153

EXPERIMENT NO.10
To determine engine performance curve of 4-Stroke Diesel Engine.

10.1 Objective:
 To understand the working of 4-Stroke Diesel Engine on Engine Test Bed.
10.2 Introduction:
The experiments required for this experiment will be conducted on SOLTEQ Engine Test
Bed Model TH03. The experiment to be done is to compare the performances and exhaust
emission of a standard diesel fueled single cylinder, 4-stroke diesel engine, 2stroke or 4-
stroke petrol engine running at different speed and load against the same engine’s
conditions. The engine speed is varied from 1200 RPM to 2400 RPM and various data such
as air intake speed, temperature, torque, power and gas emission produced. The data of the
petrol or diesels engine running at standard conditions will be recorded in the sheet of
computer. The dynamometer and other measurement device needed calibration before
preceding the experiment.

Figure - 1: Engine Test Bed

153
 154
10.2.1 Components:

 CONTROL PANEL.  WEIGHING BALANCE.

 DYNAMOMETER
 FUEL TANK.
CONTROLLER.
 EDDY CURRENT  INDICATOR.

DYNAMOMETER.
 AIR VELOCITY SENSOR.  EXHAUST.

 AIR INTAKE.  ENGINE.

10.2.2 Specifications of the diesel engine on the engine test bed (Model: TH03-E).

Model RK95-1-NB-RDK

Brand Kubota Engines Type 4-cycle, Single cylinder, Horizontal

Bore 86 mm

Stroke 84 mm

Piston 487 cc
displacement

Maximum 7.08 kW/2400 rpm

output

Continuous 6.00 kW/2200 rpm

output

Maximum 30.21 Nm/1800 rpm

torque

Combustion Direct injection

system

Fuel Light Diesel oil

Starting Cell Start

system

154
 155
10.3 General Requirements:
Electrical supply: 220-240VAC/50Hz/2A
Cooling Water: 20 LPM, 20-30 m Head
Since all the power is dissipated as heat to the surroundings, adequate ventilation must be
provided.
1. Load Indicator:
A safe load indicator or an automatic safe load is a device which is installed on a control
panel to alert the operator if the engine is exceeding the safe operating range of the
machinery.

Figure- 2: Load Indicator

2. Weighing Balance:

A beam balance is a device to measure the weight or mass. These are also known as mass
scales, weight scales, mass balance, weight balance or simply scale, balance or a balance
scale.

Figure- 3: Weighing Balance

3. Control Panel:

The control panel is a component of Microsoft Windows that provides the ability to view
and change the system setting. It allows the user to modify system i.e., setting and control.

Figure -4: Control Panel

155
 156

4. Exhaust Manifold:

An exhaust manifold collects the exhaust gases from multiple cylinders into pipe. Exhaust
manifolds are generally simple cast iron or stainless unit.

5. Dynamometer Controller:

A dynamometer is used to determine the torque and power required to operate a driven
machine such as pump. The engine and dynamometer are carried on a solid steel base plate
resiliently mounted with a solid steel frame work.

Figure- 5: Dynamometer Controller

6. Air intake Manifold:

Air intake manifold is a part of engine that supplies the fuel or air mixture to cylinders. Air
to fuel ratio is round about 14.7:1.
7. Fuel tank:

A fuel tank is a safe container for flammable fluids. Through, any storage tank for fuel is
typically applied to part of an engine system in which the fuel is stored.

8. Velocity sensor:

A velocity sensor is a sensor that measure air velocity.

9. DP transmitter:

This equipment will sense the difference in pressure between two points and produce an
output signal reference to a calibrated pressure range.

Figure- 6: DP Transmitter

156
 157

10. Computer compartment:

A computer compartment consists of a monitor i.e., it contains a software that shows

the reading of different parameters in engine test bed.

11. Temperature sensors:

A temperature sensor is a device, an RTD, that collects the data about temperature

Figure - 7: Temperature sensors

from a particular source.

TT1: AIR INLET PIPE TEMPERATURE.

TT2: EXHAUST ORIFIES.TT3: FUEL TANK SENSOR.

TT4: ENGINE OIL TEMPERATURE.

12. Load bank:

A load bank is a device which develops an electric load, applies the load to an electrical
power source and converts or dissipates the resultant power output of sources.

Figure- 8: Load Bank

157
 158
10.4 Installation Requirements:

1. Install the engine test bed at a well-ventilated place as the engines produce harmful exhaust
gasses during the engine testing.
2. The engine test bed and the control panel must be placed at a rigid and leveled floor that has
adequate strength to support its complete weight.
3. Inspect the equipment and make sure that there is no physical damage before the installation.
4. Connect the l-phase (220-240VAC/50Hz) power supply to the Earth Leakage Circuit Breaker
in control panel.
5. Connect the water supply and drainage for the load tank located at the bottom of the control
panel.
6. Install the load cell on the load cell brackets provided and tighten the nuts properly. Remember
to place O-rings provided in between the nuts and the brackets to secure. Care must be taken
when installing the load cell; use only bare hands to tighten the screws to avoid load cell damage.
7. Install the weighing balance on the stand and connect the power supply to it. Level the balance
by adjusting the leveling feet and confirm it using the bubble spirit level.
8. Locate the speed sensor at the DC motor. Tum the motor and make sure that the sensor
doesnot-hiton1fie tooth of inducting metal. Adjust the sensor distance if necessary but make sure
that the sensing distance is kept within 2 mm or else the sensor will not be able to detect the
revolution.
9. Check all screws and mounting QD Test Bed. Make sure that they are all properly tighten and
screwed properly.

10. Connect the power supply and sensors cable from the engine test bed to the control
panel.
11. Locate all temperature sensors (TI1 until TT4) and make sure that there are in place.
Install the air velocity sensor into the air intake duct make sure that the sensor element is
aligned to the air flow with the element in the middle position of the duct.

12. The unit is now ready.

10.5 Commissioning Procedure:

1.Install the Engine Test Bed as Instructed above.
2.Push the reset button of the Earth Leakage Circuit Breaker (ELCB) inside the control
panel after the main power supply is switched on. The ELCB should be kicked off, indicating
that the ELCB is functioning properly. If not, have a trained wireman to inspect the trainer
for any electrical leakage. The ELCB should be tested at least once a month.

158
 159

3.Remove the mechanical guard at the engine coupling and install any of the engines
supplied. Remember to secure all hexagon screws on the coupling properly and replace the
mechanical guard.
4.Connect the air intake hose and the exhaust hose. Connect the fuel tank to the engine and
fill the fuel tank with appropriate automotive fuel. Then hang the fuel tank on the under-
hook of the weighing balance and open the fuel supply valve on the fuel tank.
5.Check that all temperature sensors (TT1 until TI4) are in place and sensor's wires are
connected properly. Connect the connecting wires of the temperature sensors.
6.Open the tab water to supply water to the load bank.
7. Make sure that all switches on the control panel are off. Switch on the main power supply
follows by the main switch on the panel.
8.All the indicators should lit-up when the main switch is tum on.
9.Switch on the cooling fan for the DC motor.
10. Remove the fuel tank from under hook of the weighing balance temporally; press the
ON/OFF button on the weighing balance to tum it on. After the initialization is completed,
press the RE- ZERO button to tare. Then, replace the fuel tank on the under-hook.The
weighing balance is now giving the total weight of the fuel and the fuel tank.
11. Check the ·temperature readings on the front panel, .T1 until T4. The temperature
readings should close to the surrounding temperature.
12. Check the measurement of the voltage, current, speed, torque, DP1 (for orifice) and air
velocity readings. The readings should be closed to zero. Adjust the tensions of the load cell
to get the torque reading as close to zero as possible. Otherwise, take the reading as zero
offset value for the experiments.
Note: The torque sensor needs to be warm-up. Switch on the equipment main switch for
approximately 30 minutes before the adjustment of the torque sensor.

13. Start the engine and set the engine speed to approximately 3000 RPM on the speed
Indicator at no-load condition. (Refer to Section 5.0 for general engine operations)
14. Now apply different loads to the engine and observe that the voltage, current and torque
readings will change accordingly. Observe that the Air Velocity indicator is showing air
flow in the duct as well.
15. The unit is now ready for use.

159
 160

10.6 Criteria of Performance:

The performance of the internal combustion engine is characterized with several geometric
and thermodynamic c parameters. For any one cylinder, the crankshaft, connecting rod,
piston and head assembly can be represented by the mechanism shown in Figure below:

rod

Below are the following geometric parameters:

B = bore (m)
I = connecting rod length (m)
A = crank. Radius (m)
S = stroke (m)
E = crank angle (degree)
The crank radius is one-half of the stroke. The top dead center (tdc) of an engine refers to
the crankshaft being in a position such that e = 0°. The volume in this position is minimum
and is often called the clearance volume, Vc. Bottom dead center (bdc) refers to the
crankshaft being at Ѳ = 180°. The volume is maximum, V1 in this position.

 Fuel Flow Rate:

The mass flow rate of fuel could be determined by recording the initial weight m1) and final
weight (mb) reading in a specific time interval(t)

Fuel Consumption = m1-m2 / t

160
 161

where,

m1 = initial weight of fuel (g) m2 = final weight of fuel (g) t = time (s)

 Air Intake Rate:

Air flow rate could be determined by multiplying the cross-sectional area of air inlet pipe
with air velocity.

𝜋𝑑 2
=
4
*V
where,
d = Intake pipe diameter (m)

v = Intake air velocity (m/s)

 Exhaust Flow Rate:

From the derivation of Bernoulli's Theorem, it is shown that the incoming air velocity at the
orifice throat.

 Displacement Volume (Vd):

The displacement volume is the difference between the maximum and the minimum volume
for a single cylinder.

161
 162

where,
V1 = maximum volume at bottom dead center
Ve = clearance volume (the volume in this position is minimum) b = bore
s = stroke
n = number of cylinder => (n = 1)

 Brake power (Wb):

The brake power is the rate at which 'work is done. This is the measured output of the
engine. The engine is connected to a DC generator, which can be looked in such a way that
the torque exerted by the engine can be measured.

The torque is obtained by reading off a netload, F at a known radius, r from the axis of
rotation and hence the torque, T is given as follows:
T = Fx r
The brake power and torque are related by:

Wb = 2πNT/60
where,

m = engine frequency (rad/s)

N = rotational speed of the crankshaft (rpm)

 Volumetric efficiency:

For internal combustion engines, the volumetric efficiency is defined as the ratio of the
actual mass of air drawn in during the suction stroke to the mass of air which would fill the
swept volume of the cylinder at atmospheric pressure and temperature.

𝜼𝒗 =𝑽𝒂/𝑽

Where,
Va = Intake mass flow rate of air (kg/s)
Vs = Mass of air which would fill the swept volume of the cylinder at atmospheric
pressure and temperature (kg/s) per unit time

 Air/Fuel ratio(A/F):

Air/Fuel ratio is defined as the air flow rate divided by the fuel flow rate.
A/F=ma/mS
162
 163
10.7 General Operating Procedures:
10.7.1 Starting:

1. Check the lubricant level regularly and make sure it is always filled with sufficient level of
lubricant.
2. Fill the fuel tank with fuel. Use unleaded automotive gasoline only.

3. Turn the STOP SWITCH clockwise to the position “1”

4. Open the fuel supply valve on the conical fuel tank.

5. Set the speed control lever 1/3 of the way towards the high-speed position.

6. Close the choke lever. If the engine is warm or the ambient temperature is high, close the
choke lever half-way, or keep it fully opened.
7. Pull the starter handle slowly until resistance is felt. This is the “compression” point. Return
the handle to its original position and pull it swiftly. Do not pull out the rope all the way.
8. After starting the engine, do not release the starter handle. Return to its original position
while holding the handle.
9. After starting the engine, gradually open choke by turning the choke lever and finally keep
it fully opened. Do not fully open the choke lever immediately when the engine is cold or the
ambient temperature is low, because the engine may stop.
10. After the engine starts, set the speed control lever to the low-speed position (L) and warm
it up without load for a few minutes.
11. Gradually move the speed control lever toward the high-speed position (H) and set to the
required engine speed. Whenever high-speed operation is not required, slow the engine down
(idle) by moving the speed control lever to save fuel and to extend engine life.

10.7.2 Stopping:

1. Set the speed control lever in the low-speed position and allow the engine to run at low
speed for 1 minute before stopping.
2. Turn the STOP SWITCH counterclockwise to the position “0”

3. Close the fuel valve at the fuel tank.

4. Pull the starter handle slowly until resistance is felt then return the handle to its original
position. This will prevent condensation of moisture in the engine.

10.7.3 Sample data:

Engine: 4-Stroke Diesel Engine (Brand: Robin Engines, Model: EX17D)
163
 164

Figure -9, 4-Stroke Diesel Engine

Displacement Volume : 169cc , Air intake Duct diameter: 0.0548 m, Exhaust diameter
: 0.064 m, Exhaust orifice: 0.032 m, Fuel Type: Petrol, Air Density : 1.225 kg/m3

Voltage (V)

Current (A)

Torque (Nm)

Speed (RPM)

Air Intake (m/s)

Exhaust DP (Pa)

Air Temp (degC)

Fuel Temp (degC)

Oil Temp (degC)

ExhaustTemp
(degC)
Initial Fuel Weight,
Wi (g)
Final Fuel Weight,
Wf (g)
Time (s)

164
 165

Determination of Engine Performance Curves:

Engine: 4-Stroke Diesel Engine (Brand: Robin Engines EX17D)
Displacement Volume: 169cc Air Intake Duct Diameter: 0.0548 m Exhaust
Diameter: 0.064 m
Exhaust Orifice: 0.032 m
Fuel Type: Petrol
Air Density: 1.225kg/m3

Speed Voltage Current Electrical Power Brake Power Torque Remarks

(RPM) (V) (A) (kW) (kW) (Nm) (Load- Watt)

165
 Voltage Current Torque Speed Air Intake Exhaust DP Air Fuel Oil Exhaust Initial Fuel Final Fuel T(s) Remarks
(V) (A) (Nm) (RPM) (m/s) (Pa) Temp Temp Temp Temp W W (load- Watt)
( C) ( C) ( C) ( C) (g) (g)

166
166
 167

167
 168

10.8 Observations:
------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------

168
 169

LAB REPORT

Prepare the Lab Report as below:

10.1 TITLE:
------------------------------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------

10.2 OBJECTIVE:
------------------------------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------

10.3 APPARATUS:
------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

10.4 PROCEDURE:
(Note: Use all steps you studied in LAB SESSION of this lab to write procedure and to complete
the experiment)

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------
169
 170
------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

170
 171
10.5 DISCUSSION:

Q1: What is the difference between brake power and electrical power?

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

Q2: What is the effect on engine efficiency if the speed of engine increases?

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------------------------------

10.6 CONCLUSION /SUMMARY:

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------
171