Engine Setup.docx

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Engine:

An engine is a machine designed to convert energy into useful mechanical motion. Heat engines like internal combustion engines and external combustion engines (Steam Engine) burn fuel to create heat; simply it is the conversion of chemical energy in to mechanical energy.

Engines for automotive and construction equipment may be classified in several ways depending on the type of fuel used, type of cooling employed or type of valve and cylinder arrangement. They all operate on internal combustion principles. The most common method of classification is based on the type of fuel used, that is, whether the engine burns gasoline or diesel fuel.

ATALON Engine test bed comes with internal combustion four stroke diesel engine. Engine used in our test-bed is a tractor engine (Simpsons Make).

New #9 / Old #5, N. G .O. Colony Sriperumbudur- 602 105


Test Bed Engine Specification:

MODEL S 217

Capacity 21 kW (28 bhp @ 2000 rpm)Type / Configuration Vertical in-line Diesel EngineBore 91.44 mmStroke 127 mmNo. of Cylinders 2Displacement 1670 ccCompression ratio 18.5:1Cycle 4 StrokeRotation Clockwise (viewed from front)Aspiration NaturalCombustion System Direct InjectionFuel Pump MICO Bosch In-line PumpGoverning MechanicalEngine Starting System ElectricalCooling System WaterElectrical System 12 Volts (Dynamo/Alternator)Flywheel Housing SAE 1 or SAE 3Flywheel Can be made to suit applicationWeight (Bare Engine) 200 kgLength x Width x Height 489 x 536 x 756nmmFan Centre from Crank Centre 282.6 mmPower Take-off From Crankshaft axially or radially. Gear driven

PTO Training gears on LHS beneath Fuel PumpAir-compressor Optional

Dynamometer:



A dynamometer or “dyno” in short is a device for measuring force, moment of force (torque), or power. For example, the power produced by an engine, motor or other rotating prime mover can be calculated by simultaneously measuring torque and rotational speed (rpm).

A dynamometer can also be used to determine the torque and power required to operate a driven machine such as a pump. In that case, motoring or driving dynamometer is used. A dynamometer that is designed to be driven is called an absorption or passive dynamometer. A dynamometer that can either drive or absorb is called a universal or active dynamometer.

EDDY CURRENT DYNAMOMETER

MODEL E 50

Maximum Power 100 bhp (75Kw) @ 3000 to 6000 rpm

Maximum Torque 234 Nm @ 1500 to 3000 rpm

Accuracy of Torque Indication

+ 0.25% of Max. Dyno Torque

Sensors Mounted in the Test Bed:



ATALON test bed is equipped with almost all possible kinds of sensor which always come in handy for research scholars as well as students to nurture their knowledge of understanding in to a new level.

List of sensors used:


2. Temperature Sensor. 1. Pressure Sensor.

Lambda Sensor. 4. Hot-film Mass Air Flow Sensor.


Control Panel for Engine Test Bed:


6. Pressure Switch. 5. Combustion Sensor.

7. Load Cell8.


Combustion Analyzer:

Combustion Analyzer (Model ECA 1.0.1) is capable of recording data from all the sensors at different load conditions.


Combustion Analyzer


Exhaust Gas Analyzer:

Testing device used to measure the chemical content of the exhaust gases. The system we use known as 5 Gas Analyzer, which has the capability to measure five gases (CO, HC, CO2, O2, NO) that is emitted from the exhaust gas.



Smoke Analyzer:

Smoke meter is a device used to measure the soot concentration of the exhaust gas of diesel and GDI engines.

Current Research Work:

Current research work is focused in vehicle emission reduction, emission produced by motor vehicles, especially internal combustion engines.

Hydrocarbons - A class of burned or partially burned fuel, hydrocarbons are toxins. Hydrocarbons are a major contributor to smog, which can be a major problem in urban areas. Prolonged exposure to hydrocarbons contributes to asthma, liver disease, lung disease, and cancer. Regulations governing hydrocarbons vary according to type of engine and jurisdiction; in some cases, "non-methane hydrocarbons" are regulated, while in other cases, "total hydrocarbons" are regulated.

Carbon monoxide (CO) - A product of incomplete combustion, carbon monoxide reduces the blood's ability to carry oxygen; overexposure (carbon monoxide poisoning) may be fatal. Carbon Monoxide poisoning is a killer in high concentrations.



Nitrogen oxides (NOx) - Generated when nitrogen in the air reacts with oxygen at the high temperature and pressure inside the engine. NOx is a precursor to smog and acid rain. NOx is a mixture of NO, N2O, and NO2. NO2 is extremely reactive. It destroys resistance to respiratory infection. NOx production is increased when an engine runs at its most efficient (i.e. hottest) part of the cycle.

Particulate matter – Soot or smoke made up of particles in the micrometer size range: Particulate matter causes negative health effects, including but not limited to respiratory disease and cancer.

Sulfur oxide (SOx) - A general term for oxides of sulfur, which are emitted from motor vehicles burning fuel containing sulfur. Reducing the level of fuel sulfur reduces the level of Sulfur oxide emitted from the tailpipe.

This research work is carried out with new and improved design of catalytic converter and mixture of additives in the fuel used.

Colleges Participated for UG & PG Student Activities:

ATALON with its knowledge and expertise in the field of NVH and automotive product testing has helped various college students from in and around Chennai to nurture their knowledge in the field of Automotive Engineering.

1. PSG College of Technology, Coimbatore2. VIT, Vellore3. Anna University, Chennai4. IIT Madras5. Sathyabama University, Chennai6. Karpagam Institute of Technology, Salem7. Loyola College of Engineering, Chennai8. GKM College of Engineering, Chennai9. M KUMARASAMY College f Engineering, Karur, are among the few.



Engine Projects for B.E/M.E/ PhD. Courses:

Engine & Combustion study related projects: 1. Conversion of Naturally aspirated diesel engine to turbocharged engine for improving the

performance for Genset applications.2. Comparison study of Combustion parameters in Naturally aspirated and turbocharged diesel

engine for Genset applications3. Optimization of catalytic converter location for off road diesel engine applications with and

without thermal barrier coatings4. Diesel Engine performance & Emission study using pneumatic controlled hot and cooled

Exhaust gas recirculation system 5. Experimental study on smoke and NOx optimization parameters in diesel engine for Genset

engine applications6. Experimental study on engine performance With and without Hot EGR system in naturally

aspirated diesel engine7. Experimental investigation on engine performance with and without cooled EGR in TDi

system8. Experimental study on emission performance of cooled EGR system in naturally aspirated

diesel engine9. Experimental study on engine performance & emission with and without Hot EGR system

in Turbo charged system10.Combustion parameter studies on naturally and turbocharged diesel engine with hot exhaust

gas recirculation for Genset applications.

Durability study related projects:

11.Design and development of clutch performance test rig12.Design and development of durability performance test rig for passenger car shock

absorbers. 13.Study on Thermal Barrier coated Diesel Oxidation Catalytic converter Durability

performance.



Cooling System related projects:

14.Benchmarking the passenger car comfort performance of HVAC system during climate change conditions.

Noise and Vibration related projects:

15.Study on vibration levels of diesel engine with and turbocharger diesel engine for proper test bed installation.

16.Experimental investigation on vibration level of passenger car brake system17.Experimental study on connecting rod structure behavior using modal analysis18.Benchmarking vibration characteristics of passenger car on smooth and rough road

conditions19.Comparative study on engine noise level mapping for naturally and turbocharged diesel

engine20.Study on noise and performance analysis of Wiper Motor for passenger car applications21.Study on Engine crankshaft bearing performance and fault diagnostics.22.Study on Natural frequencies of engine radiator in correlation with engine performance for

off road vehicle applications.23.Study on natural frequencies of engine radiator in correlation with vehicle performance24.Study on coolant Thermal characterics for diesel engine radiator system along with natural

frequencies 25.Experimental study on alternator performance in diesel engine for off road applications26.Characterization study on Brake pedal effectiveness of passenger car on rough and smooth

road conditions27.Experimental investigation on Wheel natural frequency performance using modal analysis in free condition and comparison along with vehicle28.Benchmarking Vibration characterization of passenger car steering wheel on smooth and rough road conditions.29.Engine/ Vehicle bearing fault diagnosis using vibration measurement techniques

AUTOMOTIVE ELECTRONICS PROJECTS:



1. Design and development electronic sensing system for brake pedal travel during braking conditions in vehicle

2. Data acquisition and interpretation through CAN for monitoring sensor performance conditions inside the engine compartment.

3. Design and development electronic sensing system for pedal force measurement during braking conditions in vehicle

4. Design and development of electronic system to measure gear indication for two wheeler applications.

5. Design and development of sensor to detect steering angle and position to study steering wheel effectiveness

6. Development of accurate speed measurement system to study vehicle location and co-ordination through GPS.

7. Design and development sensor system to study vehicle pitching8. Design and development sensor system to study vehicle yawing 9. Design and development sensor system to study vehicle rolling 10.Design and development of data logging system for measuring temperature, humidity inside

the passenger car compartment.11.Development of battery performance monitoring system for passenger car applications12.Design and development of door closing and opening electronic indications for passenger car

applications.13.Design and development of electronic system using lambda sensor for monitoring emission

failures in passenger car.14.Design and development of electronic indications system for proper seat locking inside the

passenger car compartment.15.Design and Development of Electronic sensor system to study vehicle ground clearance.

Design & Analysis Projects:

1. Design and structural analysis of connecting rod using Catia-V5& Ansys software.2. Design and development of mini engine for aerospace applications using pro-E3. Die Design and mold flow analysis for oil sump using Catia V5 software.4. Design and analysis of Diesel engine flywheel using Ideas & Ansys software5. Design and structural analysis of crankshaft using Catia-V5& Ansys software.6. Design and computational analysis of EGR cooler system for Truck engine applications

using Ansys CFX.



NVH Related Projects:

1. Free Vibration.2. Forced Vibration.3. Slider Crank Chain Mechanism.4. Study of Ball Bearing.5. Dynamic Balancing of Rotor Planes.6. Acoustic Emission.7. Cutting Force Measurement.

a. Millingb. Lathec. Drillingd. Grinding


Engine Setup.docx

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