Ver.

1- 2010-03

Construction Machinery Ⅰ

Structure and Maintenance of

Internal Combustion Engine

Chapter 1
Outline of Internal Combustion Engine

The Construction Equipment Training Center(CETC)

Japan International Cooperation Agency
© Employment and Human Resources Development Organization of Japan 1
Chapter 1 outline of internal combustion engine
Engine
Internal Combustion Engine
Reciprocating

Rotary

Injection

External Combustion Engine

Steam

Turbine

Table1-1 classification of heat engine 2

 1-1 classification
Section 1 Kinds of internal combustion engine
1.1 classification
(1) classification by used fuel
Reciprocating engine
a Gasoline engine

b Diesel engine

c LPG engine

3
 1-1 classification

(2) classification by cycle of engine

Reciprocating engine

(a) 4 cycle engine

(b) 2 cycle engine

4
 1-1 classification
(3) classification by layout of cylinder and its
direction

1-1
a In-line b opposed cylinder c Vee

Fig 1-1 cylinder layout 5

 1-1 classification

(4) classification by valve layout

a over head valve engine

b side valve engine

6
 1-1 classification

(5) classification by cooling system

a Water cooled engine

b Air cooled engine

7
 1-2 kinds and use

1.2 kinds and use

(1) for vehicles
small, high out-put, high response low
fuel consumption ratio, low cost, low
noise level and low vibration level, low
emission

Gasoline engines for cars

diesel engines big size vehicles.
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 1-2 kinds and use
(2) for construction or agricultural machines
diesel engines ;
(1) can be operated continuously on
the inclinations
(2) have certain water tightness
(3) suit for features of the load of site
(4) are dust proof.
(5) have high durability
(6) have easy maintenability
(7) can be easily started.
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 2-1 principle of internal combustion engine
Section 2 basis of internal combustion engine
2-1 principle of internal combustion engine
Cylinder head

piston cylinder

Connecting rod

Fly wheel

Crank shaft

Fig 1-2 structure of engine

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2-1 principle of internal combustion engine

TDC

piston
stroke

BDC

Connecting rod

crank shaft

Fig 1-3 stroke of piston

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 2-1 principle of internal combustion engine
(1) 4 cycle engine
Ignition plug
Intake valve Exhaust valve

Exhaust
Mixture gas

Intake compression explosion exhaust

Ex. intake compression expansion
cylinder internal pressure

exhaust
Valve over lap combustion

Ex. V. open
In. v. open

In. v. close
In. v. close

Ignition
timing

Fig 1-4 operation of 4 cycle

1-1
engine & p-θ diagram 12
 2-1 principle of internal combustion engine

(2) 2 cycle engine

Ignition plug

Exhaust
port
scavenging Exhaust gas
port

Intake Fresh air

port

Exhaust (Crank
exhaust compression explosion chamber Compression)
Upward process Downward process

Fig 1-5 2 cycle engine

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 2-1 principle of internal combustion engine

(3) comparison of 2 cycle engine and 4 cycle engine

4cycle 2cycle
engine engine
a power Large Small
b rotation Rough Smooth
c Exhaustion Good Worse
d structure Simple, Complex,
low cost high cost
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 2-1 principle of internal combustion engine

(4) rotary engine

intake compression explosion exhaust

Fig 1-6 principle of rotary engine

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 2-2 performance of internal combustion engine
(1) piston swept volume and compression ratio

Combustion chamber volume

R=(Vc+Vb)/Vc=1+Vh/Vc
R : compression ratio Stroke volume

Vc : volume of chamber
Vb : volume of stroke

Top Dead Center Bottom Dead Center

(TDC) (BDC)
Fig 1-7 piston swept volume and compression ratio of reciprocating engine

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 2-2 performance of internal combustion engine

(2) basic cycle

Fig 1-7 PV diagram Fig 1-8 otto cycle Fig diesel cycle

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 2-2 performance of internal combustion engine

(3) heat and work

a work and energywhere,
W=FS W: work (N ・ m), F:
force(N)
S: distance(m)
1 PS = 735.5 N ・ m/s

b. First law of thermodynamics

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 2-2 performance of internal combustion engine

scavenging

Exhaust port

Scavenging port
Fig 1-11 sabathe cycle Fig 1-12 2cycle gasoline engine

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 2-2 performance of internal combustion engine
(4) thermal efficiency, fuel consumption ratio,
heat balance
a. Thermal efficiency
lower calorific value
H2O : gas

higher calorific value

H2O : liquid
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 2-2 performance of internal combustion engine

a. Thermal efficiency

(a) theoretical thermal efficiency

ηth = Wth/Q1 = (Q1-Q2)/Q1 = 1-Q2/Q1

where
Wth: theoretical work
Q1: supplied heat
Q2: heat loss
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 2-2 performance of internal combustion engine

a. Thermal efficiency

(b) Indicated thermal efficiency

indicated thermal efficiency ηi= Wi/Q1

(c) brake thermal efficiency

Brake thermal efficiency ηe= (Wi-Wf)/Q1
= We/Q1

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 2-2 performance of internal combustion engine

a. Thermal efficiency

(d) mechanical efficiency

ηm= We/Wj = ηe/ηi

ηm of a gasoline engine : 80% to 87%

ηm of a diesel engine : 75% to 90%.

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 2-2 performance of internal combustion engine

a. Thermal efficiency
b. fuel consumption rate

b = (f x 103)/P
= Q1x 3.6x106)/(HuxWe)
=(3.6x106)/(Hux ηe)

Where Hu: lower calorific value

Q1: supplied calorific value (Kj)

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 2-2 performance of internal combustion engine
(4) thermal efficiency, fuel consumption ratio,
heat balance
Kinds of Thermal Fuel
engine efficiency consumption
(%) ratio b
(g/kw·h)
gasoline 25 - 29 250 - 320
engine
Diesel engine 30 - 34 210 - 290

Table 1-2 25
2-2 performance of internal combustion engine

mechanical loss
heat energy of fuel
exhaust loss
heat loss radiation loss
mechanical loss
Indicated power
net effective work

Fig 1-13 heat balance

table 1-3 heat balance of engine (%)
kind of engine gasoline engine
passedger high speed
heat balance car truck diesel engine

net effective work 25 - 28 23 - 26 30 - 34

cooling loss 32 - 34 33 - 35 30 - 31
exhayust & radiation loss 33 - 37 34 - 38 30 - 33
mechanical loss 1-1
5-6 5-6 5-7
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 2-2 performance of internal combustion engine

(5) engine power and engine torque

a. Engine power
Power loss
(1) friction between a piston and piston
ring and a cylinder.
(2) friction of bearings
(3) power needed for auxiliary equipments
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 2-2 performance of internal combustion engine

(5) engine power and engine torque

b. Torque
where T: torque [N·m] :
T = F·R R: radius of certain rotating body
F: force applied there at right angle

T = (Pex60x1000)/(2xπxn)
where T: torque [N·m]
Pe: brake power[kW]
n : engine speed(rpm)
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2-2 performance of internal combustion engine

torque

Fuel consumption ratio

r
we
po
power

torqu
e

Fuel consumption
ratio

Fig 1-14 performance

1-1
curve of engine 29
Mark

1-1 30