Assignment No.

01

Qualification Unit number and title

BTEC Levels 4 and 5 Higher Nationals UNIT 25: ENGINE AND VEHICLE DESIGN AND
specification in Automotive Engineering PERFORMANCE

Student name Assessor name

ROYSTON .A. DSOUZA Waheed Khan

Date issued Completion date Submitted on

16-03-2018 26-03-2018

Assignment title Design engine features and evaluate engine performance

Learner declaration

I certify that the work submitted for this assignment is my own and research sources are fully
acknowledged.

Student signature: ROYSTON .A. DSOUZA Date:

 Achieved/
Learning outcomes Not Evidence to meet outcome
Achieved
Identify and discuss the Engine design features
1.1
engine design features Effect on Engine performance.
that contribute to the
selection of an engine for
a given application
Analyze the effects of Features such as Bore, Stroke, Con rod to Crank
1.2
altering engine design ratio, No. of cylinders
features for a given
application

Determine the Torque at peak power

2.1
performance Power at Max torque
characteristics of a given HP Per liter
engine Calculate Indicated Horse power
Carry out and record the Outcomes of an engine performance
2.2
outcomes of an engine
performance mapping
procedures

2.3 Interpret performance Selection and justification of engine

curves and select and
justify the use of an
appropriate engine for a
given application

Achieved/
Learning outcomes Not Evidence to meet outcome
Achieved
Identify and apply
M1 Effect of changing bore, stroke, and number of
strategies to find
cylinders to obtain the results
appropriate solutions by:
Suggesting the best
method to obtain 25%
more power

Select/design and apply

M2 Preparation of Heat Balance Sheet
appropriate methods/
techniques: to find heat
value of the fuel
consumed and its
distribution in the engine
Use critical reflection to
D1 Analysis of obtained data
evaluate result and justify
valid conclusions by: secondary research
Analysing the data Sankey Diagram
Task 1: (LO 1: 1.1)

Identify and discuss the engine design features that Contribute to the selection of an engine
for a vehicle. (P1.1)

Engine Design Features

Engines are classified or described by their

design features. These are as follows.

Automotive engines
The engine and components described so far
are representative of those used in passenger
and light and commercial vehicles, but there
are others. All manufacturers have a wide range
of engines, and while the basic engine
construction and principled remain the same.
There are many changes in design that occurs
as a result of advances in technology.

https://c7.alamy.com/comp/BB4D45/diesel-engine-equipped-with-a-precombustion-chamber-BB4D45.jpg

1. Number of cylinders

This has already been discussed. The number of cylinders can range from two to twelve, or an even
number

2. Cylinder arrangement

An engine can have cylinders which are in-line, horizontally opposed or V-type.

3. Cubic Capacity

This is also referred as piston displacement. It is the size of engine, being the total volume, in liters, of all
cylinders. A small passenger car engine could have the capacity of 1.5 liters. While a large passenger or
light commercial vehicle could have a capacity of 4 liters or more.

4. Valve mechanism

This relates to whether the engine is an overhead-valve (OHV) or an overhead-camshaft (OHC). It can also
relate to the number of valves. Some four-cylinder engines in particular have four valves per cylinder and
so are referred to sixteen valve engines.

5. Number of camshafts

Some in-line engines have a single overhead-camshaft (SOHC). Other in-line engines have two overhead-
camshafts and referred to as double overhead-camshaft engines (DOHC). V-type engines have two
overhead-camshafts; they can also be designed with four overhead-camshafts.
Four overhead-camshafts are referred to as Quad cams.
8. Type of fuel or fuel system
Engines are designed to run on a particular fuel.
This can be petrol, distillate, liquefied petroleum gas (LPG) or natural gas for vehicles. Dual-fuel engines can
run on petrol or gas.
Petrol engines fitted with electronic fuel injection systems are often called EFI engines with a carburetor
are called carburetor engines.

Effect on Engine performance.

The question itself point toward that there's some great secret to be
removed from simple hardware pieces. Engine mounts are simply
brackets, mostly metal, that attach to the engine on one end and the
car's engine bay on the other. They're intended to keep the engine set
up. In spite of the fact that Engine mounts alter extraordinarily in
appearance to assist changed engine formats, they're all comparable in
structure.
That is, people who don't want to think about them. Individuals who
need the motor's vibrations and wiggling around to be limited however
much as could be expected so they don't need to hear it, believe it, or
stress over Let's face it, which is the vast majority - this current
statements went down by the way that most cars sold are of the non-
execution variety.
http://gasturbinespower.asmedigitalcollection.asme.org/data/journals/jetpez/936300/
gtp_139_11_112806_f001.png

1. Aluminum engine blocks

Benefits: Lighter weight leads to more efficiency and better
handling
Drawbacks: Can warp at high temperatures

https://dustrunnersauto.com/wp-content/
uploads/2016/07/LT1vsLS1Featured.jpg

2. On-board Engine Computers

Benefits: Fuel economy, better diagnosis of problems
Drawbacks: Cost, complexity

https://previews.123rf.com/images/kurhan/kurhan1211/
kurhan121100456/16279116-car-mechanic-working-in-auto-repair-service.jpg

3. Overhead Camshafts

Benefits: Better performance

Drawbacks: Increased complexity

https://s3.amazonaws.com/lib.americanmuscle.com/files/
techguides/Featured-Images/1993-foxbody-convertible-mustang-
camshaft.jpg
Task 2: (LO1: 1.2 and M1)
Analyze the effects of altering engine design features such as Bore, Stroke, Con rod to Crank
ratio, No. of cylinders for a 5 seater passenger vehicle application. (P1.2)

Introduction
Over the past several years, road transportation
has seen some significant advances in what are
considered alternative technologies. Energy
storage, electric drive systems, and fuel cell
technology all seem to be poised to find a
significant place in the automotive marketplace.

But it would be a mistake to believe that such

technologies will completely sweep aside what has
come before. Instead, the internal combustion
engine will continue to be integral to the
transportation of people and goods for the
foreseeable future.

https://hips.hearstapps.com/amv-prod-cad-assets.s3.amazonaws.com/images/12q1/435356/booster-club-how-
forced-induction-is-changing-the-performance-landscape-feature-car-and-driver-photo-440016-s-original.jpg

Engine performance:
The variable to be considered are many out of which the speed, load and the air fuel ration and mean
effective pressure are important in engine performance level Performance of an engine means how its
output varies over the entire range of its operation. Then how effectively the conversion from the fuel
energy to engine power is carried out the efficiency and specific fuel consumption curves are also been
studied.

Effects on such bore, stroke then crank-ratio, con rod then number of cylinder on the engine design and
its performances:-
If an engine has larger bore than stroke then it's known as over-square engine.
Such engines can run quicker and therefore there for not that reliable in future as an example auto engines
and the Bikes. If an engine has larger stroke length than bore, then it's known as under-square engines.
These kind of engines are going to be slower than short stroke engines are going to be reliable also as
economical as a result of higher compression.

Changing the number of engine cylinder that is important to engine efficiency:-

When it involves the performance and efficiency of an opposed-

piston, two-stroke engine, will the amount of cylinders build a
difference then through observation it is entirely right.
Well has determined that its three-cylinder then opposed-piston
engine is that the best design from a gas-exchange perspective,
particularly in comparison to a 2 or four-cylinder style.
The reason that is the gas exchange period in a very two-stroke
engine is regarding 120 degrees crank angle.

http://achatespower.com/wp-content/uploads/2012/05/cross_charging_diagram.jpg
Changing of stroke to bore ratio and how it affects to engine performance and efficiency:
  While there are several issues that contribute to an engine
potency the first factor that must be thought of is that the
engine geometry itself
 Not exclusively will the length of the Engine issue anyway
the angle proportion of the Engine chambers plot by the
stroke-to-exhaust proportion likewise matters.
 Simple geometric relationships show that an engine
cylinder with longer stroke-to-bore ratio can have a smaller
area exposed to the combustion chamber gasses
compared to a cylinder with shorter stroke-to-bore ratio.
The smaller space leads on to reduce in-cylinder heat
transfer raised energy transfer to the rotating shaft and
thus higher efficiency.
 To attain high power density the engine should operate at
a high engine speed up to 18,000 rpm for the Formula one
engine that results in high mechanical phenomenon forces
that has to be restricted by employing a little stroke-to-
bore ratio. For applications that demand high efficiency a
long stroke-to-bore ratio.
https://upload.wikimedia.org/wikipedia/commons/thumb/b/bf/
Bore_Stroke_Ratio_Animation.gif/220px-Bore_Stroke_Ratio_Animation.gif

The effect of changing a con rod length to crank ratio and how it affects the engine design performance:-
 Con rods are a part of the basic mechanism at the guts of just about each race engine within the
world and there's very little to create me assume that this is often close to modification
 In managing the forces exerted on adjacent elements by a con rod we have a tendency to tend to
separate their mass into a reciprocator part that we have a tendency to assume travels up and
down with the piston and a rotating part that we tend to assume travels around with the crankpin
on that it operates.
Effect of changing a con rod length to crank ratio:

http://st.hotrod.com/uploads/sites/21/2002/03/p140792_image_large.jpg

 In race engine engineers we have a tendency to usually take care to stay each piston assembly
mass and shaft inertia to a minimum. One thing which may appear a very engaging idea so is to
shorten the con rod. Not solely would we have a tendency to save mass within the con rod however
the block may well be created shorter reducing the mass of the block and lowering the peak of the
middle of gravity of the engine.
By this modification and changes it can deliberate more power of 30% increasing in both power and
torque.

In last here are those other another tips on how to improve the engine performance:-

Basically there are 2 methods to improve it:-

1. By increasing the input energy
2. By increasing the engine efficiency

Absolutely Change Air filter over Period of Time

https://i.ytimg.com/vi/ZXUbz6WU06k/maxresdefault.jpg

PCM/ECU Remapping

http://www.auto-set.com/wp-content/uploads/2018/01/ECU-Remapping.jpg

1) Using of polished and clean intake manifolds which minimizes the resistance to intake the air. Thus
the cheaper method involves the manual polishing using a different grade of sanding and polishing
tools which are manually run around the passage, then smoothing off rough edged and polishing
the air passages.
2) Using of two exhaust valves in each cylinder thereby the decreasing the resistances to flow of
exhaust gases.
3) Using of bigger tail pipes and free flowing mufflers they are of conventional one.
4) screwing the spark plug so that the inside electrode gas is facing into the intake valves, this may be
done by using a marker pen to put the straight line mark on the plug insulator which is aligned with
the electrode gap at the bottom of the plug.
5) 5 remapping that is changing of the engine management software which can resulted into the 5 to
7% of increase in both power and torque.
6) Some manufacturer provide bolt on upgrades to their vehicles.
Task 3: (LO2: 2.1)

A 4 Cylinder turbocharged Compression ignition engine with specifications stated below is

available in lab. (P2.1)

 Engine Type: Common Rail 4 Cylinder

 Bore X Stroke: 91X96
 Displacement: 2497
 Compression Ratio: 17.1:1
 Power Output(Ps/rpm): 145/3800
 Max. Torque(Kg.m/rpm): 33/2000
 Aspiration: Turbocharged
 Engine Model: HyundaiD4CB
 Valves Per Cylinder: 4
 MEP: 74 PSI

Determine the performance characteristics of the given engine, by calculating the following:
a. Torque at peak power
b. Power at Max torque
c. HP Per liter
d. Calculate Indicated Horse power
Task 4: (LO2: 2.2, M2 and D1)

Carry out and record the outcomes of an engine performance on the dynamometer in the
lab. (P2.2)
You have to perform the experiment at the engine test rig and find out all the below mentioned
performance mapping like
(a) Draw power and torque curves over various RPM ranges also work out Mechanical, Thermal and
volumetric efficiency.
(b) Graphical account of emissions from the test Engine.(CO,THC, NOx)
(c) Calculate specific fuel consumption and draw curve over various power and RPM ranges.
(d) Report should contain observation sheet, logbook and supporting photographs that are taken while
performing the experiment.

Solution:
Below there is a power and torque curves over the various RPM ranges:-
Below there is a performance curves for brake specific fuel consumption over various torques and power
ranges:-
Task 5: (M2 and D1)

The following observations were made during a trial of a single- cylinder, four stroke cycle
gas engine having cylinder diameter of 18 cm and stroke 24 cm.
 Duration of trial : 30 min
 Total no. of revolution: 9000
 Total no. of explosion : 4450
 Mean effective pressure : 5 bar
 Net load on the brake wheel : 40 kg
 Effective diameter of brake wheel : 1 m
 Total gas used at NTP : 2.4 m3
 Calorific value of gas at NTP : 19 MJ/m3
 Total air used : 36 m3
 Pressure of air : 720 mm Hg
 Temperature of air : 17oC
 Density of air at NTP : 1.29 kg/m3
 Temperature of Exhaust Gas : 350oC
 Room temperature : 17 oC
 Specific Heat of exhaust gas: 1kJ/kg K
 Cooling water circulated : 80 kg
 Rise in temperature of Cooling Water : 30 oC
Solution:
Analyze the result obtained in the above trial and draw a Sankey Diagram Comment on the losses
incurred and the ways to minimize in order to enhance the performance of the engine

Sankey Diagram:
Process on avoiding the heat losses incurred through every system and how to minimize it to increases
the performance for the engine:

Heat losses through the exhaust gases:

 Automakers are rising mileage by abusing a substitution controls approach that uses the waste
warmth from vehicle motors Currently up to sixty fifth of the glow vitality made in ignition Engines
 whether or not fuel or diesel is wasted It is completed by the dominant the oil temperature of an
engine through which might able to minimize the heat losses through the exhaust system Also done
by using many advanced system such as EGR that is exhaust gases recirculating through it can
minimize by recirculating the exhaust gases in which it senses some of the oxygen present and send
it to intake manifold to recirculating the energy

Heat losses through the cooling water:

 Internal combustion engine cooling uses either air or a liquid to get rid of the waste heat from an
enclosed combustion engine
 Engines are inefficient therefore a lot of energy enters the engine than comes out as mechanical
power the difference is waste heat that should be removed.
 Some high efficiency engines run while not specific cooling and with only incidental heat loss design
referred to as adiabatic.
 Such engines are able to do high efficiency however compromise power output duty cycle engine
weight durability and emissions while heat loses can be avoided through the cooling system by
doing schedule services of the vehicle Using proper coolant and up to level coolant to minimize the
heat

Heat which is also equivalent through the Indicating power:

 Indicated power is nothing but the actual power which is generating within an engine is called an
indicating horse power
 In this too heat losses occurred due to some of the moving parts of an engine due to this it causes a
friction in it and also causes the thin film in it
 This can be also minimize by doing proper schedule maintenance of the vehicle
 Lubrication and cooling system should be proper and maintain
 If there is an damage in any parts of an engine such as wear out of the bearings damages of the oil
filters improper viscosity of oil filled with it or any electronic problems can also give rise to heat
loses through the system

Heat incurred through the Brake Power:

 Brake power it’s an output power in which the power goes from the engine to final wheel in motion
It is the final power which is last up to the crankshaft and goes through means of mechanical power
to the final drive up to the wheel
 The drawback with reducing an engine’s compression quantitative relation is that you just
additionally decrease its growth ratio that successively reduces its thermal efficiency
 There are ways in which around this however to my data they're not normally used
 The engine with the lower compression with turbo are going to be less fuel economical than
constant engine with higher compression minus the turbo The low compression engine also will be
less powerful within the rate vary below the turbochargers boost threshold the rate vary at that the
turbo will turn out boost pressure
Task 6: (LO2:2.3)

Interpret given performance curves and select and justify the use of an appropriate
engine for light vehicle application. (P2.3)

The performance curves it shows the air-fuel ratio torque and the power over various
RPM ranges exhaust emission and the fuel consumption varies up to it

According to the graph and given data given:

 Power which is given in = 0 to 400 HP (KW)

 Torque specified with the = 500 to 1200 lb-ft (NM)
 Fuel consumption which is there in = 0 to 20 gal/hr (L/hr)
 And the engine speed varies in = 800 to 2200
If we will see first the link between the engine speed over the fuel consumption then:

 Basically when the vehicle is at stationery or in an idle condition fuel doesn’t consumed more due
to engine runs at idle speed over 800 to 1000 RPM ranges as show in the graph
 As well as every vehicle having different idling RPM and could be specified up to 800 to 1000 RPM
 but as the vehicle turns into the stationery motion into the rotary motion means when the vehicle
is in moving condition hence the engine speed get increases so as increasing the engine speed the
fuel consumption occurs at higher level
 As show in the graph when the engine speed is there in 800 to 100 RPM the fuel consumption is
less at below 0 gal/hr
 But at the same time when the engine speed increases from 1000 to maximum range from the
1200 to 1400 RPM the fuel consume over 4 gal/hr.
 Propelling the increases speed of the engine when it reaches up to 1600 to 1800 RPM the fuel
consumption gets higher up to 8 gal/hr. which is double of previous RPM range
 When the engine speed is about the 1800 to 2000 RPM the fuel consumption raises to higher
extent of 12 gal/hr.
 And above 2000 to 2200 RPM the fuel consumption obviously getting higher from 12 to 16 gal/hr
 As a result it shows that when the engine speed gets higher the power is more at higher RPM
where the moving parts moves rapidly and faster and for more power it requires higher air fuel
ratio due to it the fuel consumption rise to higher and whereas due to maximum power and output
the fuel consume to a more extent

Going through the graph when it comes to the torque and the power with the fuel of an
engine:

 Torque or moment of force is rotational force

 Just as a straight power is a push or a draw a torque can be thought of as a turn to a protest.
 When there is a more torque the power generation of an engine’s get reduced due to less engine
speed It is happen due to the transmission given with the vehicle where transmission varies both
the speed and torque when there will be more torque the power generation will be less and on
other side when the power will be higher the torque generation would be less
 Torque or moment of force we just required to uplift your vehicle from idle condition to moving
condition Vehicle needs a moments a momentum or inertia required in starting condition and can
be possible through the transmission and by means of spur and helical gear present in the
transmission of the vehicle.
Bibliography
https://c7.alamy.com/comp/BB4D45/diesel-engine-equipped-with-a-precombustion-chamber-BB4D45.jpg
http://gasturbinespower.asmedigitalcollection.asme.org/data/journals/jetpez/936300/gtp_139_11_112806_f001.png
https://dustrunnersauto.com/wp-content/uploads/2016/07/LT1vsLS1Featured.jpg
https://previews.123rf.com/images/kurhan/kurhan1211/kurhan121100456/16279116-car-mechanic-working-in-
auto-repair-service.jpg
https://hips.hearstapps.com/amv-prod-cad-assets.s3.amazonaws.com/images/12q1/435356/booster-club-how-
forced-induction-is-changing-the-performance-landscape-feature-car-and-driver-photo-440016-s-original.jpg
http://achatespower.com/wp-content/uploads/2012/05/cross_charging_diagram.jpg
https://upload.wikimedia.org/wikipedia/commons/thumb/b/bf/Bore_Stroke_Ratio_Animation.gif/220px-
Bore_Stroke_Ratio_Animation.gif
http://st.hotrod.com/uploads/sites/21/2002/03/p140792_image_large.jpg
https://i.ytimg.com/vi/ZXUbz6WU06k/maxresdefault.jpg
http://www.auto-set.com/wp-content/uploads/2018/01/ECU-Remapping.jpg

REFERENCES

 Class notes, PPT and PDF

 Discuss with Sir and Class mates.

BOOKS
 Hand-outs of notes that have been given in the class.
 Automobile Engineering Vol- 01 & 02 Dr. Kripal Singh

THANK YOU.
Assignment Feedback

Formative Feedback: Assessor to Student

Action Plan

Summative feedback

Feedback: Student to Assessor

From task 1:-I had learned about the engine design features and basic terminologies used in automotive
fields
From task 2:- I’m understand about the how it affects by changing such bore to stroke ratio then number
of cylinder and con rod to crank ratio and how it directly effects to engine design feature and its
performances level
From task 3:- I came to know about how to find out the peak power at maximum torque HP per liter and
how to calculate the indicating horse power From given CI engine specifications
From task 4:- In this task there are many difficulties but I’m get to know about the how to find out the
various power and torque over various RPM ranges by performing experiment on brake dynometer
And also get to know about how to find out the BSFC value and its performance curves over various RPM
ranges in similar way.
From task 5:- Now I get to know about how to prepare the heat balance sheet on every system of the
engines such as through cooling exhaust radiation or unaccounted heat and IHP.
D1:- I had learned about the how to prepare the Sankey diagram by obtaining the results.
From task 6:- Now I’m able to understand the how to interpret the values from the given table in brief
and show the air/fuel ratio torque and the power with that exhaust emissions and fuel consumption.

Assessor signature waheed@ragc.in Date

Student signature sd1719hnda_aoroop@ragc.in Date