Cylinders configuration • ICEs can be classified by their cylinders configuration In-line V-shape W-shape Radial Opposed Horizontal Wankel http://auto.howstuffworks.com/
  • 46. 29 de setembro de 2016 | 46 SistemasAutomóveis Cylinders configuration • In-line configuration • most used, simple and inexpensive • single engine block where cylinders are aligned • main disadvantage (against other configurations) is requiring a longer crankshaft http://auto.howstuffworks.com/
  • 47. 29 de setembro de 2016 | 47 SistemasAutomóveis Cylinders configuration • V-shape configuration • cylinders are disposed in two blocks, in a V shape • the two blocks share a common crankshaft • main advantage is having a shorter crankshaft for the same number of cylinders (comparing to the in-line configuration) • most used when the number of cylinders is ≥ 6 http://auto.howstuffworks.com/
  • 48. 29 de setembro de 2016 | 48 SistemasAutomóveis Cylinders configuration • W-shape configuration • similar to V-shape but has 3 blocks of cylinders • This allows to have more cylinders with the same space (comparing to other configurations), i.e. shorter crankshaft • mostly used for 12-cylinder engines http://auto.howstuffworks.com/
  • 49. 29 de setembro de 2016 | 49 SistemasAutomóveis Cylinders configuration • Opposed-Horizontal configuration (aka boxer or flat) • more balanced, because the movement of one piston is compensated by the movement of the other moving in the opposite direction • allows a lower center of gravity for, improving driveability • pistons movement is not affected by gravity (like in other configurations) http://auto.howstuffworks.com/
  • 50. 29 de setembro de 2016 | 50 SistemasAutomóveis Cylinders configuration • Radial configuration • pistons arranged in circle (around the crankshaft) • typically 3-9 cylinders • mostly used in airplanes http://auto.howstuffworks.com/
  • 51. 29 de setembro de 2016 | 51 SistemasAutomóveis Cylinders configuration • Wankel configuration • Piston rotates (instead of linear movement, as in traditional ICEs) • Rarely used, due to inherent technical limitations (e.g. cooling, lubricating) http://auto.howstuffworks.com/
  • 52. 29 de setembro de 2016 | 52 SistemasAutomóveis Cylinders volume vs number • Two approaches (for the same volume – CC): • More cylinders of smaller capacity • Less cylinders of larger capacity • Pros of having more cylinders • Better thermal efficiency • Larger specific power (relation between the engine capacity and power) augmenting the engine´s maximum regime • Greater uniformity of engine torque • Better balance of mass in motion, which results in lower engine vibrations • Cons of having more cylinders • Larger crankshaft length, resulting in torsional vibration problems • Increase in engine volume and weight • Decrease in mechanical efficiency and thus in engine power
  • 53. 29 de setembro de 2016 | 53 SistemasAutomóveis Cooling System • Objectives • Guarantee a suitable engine operating temperature • cooling it down (after reaching a stationary regime) • helping to warm it up (keep fluid inside engine, while cold) • keep the physical and chemical proprieties of the lubricating oil • can deteriorate upon overheating • supply heat to acclimatize the interior of the vehicle • Facts • Most of the heat is dissipated through the exhaust • leading to wasted energy, thus low energy efficiency • Some heat is dissipated via lubricating oil (and oil cooler) • fixed engine parts (e.g. block, head) are cooled by the main cooling system • moving parts (e.g. pistons, crankshaft, rods) are mostly cooled by the lubricating oil
  • 54. 29 de setembro de 2016 | 54 SistemasAutomóveis Cooling System • Liquid-cooled engine • dedicated cooling circuit (pump, thermostat, radiator, fan,…) https://tyeschenbach.files.wordpress.com/2013/06/cooling.jpg
  • 55. 29 de setembro de 2016 | 55 SistemasAutomóveis Cooling System • Air-cooled engine • air circulates over hot parts; extended cylinders radiation area http://www.vdubxs.com/vintage-speed-vw-split-screen-rear-end- transformation/air_cooled_engine/#sthash.k3hPi7nw.dpbs
  • 56. 29 de setembro de 2016 | 56 SistemasAutomóveis Lubricating System • Objective • Mitigate friction and overheating of moving parts http://www.britannica.com/technology/lubrication
  • 57. 29 de setembro de 2016 | 57 SistemasAutomóveis Glossary (English  Portuguese)
  • 58. 29 de setembro de 2016 | 58 SistemasAutomóveis Bibliography [1] Ricardo Marques (1030379), André Soares (1021069), class project under the SIAUT course, ISEP, 2011.