DEPARTMENT OF ELECTRONICS &

INSTRUMENTATION ENGINEERING
Arockia Vijay Joseph,
Assistant Professor(OG),
SRM University,
arockiavijay.j@ktr.srmuniv.ac.in
EI1109 - AUTOTRONIX
 UNIT - III
SPARK IGNITION ENGINE
MANAGEMENT
Ignition System
 Includes
• Requirements
• Components
• Principle of Operation
• In Detail about Types of Ignition System
• Fault Diagnosing
 Requirements
• Compression ratio
• Combustion chamber
design
• Air-fuel ratio
• Engine Speed range
• Engine load
• Combustion Air and fuel
temperature mixture

• Emission regulations Spark plug

Piston
CONTACT BREAKER IGNITION SYSTEM
COMPONENTS & PRINCIPLE OF
OPERATION
Components
 Primary Circuit
Ignition switch

Distributor
and cam
Ballast
resistor Condenser
Battery

Ignition
coil Contact breaker
 Secondary Circuit
Distributor
cap

Rotor arm
Spark plugs

Ignition coil
 Secondary
+ terminal terminal Battery

- terminal Spark
Soft iron plug gap
Casing core
Primary
windings Primary
winding Secondar
Secondary y winding
windings

Insulator
300
Insulation turns 18000
Laminated turns
paper Contacts
iron core
BACK
EMF =
200V
Types of Ignition coil
 Distributo
r cap

Rotor
arm

Condenser
Cam

Base
Contact
plate
breaker

Distributo
r body
Drive
gear
 Centre
contact
End
contact

Coil HT terminal
Spark
plug HT
terminal

Securing
lug

Spring
loaded
contact

Brass
contact
 Distributor Operation
To coil primary Cam
Centre
Contacts
terminal

Shaf
t

Ga
p
Outer
terminal
Rotor
arm

15 of 15
 Silicone
jacket
Spark
plug
end

Termina
l
Contacts Rubber
boot

Condenser Distributor
end

Erosion - no
condenser
 Termina
l

Insulato
Hex r

Ballast Coi
resistor l

Meta
l Gasket
shell
Thread Centre
electrode

Side Gap
electrode
Use of Condenser
Ignition Timing
ELECTRONIC IGNITION
SYSTEM
 Why replace the Contact
Breaker?
• Accuracy limits.
• Emission limits
• Current flow in primary
circuit is only 4A
• Weaker mixtures need
more energy from spark.
Electronic Distributor IS
Distributor cap

Ignition
switch

Coil

Spark plug

Speed sensor
ICM
 Types of Sensors Involved
• Optical Type
• Induction Type
• Hall IC Type
Photo-coupler
O/P of Photo-coupler
 Advantages
• Greater Sensitivity
• Wide Dynamic Range
• Free from EMI
• Both Point and Distributed Range
Induction Type
Hall Effect Type
 Triggering Device
• Hall Effect Type
• Inductive or Magnetic Pick up coil Type
• Optical Type
Along with the triggering device we have an ignition
module which switches ON and OFF the spark plug based
on the signal from the triggering device.
Hall Effect Type
 Induction Type or
Magnetic Pick up coil
Optical Sensor Construction
 Optical
sensor

Timing disc
with slots
 Operation
Simple timing
disc or rotor
plate
Receiver Volts

Transmitter

Time

Transmitter
Ignition Module
Types of Ignition System
Programmed Ignition
System
 What is it?
• Requirements are programmed in ECU’s memory.
• ROM data are obtained through rigorous testing on
engine dynamometer.
• Term coined by ROVER
• FORD, BOSCH and some more named as “Electronic
Spark Advance”
 Advantages
• Ignition timing is accurate to the requirements.
• Control inputs like engine speed, engine load, coolant
temperature and knocking effect.
• Starting improved
• Fuel efficiency
• So emissions are reduced.
• Wearing components reduced.
Schematic Diagram
 Thermistor
(-90 to 180˚C)
• A thermistor is a temperature-sensing element composed
of sintered semiconductor material which exhibits a large
change in resistance proportional to a small change in
temperature.
• It is made up of ceramic or polymer materials.
Engine Coolant Temperature
Sensor
1 ECT sensor
2 PCM
3 CPU
Diaphragm
Manifold Air Pressure Sensor
Vapor Deposit
O/P Characteristics
 Crankshaft Position Sensor/
Inductive Type Engine Speed Sensor
Crank Shaft Position
Piston Position Sensor
Characteristics of Hall Effect
Sensor
Piezoelectric Knock
Sensor
Characteristics of Knock
Sensor
 From ECU
• For Primary Circuit
The primary winding current is been
controlled by a heavy duty transistor.

Switch On ---- Ignition Timing

Switch Off ---- Dwell period
Distributorless Ignition
System
Schematic Diagram
Direct Ignition System
 UNIT - IV
COMPRESSION IGNITION
ENGINE MANAGEMENT
CARBURETTED SYSTEM
 History and Development
 Invented by Karl Benz in the year 1885 and was patented in
1886.
 It was further developed by Hungarian Engineers.
 In1900 carbureted system became an important step
forward in Automotive engineering.
 Until late 1980s carbureted system were the usual fuel
delivery method used.
Parts of a Carburetted System
 Fuel Tank.
 Fuel lines/Pipes.
 Fuel Pump.
 Fuel filter.
 Air filter.
 Carburetor.
 What is a Carburetor?
A device that blends air and fuel for an IC engine for combustion.
A device that atomizes and vaporizes the fuel for purpose of
combustion.
A carburetor mixes the air and fuel in a particular ratio, which is
accurately 14.7:1.
The ratio can be changed by the usage of its parts namely a choke.
It works on Bernoulli's principle,ie,the faster air moves, the lower
its static pressure, and the higher its dynamic pressure.
 Types of Air-Fuel mixtures
 Normal – 14.7:1 (Blue flame)

 Rich – 10 to 12:1 (Yellow flame)

 Lean-Air units greater than 15.(Whitish-blue).

 Factors to be considered for the
mixture:
 Ambient temperatures
 Atmospheric pressures
 Engine speeds and loads
 Centrifugal forces namely cold/hot start, idling/slow
running, acceleration and high power at full throttle.
Circuits (Parts of a Carburetor)
 Open pipe called “Barrel”.
 Air horns.
 Venturi.
 Float Chamber.
 Float.
 Mixture needle.
 Throttle valve.
 Choke valve.
 Operation
 A carburetor basically consists of an open pipe, a "throat" or
"barrel" through which the air passes into the inlet manifold of
the engine.
 The pipe is in the form of a venturi: it narrows in section and
then widens again, causing the airflow to increase in speed in
the narrowest part.
 Below the venturi is a butterfly valve called the throttle valve
— a rotating disc that can be turned end-on to the airflow, so
as to hardly restrict the flow at all, or can be rotated so that it
(almost) completely blocks the flow of air.
 Contd..
This valve controls the flow of air through the carburetor
throat and thus the quantity of air/fuel mixture the
system will deliver, thereby regulating engine power and
speed.
Fuel is introduced into the air stream through small holes
at the narrowest part of the venturi.
 Fuel flow in response to a particular pressure drop in the
venturi is adjusted by means of precisely-calibrated
orifices, referred to as jets, in the fuel path.
 Barrel
 Barrel is cylinderical pipe like structure through which
the air flows half the way and the rest air-fuel mixture.
 Types: a)Single Barrel
b)Multiple Barrel.
 Multiple barrels are used to accommodate the higher
flow rate with large engine displacement.
High performance 4 barrel
carburetor
Venturi
 Types of Venturies
 FIXED VENTURI:
 Here the fuel flow is altered by varying the air-velocity
in the venturi.
 It is used in down draft corburetors.
 VARIABLE VENTURI:
 Here the fuel jet opening is varied by the slide, which
simultaneously alters air flow.
 It is controlled by a mixture needle.
 It is used in side draft and updraft carburetors.
 Throttle Valve
 The throttle valve is usually connected through a cable
or a mechanical linkage of rods and joints.
 Even by pneumatic mechanism.
 These are connected to the accelerator pedal or any
other equivalent actuaters depending on the type of
vehicle.
 When the actuator is completely pressed,throttle valve is
opened completely when released it’s the opposite.
 Choke
A choke is a mechanical device in a carburetor
which ensures in making a rich air fuel
mixture.
This is required in cold starting conditions.
Types:
Manual choke
Automatic Choke (Thermostatic operation)
 Types of Carburetor
Natural or Side draft.

Down draft.

Up draft.
Natural or Side draft
Down draft
Up Draft
 Fuel Pump of C.S
It is used to deliver fuel from the fuel tank to
the corburetor.
Types
Mechanical fuel pump
Electronic fuel pump
 Parts of a fuel pump
Body
Diaphragm
Inlet/outlet valve
Inlet/outlet nozzle
Rocker lever
Pivot pin
Lever return spring
Diaphragm spring
Crankcase seal
Diaphragm chamber.
Exploded view of a pump
Float and float chamber
 HISTORY AND DEVELPOMENT
• Fuel Injection Technology Has Been Developed Around 1920’s.
• Rudolph Diesel Contracted With Awgsburg And Krupp Of Germany
In 1893 To Develop A More Efficient Internal Combustion Engine.
• His First Experiment On Oil Was Not Satisfactory Probably Because
Of The Crude Injection Equipment With Large Dead Fuel Volume.
• Dr.Diesel Resorted To Use The Compressed Air Equipment Available
From The Coal Dust Experiments.
• His First Experiment With Air Injection Proved So Successful That
This Become The Accepted Method Of Injection Of Many Years.
• Robert Bosch In Germany Developed The First Petrol Injection
System For Mercedes Racing Cars.
 FUEL INJECTION SYSTEM
• Diesel fuel injection system:
• Injects fuel in to the combustion chamber of a diesel
engine when the piston reaches near the compression
top dead centre. Injection is high pressure
• Petrol injection system:
• Spray of fuel is injected in the induction manifold
near inlet valve during suction stroke when intake valve
is opened.Injection is low pressure
MERCEDES BENZ SL300
 Types of petrol injection
1.ACCORDING TO THE LOCATION OF INJECTOR:
Direct injection
Port injection
Throttle body injection
2.ACCORDING TO THE DURATION AND TIMING OF FUEL:
Continuous type
Intermittent type
Sequential type
3.ACCORDING TO NUMBER OF INJECTORS:
Single point injector
Multi point injector
4.ACCORDING TO CONTROL METHOD:
Mechanical method
Electronic method
 Gasoline-Engine Fuel
Delivery Systems Direct (In-Cylinder) Fuel-
Injection

1996 ????

Advanced Multi-Port-
Fuel-Injection

1995 ????
Multi-Port-Fuel-Injection

1980 ????
Single-Point,
Throttle-Body
Fuel Injection

1980 1995

Carburetor
1900
1985
OBJECTIVES OF THE INJECTION
SYSTEM
The injection system of the compression ignition engine should fulfill
the following objectives consistently and precisely:
1. Meter the appropriate quantity of fuel, as demanded by the speed
of, and the load on, the engine at the given time.
2. Distribute the metered fuel equally among cylinders in a multi-
cylinder engine.
3. Inject the fuel at the correct time (with respect to crank angle) in
the cycle.
4. Inject the fuel at the correct rate (per unit time or crank angle
degree).
5. Inject the fuel with the correct spray pattern and sufficient
atomization as demanded by the design of the combustion
chamber, to provide proper penetration also.
6. Begin and end injection sharply without dribbling or after
injection.
To accomplish these objectives, a number of functional elements
are required. These constitute together, the fuel injection
system of the engine. These elements are as follows.
1. Pumping elements to transfer the fuel from the tank to the
cylinder, along with the associate piping and hardware.
2. Metering elements to measure and supply the fuel at the rate
as desired by the speed and load conditions prevailing.
3. Metering controls to adjust the rate of the metering elements
for changes in load and speed of the engine.
4. Distributing elements to divide the metered fuel equally
among the cylinders in a multi cylinder engine.
5. Timing controls to adjust the start and stop of injection.
6. Mixing elements to atomize and distribute the fuel within the
combustion chamber
 FUEL SUPPLY SYSTEM
IT CONSISTS OF,
• STORAGE TANK
• FILTER
• FUEL PUMP
• FUEL INJECTOR
• NOZZLE
• OIL GAUGE IN THE DASH BOARD AND NECESSARY CONNNECTIONS AND PIPE
LINES.
 Port-Fuel-Injection

Carburetor

Direct-Injection
 Fuel injection systems
There are two main classifications for fuel-injection systems,
namely
1. Air injection which had become obsolete but now some
interest has been shown by researchers (however very
high pressure is required for air) and
2. Solid (or airless) injection systems.
The airless, mechanical, or solid injection systems consist of three types.

1. Individual pump system: this consists of a separate metering and

compression pump for each cylinder.
2. Distribution system: this consists of a single pump for compressing
the fuel (which may also meter), plus a delivery device for
distributing the fuel to the cylinders (which may also meter).
3. Common rail system: a single pump for compressing the fuel, plus a
metering element for each cylinder.
 Fuel Filters
A low pressure (2.5 bar) transfer pump or fuel feed pump is required to lift
the fuel from the tank, to overcome the pressure drop in the filters, and
to charge the metering or pressuring unit. Three filters are
recommended, namely,

1. A primary stage (a metal- edge filter to remove coarse particles, larger

than 25 microns).

2. A secondary stage (a replaceable cloth, paper or lint element to remove

fine particles from about 4 to 25 microns) and

3. Final stage (a sealed, non-replaceable element) to remove fine particles

that escaped the secondary stage.
 The volume of fuel injected per second, Q, is given by

.
    60   N 
Q   d 2  V f    i 
4   360 N   60 

where d is the diameter of one orifice in m,

Ni is the number of injections per minute, = N/2 for
a 4-stroke engine,
N is the engine speed in rev/min,
θ is the duration of injection in crank angle degrees,
Q is expressed usually in mm3/degree crank angle/liter
cylinder displacement volume
 UNIT - V
DIGITAL ENGINE CONTROL
SYSTEM
Anti-Lock Braking System-
ABS
In-Detail
Originally developed for Aircraft
 Purpose of ABS
• Applying brakes harder under slippery surfaces causes the
wheels to lock.
• When wheels get locked the steering control is lost and in
most cases it causes longer stopping distance.
• The Anti-Lock Braking system prevents wheel’s locking or
skidding, no matter how hard the brakes are applied or how
slippery the road surface is.
• Steering is under control and the stopping distance is reduced
generally.
ABS - Generation
Real Time Model
 ABS Requirements
• Steerability
• Stability
• Reduction of tire wear
• Reducing stopping distance
• Low Noise
• High Reliability
• Safety
• Low cost
 Concept???
Which sensor signal could be used?
1.Wheel Speed
2.Vehicle Speed Vs. Ground
3.Vehicle Acceleration
4.Wheel Brake Pressure
5.Master Cylinder Pressure
Components in ABS
Anti-Lock Braking System consists of the following
components,
• Brake pedal
• Master Cylinder
• Wheel Speed Sensor
• Electronic Control Unit
• Hydraulic Control Unit
• Toothed rotor
Hydraulic Control Unit
Wheel Speed Sensor

???
 ABS Hydraulic Operation
• It consists of an Electronic Control Unit(ECU) which controls the
hydraulic pressure of fluid, either by releasing the lock on the wheel or
applying brake on the wheel
 Road Conditions
• Dry
• Wet
• Ice
• Oil
 ABS Braking Cycle Operations
• Pressure Isolate
• Pressure Dump
• Pressure Built/Normal
Cruise Control ?#@!

123
Cruise Control System
 Cruise control system controls the speed of
your car the by adjusting the throttle
position. The throttle valve controls the
power and speed of the engine by limiting
how much air the engine takes
 Cruise control systems use a PID control
scheme
 Distance - Integral factor
(The integral of speed is distance)
 Speed - Derivative factor
(The derivative of speed is acceleration)

124
Adaptive Cruise Control (ACC)
 Adaptive Cruise Control (ACC) is a feature that allows a vehicle's
cruise control system to adapt the vehicle's speed to the traffic
environment.
 It’s a radar-based system that can monitor the vehicle in front and
adjust the speed of the vehicle to keep it at a pre-set distance behind
the lead vehicle, even in most fog and rain conditions.
 The system measures distance as a function of speed and can monitor
the traffic ahead while ignoring stationary objects such as road signs
and telephone poles.

125
ACC Radar
 ACC is achieved through a radar headway sensor, digital signal
processor and longitudinal controller.
 The 77-GHz Auto cruise radar system made by TRW has a forward-
looking range of up to 492 feet (150 meters), and operates at vehicle
speeds ranging from 18.6 miles per hour (30 kph) to 111 mph (180
kph).
 Delphi's 76-GHz system can also detect objects as far away as 492
feet, and operates at speeds as low as 20 mph (32 kph).

127
Constituents of ACC System
 A sensor (LIDAR or RADAR) usually kept behind the grill of the
vehicle to obtain the information regarding the vehicle ahead. The
relevant target data may be velocity, distance, angular position and
lateral acceleration.
 Three radar beams together with an integrated yaw rate sensor, enable
the system to differentiate between vehicles in the same lane and those
in other lanes.
 Longitudinal controller which receives the sensor data and process it to
generate the commands to the actuators of brakes throttle or gear box
using Control Area Network (CAN) of the vehicle.

128
Classification of ACC
Today’s modern system has evolved from the basic cruise control system.
Each succeeding evolution has increased its functionality over the previous
evolution. Based on the application of ACC system can be broadly
classified into
 Longitudinal ACC

 Distance Control
 Stop & Go
 Lateral ACC

 Lane Detection/keeping/Changing
 Collision Avoidance

 Co-operative ACC

129
Vehicles supporting ACC
Full cruise control (able to bring the car to a complete stop):
 BMW 7 Series, 5 series, 6 series Active Cruise Control with "Stop & Go"
option, 2007+ models. (radar)
 Mercedes-Benz Models equipped with "Distronic Plus" ACC with
"Presafe Brake" option. (radar)
Partial cruise control (cuts off below a set minimum speed, requiring
driver intervention):
 Audi A4 (see a demonstration on YouTube), A5, Q5, A6, A8 (uses also
data from navigation and front camera sensors)
 2004 Cadillac XLR, 2005 STS, 2006 DTS (shuts off below 25 mph)
 2007 Chrysler 300C (laser, for a limited time, now uses a Bosch radar-
based system)

131
 2011 Dodge Charger (radar, by Bosch)
 2003 Honda Inspire, Legend, 2007 Honda CR-V series III - Adaptive Cruise

Control and Collision Mitigating Braking System

 Hyundai Genesis (Smart Cruise Control, delayed)

 2011 Jeep Grand Cherokee (radar, by Bosch) 1998 Nissan Cima, Nissan Primera

T-Spec Models (Intelligent Cruise Control)

 2010 Porsche Panamera, 2011 Porsche Cayenne

 Subaru Legacy & Outback Japan-spec called SI-Cruise

 1997 Toyota Celsior, 2009 Sienna (XLE Limited Edition), Avalon, Sequoia

(Platinum Edition), Avensis, 2009 Corolla (Japan),[19] 2010 Prius

 Volkswagen Passat, Phaeton all generations, Touareg

 Volvo S80, V70, XC70, XC60, S60

132
Vehicle Instrumentation
Displays and Accessories
 To be measured
• Fuel level
• Temperature
• Engine Speed
• Oil Pressure
ELECTRONIC CONTROL UNIT (ECU)
(OR) BODY COMPUTER
MODULE(BCM)
 Instrument Computer
The instrument computer has
three main stages of operation: Input Output
stage stage
 Input.
 Processing.
 Output.
The input stage processes both
analogue and digital inputs.

Some input devices Analogue

require a reference
voltage to function. Digital/
This is provided by the switch
BCM’s power supply.
Analogue voltages are converted to digital signals by the Processing
A/D converter and / or amplifier, ready for processing. stage

Weak or noisy digital signals are conditioned, ready for processing.

FUEL LEVEL INDICATOR &
TEMPERATURE GAUGE
Fuel Level Indicator
Fuel level Speaker
sensor Lamp

BCM

Digital display
Analogue Display
Bimetal fuel and temperature
gauge circuits
Voltage Stabilizer
SPEEDOMETER
Mechanically Driven Analogue
Speedometer
Flexible Speedometer head
inner cable

Outer
cable
housing

Cable inner wire and gear

Drive gear
Transmission housing
 Electronically Driven
Speedometer
Computer (ECU)

Analogue
signal

Trigger
wheel Analogue or digital display

Speed sensor

Transmission housing
Vehicle Instrumentation
Displays and accessories
 A magnetic coil gauge
contains two coils and an
armature/needle Magnetic Coil Gauge
Armature/needle
It has three terminals, two for
voltage connection and one
for sensor connection DC
Ground voltage
Magnetic fields are produced in
when voltage is applied to the High Low
gauge and current flows coil coil
through the coils

The armature is moved by the Gauge

magnetic fields. Direction housing
depends upon the magnetic Input from
field strength of each coil sensor 146
 When the sensor has a low
resistance, a high current flows
through the low coil and the
sensor. The magnetic field of the
low coil dominates that of the high Magnetic Coil Gauge
coil, and the armature moves
toward the low coil
When the sensor has a high
Operation
resistance, a low current flows High Low
through the low coil and the coil coil
sensor. The magnetic field of the
high coil dominates that of the low
coil, and the armature moves +V
toward the high coil
Magnetic coil gauges are normally High Low
packaged in metal or plastic cases coil coil
that have transparent covers and
easy to read dials 147
 Magnetic Coil Fuel Gauge
Measures the amount of
The magnetic field of low
fuel in a fuel tank, using a
coil dominates and the
float attached to a
needle points toward full
variable resistor (sensor).
(F) on the fuel gauge
When the fuel level in the
tank is low, the float The float rises as the tank
drops and the resistance fills, lowering sensor
of the sensor is high resistance, allowing more
current flow through the
The magnetic field of
low coil
high coil dominates and
the needle points
toward empty (E) on the
fuel gauge
148
Magnetic Coil Oil Pressure
Gauge
A diaphragm, in conjunction with a variable
resistor, is used to measure engine oil
pressure.
As the diaphragm deflects, the resistance
measured at the input to the oil pressure gauge
varies.

The gauge is usually mounted on the

dashboard.

A warning lamp can be used to indicate low oil

pressure. It illuminates at a preset resistance
value. Lam
p