Engine Block

• It is made by pouring the molten iron or aluminum alloy into a mold.

• A typical block contains bores for pistons, pumps or other devices to
be attached to it
• Engine blocks are made from different materials including Aluminum
alloys, gray cast iron, ferrous alloys, white iron, gray iron, ductile iron,
malleable iron, etc.
Piston
• The Pistons receive the combustion pressure, moving up and down
repeatedly in the cylinders.
• Piston is pushed with the powerful explosion of mixture of air and
fuel.
Connecting Rod
• These transmit the combustion pressure received by the pistons to
the crankshaft.
• Other end of the connecting rod can be split into two parts. First is
semi-circular journal bearing seat. Other half is journal bearing cap.
• These two parts are bolted together, holding crankshaft in between.
Thus piston is now connected to crankshaft through connecting rod.
Crankshaft
• This converts the up and down motions received by the pistons to
rotary motions.
• It works same as slider- crank mechanism.
Crankshaft Casing or Oil Sump
• It is also called as oil sump.
• The sump surrounds the crankshaft. It contains some amount of oil,
which collects in the bottom of the sump.
• It retains lubricating oil in it which is pumped to different engine
parts.
Engine Head
• This provides the combustion chambers and valve mechanism.
Camshaft
• Camshaft is a type of rotating device or apparatus used in piston
engines for propelling or operating poppet valves.
• Camshaft comprises of series of cams that regulates the opening and
closing of valves in the piston engines.
• The camshaft works with the help of a belt, chain and gears.
Piston Rings
• Piston rings provide a sliding seal between the outer edge of the
piston and the inner edge of the cylinder.
• The rings serve two purposes:
• They prevent the fuel/air mixture and exhaust in the combustion
chamber from leaking into the sump during compression and
combustion.
• They keep oil in the sump from leaking into the combustion area,
where it would be burned and lost.
Fuel Injector
• This device is used in diesel engine only and delivers fuel in fine spray
under pressure.
Carburetor
• A carburetor is a device that mixes fuel and air together and delivers
the mixture to the intake manifold of an internal combustion engine.
Oil Cooler
• Oil cooler is the use of engine oil as a coolant, typically to remove
surplus heat from an internal combustion engine.
• It receives the lubricant’s heat and exchangers it with the ambient air
or the radiator coolant.
• It is typically the automatic gearbox oil that needs a dedicated oil
cooler.
Silencer
• Silencer is also called muffler.
• Device through which the exhaust gases from an internal-combustion
engine are passed to attenuate (reduce) the airborne noise of the
engine.
Governor
• It controls the speed of engine at a different load by regulating fuel
supply in diesel engine.
• In petrol engine, supplying the mixture of air-petrol and controlling
the speed at various load condition.
Detonation
• Detonation is the instantaneous combustion that occur due to
unburnt gases left in the combustion chamber resulting in high
temperature, sufficient for self-ignition
• An uncontrolled explosion of the unburnt air fuel mixture in the
engine cylinder occurring after the regular combustion of some of the
fuel charge caused by the spark at the spark plug.
Effect of detonation
1. inefficient combustion
2. loss of power
3. local overheating
4. Mechanical failure of engine
Firing Order Of An Engine
• Firing order is the sequence in which power is produced in different
cylinders of a multi-cylinder engine.
• It is achieved by proper firing of spark plugs in different cylinder.
• Firing order effects the stability , smooth running and balance of
engine.
• For example, in a 4 cylinder engine, firing order can be, 1–3–2–4
Vibration analysis
Vibration analysis can be used to:
• Find a developing problem that can be repaired to increase machine lifetime
• Detect and monitor a chronic problem that cannot be repaired and will only get
worse
• Establish acceptance testing criteria to ensure that installation/repairs are
properly conducted
Benefits
• Optional analysis & reporting service
• Low maintenance
• Maximizes availability of assets
• Helps to reduce overall costs
Back Fire
• A back-fire or backfire is combustion or an explosion produced by a
running internal combustion engine that occurs in the air intake or
exhaust system rather than inside the combustion chamber.
Back fire
Problems
• Back fire can lead do burning of muffler and other accessories in
exhaust line
• Overpressure in exhaust line damage the funnel
• Burning of inlet and exhaust valve .
Starter Motor
• A starter motor is a device that is capable of turning over an internal
combustion engine until the process of combustion takes over.
• the starter motor is rotating the crankshaft, the engine begins the
process of combustion.
Working of Starter Motor
• Internal combustion engines are typically incapable of “self starting,” which
means they require some external force to start running. This is typically
accomplished by using some method to turn the crankshaft until the process of
combustion can take over. The single most common example is an electric starter
motor that engages with a toothed flywheel or flex plate.
• In gasoline engine applications that use an electric starter, the operation of the
starter motor is relatively simple. When the ignition is activated (either via a key
or a button), power is delivered to an electric starter motor. That causes the a
small gear to extend and mesh with the teeth of a ring gear that is fixed to either
a flywheel or flex plate. This flywheel or flex plate is bolted to the crankshaft of
the engine, which allows the starter motor to turn the engine over.
• Once the engine is turning over, the process of internal combustion begins. Fuel
and air are injected into the engine, and they are ignited by spark plugs. That
allows the engine to start rotating under its own power, which causes it to start
rotating faster.
Exhaust Bypass Valve
Linear Slide Exhaust Bypass Valve
• The purpose of the exhaust cutout is to bypass the remaining exhaust
system after the point at which the cutout is installed.
• When you bypass the remaining exhaust system you are making it
easier for the engine to get rid of the exhaust.
• Therefore, you will gain horsepower and torque by making it easier
for your engine to work.
• The factory exhaust system is restrictive and holds back the full
potential of it.
Exhaust Bypass Valve
Linear Actuated Swinging Plate Exhaust Bypass Valve
• The main advantage of this design is it has been used to bypass
exhaust in turbocharger applications for decades.
• The rotation of the pivot presses the plate against and opening with
no seal, only surface contact as the seal.
• In conditions where some leaking is allowed the valves are a very
simple cost effective choice
• the design specifications mandate that there is no leakage.
Exhaust Bypass Valve