CLASSIFICATION OF IC ENGINES

They are classified on the following basis:

*NUMBER OF STROKES:
                                           *2-stroke engine.
                                           *4-stroke engine.


*FUEL USED:
                                          *Petrol or gasoline engine.
                                          *Diesel engine
                                          *Gas engine
                                          *Dual fuel engine


*WORKING PRINCIPLE:
                                          *Otto cycle
                                          *Diesel cycle


*METHOD OF IGNITION:
                                          *Spark Ignition
                                          *Compression ignition


*METHOD OF COOLING:
                                          *Air cooled
                                          *Oil cooled/Water cooled


CYLINDER ARRANGEMENT:
                                          *Vertical engine
                                          *Horizontal engine
                                          *Opposed engine cylinder
                                          *V Engine
                                          *Radial engine
                                          *Inline engine

WORKING OF CARBURETOR AND BUTTERFLY VALVE

Carburetor Accellerator Pump Cams Video

WHAT IS THROTTLE VALVE?

Many of us are familiar with "accelerator pedal",but it has an alternative name called "Throttle".
The function of this throttle valve is to increase the power of the engine by allowing maximum air/fuel mixture for combustion.


The throttle section consists of a butterfly valve and pump cams.The pump cams is connected to the throttle lever and it is controlled by the throttle pedal. The pump cam consists of two or three holes in it and is bolted to the throttle lever. The holes in the pump cams are numbered with 1,2,3.They are the easily replaceable parts of an engine throttle system.


When the accelerator pedal/throttle pedal is pressed the fuel is passed from the fuel tank and it mixes with air in the carburetor.Once the air+fuel mixture is combined they pass near the butterfly valve.
        The butterfly valve is controlled by the pump cams by means of  throttle lever,when throttle is pressed the butterfly valve opens and allows the air+fuel mixture in to the engine cylinder for combustion.Similarly when the throttle pedal is released ,the butterfly valve closes blocking the air+fuel mixture to the engine cylinder.Like wise according to the throttle pedal movement the butterfly valve acts,and according to the butterfly valve movement the engine delivers its power.
                               
Even when the throttle is completely stopped,there will be a minimum amount of air+fuel mixture which prevent the engine from kill.

                                                               1.PUMP CAMS

                                                         2.BUTTERFLY VALVE

CREATE YOUR OWN ENGINE!!

Visit the link to download your Engine simulation software and get started with your creations!!

http://www.virtualengine2000.com/

DYNO'S ENGINE ASSEMBLY ANIMATION

BIKE ENGINE WORKING

MOTOR-CYCLE CLUTCH WORKING

CLUTCH WORKING

A clutch is an integral part of an engine.It is fixed to the flywheel and the flywheel is attached to crank shaft.
The clutch plate is over rided with steel plates,friction materials and with some springs and bolts.Then on the hub of the clutch plate is connected torsion springs.
             Now the fully made clutch plate with friction materials ,plates and torsion springs is placed over the fly wheel.
Now another steel plate is fixed with a flexible diaphragm.Metallic strips are provided to hold the diaphragm within the steel plate.Then pressure plate is fixed over this steel plate and is fixed to the clutch plate.
         When the clutch is pressed,it operates the pressure plate which in turn it operates flexible diaphragm and pulls it in outwards direction.When the pressure plate is pulled in outward direction it isolates the clutch plate from the fly wheel,and thus the engine is made free.

Similarly when the clutch pedal is released ,the diaphragm is released and it goes back to its initial position.
So the pressure plate along with its clutch plate makes its contact with the engine's fly wheel.
                   Thus the clutching and de-clutching process is cleared.

For clear understanding:
http://www.techspecauto.blogspot.in/2012/03/clutch-industries-how-clutch-works.html

ENGINE POSITIONS

Engines can be kept in many positions after their assembly.The common positions are:


*Vertical engine assembly.
*Horizontal engine assembly.


In vertical engine assembly,the engine cylinder is placed vertically and the crank shaft is connected to it in such a way that it makes it rotatory movement.

Horizontal engine assembly:
                                              In horizontal engine assembly,the engine cylinder is placed in horizontal line and the crank shaft is connected in such a way that it makes rotary action.

                                                                                                             

CUBIC CAPACITY

 It  is the volume swept by all the pistons inside the cylinders of an IC engines in a single movement from top TDC to BDC. It is commonly specified in cubic centimeters (cc)
It is commonly denoted as CC.You can see an engine mentioned as 2.0L or 3.5L;its nothing but the capacity of engine.2.0L means 2000cc and 3.5L means 3500cc.CC can be easily calculated from:
                 *BORE
                 *STROKE
                 *NO OF CYLINDERS


Bore is the inner area of the cylinder.
Stroke is the movement(area) swept by the piston.
                

             It is calculated by the formula:

                Displacement=pi/4*(Bore)(Bore)*(Stroke)*(No of cylinders)

Pi=3.14

4-STROKE WORKING

2-STROKE ENGINE WORKING

TDC AND BDC

*TDC:
         TDC  means TOP DEAD CENTRE.The topmost area reached by the piston inside an engine cylinder is called TDC.


*BDC:
          BOTTOM DEAD CENTRE.The bottom most area reached by the piston inside an engine cylinder is called BDC

2-STROKE WORKING

At present 2-stroke engine is not in use as it has incomplete combustion.This working is similar to that of 4-stroke engine ;the only difference is that all the process takes place in two strokes.

1.SUCTION AND COMPRESSION:
                                                        The piston is at the bottom of the cylinder. Inlet port  is opened and lets the fuel mixture, which is already compressed a bit, flow from the lower to the upper part of the cylinder.The exhaust port is closed now.


2.POWER STROKE AND EXHAUST:
                                                                Now  when the piston moves towards BDC the spark is initiated and power stroke takes place pushing the piston down with enormous amount of energy.
When the piston is almost close to BDC the exhaust port opens and lets the exhaust gases out.


                         Thus all the process takes place in two stroke it is called as two-stroke engine.
At preset it is used in dirt bikes,marine engines etc...

                                                  1.TWO STROKE WORKING

4-STROKE PROCESS

At present 4-stroke engines are commonly used because of their higher efficiency than 2-stroke engines. They emit very low carbon monoxide comparing to 2-stroke engines.The process involved in four stroke engines is:
               *Suction
               *Compression or ignition
               *Expansion or Power stroke
               *Exhaust.


1.SUCTION:
                    During suction the piston inside the cylinder undergoes downward movement from the top; sucking the air and fuel mixture from the carburetor and from the fuel pump.At this time the inlet valve opens and allows the air,fuel mixture in to the cylinder.The exhaust valve is closed at this time


2.COMPRESSION:
                               During this process both inlet valve and exhaust valves closed, the piston returns to the top of the cylinder compressing the air, or fuel-air mixture in the cylinder.

3.EXPANSION OR POWER STROKE:

                               In this process when the piston reaches close to the TDC during the second stroke(COMPRESSION),the spark is ignited and the large amount of heat developed during that process in TDC pushes the piston down causing the third stroke with enormous amount of energy released.

This is the power stroke of the piston and this stroke gives maximum power to the engine.At this stroke both inlet and exhaust valves remain closed.

4.EXHAUST:

                 After completing the power stroke the piston reaches the TDC again and now the outlet valve is opened and the gases are sent out through it.

                 

                 This process continues as long as the engine is running.

                                                       1.WORKING OF 4-STROKE ENGINE

POWER TRACKERS

The very essentials of engines are :
                                                   *Cam shaft
                                                   *Crank shaft

CAMSHAFT:

                     It is commonly denoted as CAM.In IC engines, the camshaft is used to operate valves. It  consists of a cylindrical rod running the length of the cylindrical bank.The cams force the valves open by pressing on the valve, or on some intermediate mechanism as they rotate.The cam shaft acts as a timing sector by opening and closing the inlet and exhaust valves and making the spark plug to produce correct spark at required time.One end of the crankshaft is connected to the camshaft with the help of ruggering chain.Thus it tracks the movement of piston and crankshaft and operates according to it.


CRANKSHAFT:

                     It is commonly denoted as CRANK.In IC engines the reciprocating movement of piston is converted in to rotating movement with the help of crank shaft.To the end of the crank shaft is connected the flywheel.

ESS-ELECTRO STATIC SHIELDING

During thunder or lightning stay in your car because the metal body of your car has electrostatic shielding which discharges the charges through the rubber tyres to the ground.

How ABS (Anti-Lock Brakes) Work

ABS

ABS stands for "Anti Lock Braking system".An anti-lock braking system  is a safety system on motor vehicles which prevents the wheels from locking while braking.It allows the driver to maintain steering control under heavy braking, by preventing a locked wheel or skid, and allowing the wheel to continue to forward roll and create lateral control, as directed by driver steering inputs. It has a sensor which senses the wheel and prevents it from locking.

WORKING-DISC BRAKES

Disc brakes are one of the most powerful brakes used at present and is economical too.The wheel of the car contains a steel plate like structure mounted to the inner bore of the wheel.Over the steel plate is fixed a rigid hard clamper;which locks the plate when the brake is applied.When the brakes are applied the oil from the brake sump rushes through the brake tubes and constrains a high mechanical impact on the clampers which then lock the steel plate.Thus the dics brake brings the vehicle to complete rest.
                                    Disc brake oil must be refilled regularly or it may lead to the failure of brakes.
The defect in disc brake is that it locks the steel plate completely and thus sometimes make the tyres to skid.

   The skidding of tyres in Disc brakes are overcome with the help of ABS.

For understanding the working of disc brakes clearly:
http://www.techspecauto.blogspot.in/2012/03/what-is-disc-brakeand-its-working.html

BRAKING SYSTEMS

Brakes are used to bring the vehicle to complete rest.There are many braking techniques out of them the popular ones are:
                         *Hydraulic brakes
                         *Expanding and contracting brake
                         *Disc brakes
                         *ABS

Power Steering Animation

DRIVE TRAIN

BEST ENGINE WORKING AND ASSEMBLY

Manual Transmission working

Expanding &contracting drum brake working.

What Is a Disc Brake?And its working!

DEPICTING PICTURES

1.CAMSHAFT

2.CRANKSHAFT

3.ENGINE FLY WHEEL

4.PRESSURE PLATE WITH CLUTCH

5.CLUTCH ASSEMBLY

BASIC TERMINOLOGIES

BORE AND STROKE:
       Bore and stroke refer to the dimensions of the engine's cylinders. Bore is the diameter of a cylinder, stroke is the distance the piston travels inside the cylinder.


RPM:
       RPM stands for "REVOLUTION PER MINUTE".The number of revolutions made per minute by the fly wheel is called RPM.


TORQUE:
               Torque is a twisting force. It is the power output of an engine at one specific point in time.

For eg. 200@400.The 200 stands for torque and 400 stands for RPM.i.e the engine acquires a torque of 200NM at 400 RPM.The above is just an example we dont get a torque of 200 at 400 RPM.

                *Torque is for acceleration.Torque at a low rpm is good because you get fast acceleration .

HORSE POWER:

                        It is basically denoted as HP.HP is for speed.Horsepower is the abiltiy to do work over a period of time. Other things are taken into account, but it is based on torque so the two will follow each other to some degree. Torque comes on first because it is the instant twisting force. Horsepower is built as you get going and things like momentum of engine components come into play. 

DRIVE TRAIN:

                   The drive train is the system that transfers the energy from the engine, to the axle to turn the wheels.

You may find some cars with option "BASE AND S".

                   Where S-Sport transmission

                       BASE-Basic transmission.

COMPRESSION RATIO

What is a compression ratio??
                                              An engine is basically a pump which squeezes in air/fuel mixture and then ignites it. So that it expands back and produces mechanical energy. The compression ratio is basically telling you how much the engine squeezes a certain volume of air that it intakes. So a bike with a compression ratio of 12:1 means that for every 12 ounce volume of air that is sucked in, the piston squeezes that air to 1 ounce volume. the more air that is squeezed into the piston the more energy that is produced per engine capacity on the expansion stroke.

Clutch Industries - How a clutch works

WORKING OF CLUCH IN DETAIL BY DAMIAN BIBBY

SPARK PLUG IN DETAIL

The above figure shows a spark plug which is used in petrol engines.It consists of a central electrode and a lateral electrode ..The spark plug is made up of steel and it should have the capability to with stand heat.The plug is connected to the high voltage generated by an ignition coil or from the battery. As the electrons flow from the coil, a voltage difference develops between the central electrode and side electrode. No current can flow because the fuel and air in the gap is an insulator, but as the voltage rises further, it begins to change the structure of the gases between the electrodes. Once the voltage exceeds the dielectric strength of the gases, the gases become ionized. The ionized gas becomes a conductor and allows electrons to flow across the gap. Spark plugs usually require voltage of 12,000–25,000 volts or more to 'fire' properly, although it can go up to 45,000 volts. They supply higher current during the discharge process resulting in a hotter and longer-duration spark.


                  As the current of electrons surges across the gap, it raises the temperature of the spark channel to 60,000 K. The intense heat in the spark channel causes the ionized gas to expand very quickly, like a small explosion. This is the "click" heard when observing a spark, similar to lightning and thunder..

The heat and pressure force the gases to react with each other, and at the end of the spark event there should be a small ball of fire in the spark gap as the gases burn on their own. The size of this fireball or kernel depends on the exact composition of the mixture between the electrodes and the level of combustion chamber turbulence at the time of the spark. A small kernel will make the engine run as though the ignition timing was retarded, and a large one as though the timing was advanced.

2-STROKE ENGINE WORKING