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Abstract - Internal combustion engine plays vital other engine components. In case of this petrol
role in any automotive application and mechanical engine; insufficient compression, improper
systems. These engines are worldwide used as device combustion are the two main causes of reduction in
transforming one form of energy into another form efficiencies. Also there is insufficient spark occur,
and their cost is high so; maintenance of such Failure of Ignition coil, Intake manifold &
engines is an essential thing. In this project the focus Carburetor which highly reduce the performance of
is on the fault detection and experimental analysis of the engine. The attempt made by earlier researchers
the engine. The available literature was thoroughly for use of fault tree analysis for different case studies.
reviewed and many methods about fault detection DobrivojeCatic et.al, did work on the analysis of the
were studied. Review of research study concluded fault tree of solar concentrator .The analysis of the
that fault tree analysis which uses logic gates and operation mode of this device led to the conclusion
Boolean algebra. It is a graphically design technique
that the failure of any subsystem leads to system
that provide reliability block diagram and the tree
failure. [1]
developed will identify the root causes. By the use of
this method it is an easy way to identify failure parts RafalLaskowski applied fault tree analysis as a
of system. After identifying the failure parts of the tool for modeling the marine main engine reliability
engine these parts will be either repaired or replaced structure. In case of small fault tree the minimal cut
and carried various experimental tests such as load, sets are searched by tree inspection while for large
Speed and Morse test on the engine. To compare and complex trees appropriately selected procedures
performance of test setup with and without fault tree and algorithms were used. [2] H.E.Lambert
analysis approaches are used. The results obtained
discussed the use of fault tree analysis for
using fault tree analysis is effective in manner. The
automotive reliability and safety analysis He
performance of engine is increased after
concluded that the value of the fault tree it shows
maintenance and fault tree analysis method
facilitates successfully optimizing of maintenance logical progression of events and ties all the events
effort. together to show important system interactions that
are not displayed in an FMEA. [3] Jana Glisovic
Keywords: Fault Tree Analysis (FTA), 4-Stroke 4- et.al, presented fault tree analysis of hydraulic power
Cylinder Petrol Engine Test Rig. steering system. the potential modes of failure of the
components can be recorded, which can be, inter
I. Introduction alia, used as one of the best failure modes and effects
Internal combustion (IC) engine is a power analysis models for analyses of causes and
generating machines and used widely in automotive consequences of faults. [4]
industry. The study of internal combustion engines While going through various research papers for
has become a very important part of a mechanical Fault tree Analysis, it is understood that failure of
engineer’s education Hence it is appropriate that we any subsystem leads to the failure of whole system.
have worked on 4-stroke 4-cylinder petrol engine test Also it is observed that the fault tree analyst must
rig’. The test rig consists of Premier Padmini petrol understand how the system works as well as the
engine which is a division of the Walchand Group, specific failure modes that cause the top event to
under license from Fiat. The performance of engine occur. The use of fault tree may be used for the
is highly depends on components efficient working; experimental analysis of 4stroke petrol engine.
if these parts failed, the performance is partially or
completely decreased. The failure of a system From the review it can be observed that
depends on the time, with varying over the life cycle researchers have used the fault tree analysis for
of the system conditions. Engine failures result from different systems. Unfortunately no one has used
a conditions, effects, and situations. To understand fault tree analysis for 4-stroke 4-cylinder petrol
why engines fails and remedies to those failures, one engine. Thus, there is need of working on fault tree
must understand how engine components are analysis of 4-stroke 4-cylinder petrol engine.
designed and manufactured, how they interact with
II. Problem Statement efficiency of the petrol engine. The above fault tree
diagram is based on problems which are actually arise.
I.C. Engine is a unique event in twentieth These problems are illustrated below.
century. These engines considered to be heat engine as
they convert thermal energy into mechanical energy. In case of these petrol engine insufficient
In an internal combustion engine the products of compression & improper combustion are the two
combustion are directly the motive fluid. But overall main causes of reduction in efficiencies.
performance of engine depends on full functioning of
components. As if these parts failed e.g. carburetor,
ignition coil, spark plug, starter etc there is possibility
of engine gets totally failed or partially economy will
be given less. FTA is a very effective risk assessment
tool. Using FTA the failure component of engine will
be identified and effects of component failure are
discussed. By general observation in case of this petrol
engine insufficient compression & improper
combustion are the two main causes of reduction in
efficiencies. Implementation of FTA method
diagnosed the affected parts and will be replaced or
repaired if they influenced on engine performance. The
FTA method is very useful method for detecting the
failure parts of the system. In this study fault tree
analysis method will be helpful to diagnose the failure
of components and to improve overall efficiency of 4-
Stroke 4-Cylinder Petrol Engine setup.
III. Methodology
A.Fault Tree Analysis
FTA was introduced in the early 1960s by H.
A. Watson of Bell Laboratories in connection with the
U. S. Air Force contract to study the Minuteman Fig. 1 Fault tree analysis of I. C engine
Launch Control System. A useful tool in performing a Efficiencies are not going to reduce if &
system safety analysis is fault tree analysis. A fault only if compression should be sufficient
tree analysis is a graphical design technique that combustion should be proper. There will be
provides an alternative to reliability block diagrams. It sufficient compression if & only if there is no
is a top-down Deductive analysis structured in terms of wear & tear of pistons & cylinders. Combustion
events rather than components. is proper only if spark should be sufficient & A/F
B.Objectives: ratio should be proper.
indicator to the Faults in Spark Plug. So voltage causes misbehaving of contact breaker points resulting
should be proper in order to eliminate spark plug distributor failure. Remedies are there should be no
failure. wear of camshaft, working of contact breakers should
be proper.
(b)Fuel deposition:
Spark plug is inappropriate because of Causes of improper A/F ratio:
rough materials that accumulate on the side
electrode may melt to bridge the gap when the i. Intake manifold failure:
engine is suddenly put under a heavy load. The Possible modes of valves failure are wear failure,
voltage required to fire the plug is getting low so valve face recession, fatigue failure, thermal fatigue,
brown colour flame is not getting. The damage in erosion corrosion of valves, overheating of valves,
spark plug mainly occurs due to fouling and the carbon deposits on valves etc. The valve is subjected
overheating of spark plugs. [6] to various loads at any point of time, such as reverse
loading at a high temperature, stress concentration at
the keeper groove area and under carbon deposits at
exhaust valves. The valves generally fail by fatigue.
Exhaust valves operate at very high
temperatures and subjected to cyclic loading, the
Fig.2 Fauling of spark plug failure of the conical surface of valve is mainly caused
by the elastic and plastic deformation, and fatigue.
Deposits accumulated on the firing end may Exhaust valve stem generally fail by overheating
induce abnormal combustion (pre-ignition), causing because the temperature of the exhaust valve is about
problems that include melting of the electrodes. If the 720 ºC [7]
edges of electrodes are worn and rounded, sparks will ii. Carburetor failure:
not easily occur,remedies for stopping of fuel Engine backfiring and overheating are the
deposition are replacement of worn or damaged valve common symptoms of a potential problem with the
guides or valve guide seals, allow rich fuel mixture, carburetor. A carburetor uses intake vacuum to supply
replacement of d guide seals, allow rich fuel mixture, fuel to the engine. As air is pulled down through the
replacement of damaged spark plug. throat of the carburetor by intake vacuum, fuel is
siphoned from the carburetors fuel bowl and mixed
(c)Spark plug polarity: with the incoming air to form a combustible mixture.
If any problem arise in the above operation will affect
An important point relating to the misfire
air fuel ratio. Remedies are overcoming of above
tendency which is not always appreciated is the spark
problems.
plug polarity. The center electrode must be of negative
polarity because it is hotter than the earth electrode and iii.Air filter failure:
less voltage will be required to spark from the center
electrode to the ground electrode. Suppose the Most of times filter is clogged with dust and
manufacturer connects the coils to give a negative grime so it affects fresh air & results into pollutants.
polarity to the central electrode but the mechanic, Leakage in pipes affects volumetric efficiency.
while installing a new coil reverses the connection. Remedies are replacement or cleaning of filter.
This will result in failure of spark plug. Remedies are All above discussed failures results in
installation of spark plug should be proper. reduction of break thermal efficiency & volumetric
i. Ignition coil failure: efficiency, Mechanical efficiency of these 4-stroke, 4-
cylinder petrol engine test rig. After analyzing fault
Ignition coil failures are cause by worn out tree diagram we have done changes accordingly in
spark plugs that fail to transmit electronic signals in a present test rig & perform the same tests to check
functional and fluid manner. This creates a disruption whether the efficiencies are improved or not.
in the regular flow of power across the ignition coil
and makes the engine lose power. It is less common Experimental Analysis
but still possible that the rotor the ignition coil rests on
brakes on reduces the function of the power circuit. An experimental analysis is carried on out on 4stroke,
Remedies are replacement of damaged ignition coil. 4-cylinder Petrol engine setup is shown in figure.
= 0.004
Result-
Brake × 0.746
BMEP BSAC BSFC Ƞbrake Torque
S.N thermal
(T) = 1.38 Kw
1 0 0 0 0 0
2.Morse Test –
iv. BP[124] = × 0.746
Morse test is performed to check the
mechanical efficiency of the petrol engine.
Observation Table: = 1.35Kw
Observation of load test are mentioned in
following table 4. v.
Results –
Following result were obtained for Load test on
petrol engine without fault tree analysis mentioned in table 7
and table 8
Appendix:-
35 FTA: Fault tree analysis.
Brake Thermal Efficiency (%)
30
25 BSFC: Break specificfuel consumption
20 Before Fault BSAC: Break specific air consumption
Tree
15
Analysis BMEP: Break mean effective pressure
10 After Fault
5 Tree BP: Break power
Analysis
0 BT: Break Torque
0 2 4 6 8 10 12 14 16
A/F Ratio: Air Fuel ratio
Load (kg)
Mfuel:Mass of fuel
Graph 5: Brake Thermal Efficiency Vs Load
Mair: Mass of air
60
Volumetric Efficiency (%)
50
Before Fault
40 Tree
30 Analysis
20 After Fault
10 Tree
Analysis
0
0 2 4 6 8 10 12 14 16
Load (kg)
References:-
[1] DobrivojeCatic (2013), “Fault Tree Analysis of Solar
Concentrators” International Journal for Quality Research, vol
7, issue 4, pp 595–604.
[2] RafałLaskowski (2015), “Fault Tree Analysis as a tool for
modelling the marine main Engine reliability structure”
Scientific Journals of the Maritime University of Szczecin, vol
41, issue 113, pp 71-77.
[3] H. E. Lambert (2003), “Use of Fault Tree Analysis for
Automotive Reliability and Safety Analysis” SAE Society of
Automotive Engineers World Congress, UCRL-JC-154905.
[4] GlisovicJasna (2014), “Fault tree analysis of hydraulic power-
steering system” Int. J. Vehicle Design, vol 64, No. 1, pp 26-
45
[5] Ahmed Ali Baig (2013), “Reliability Analysis Using Fault Tree
Analysis: A Review” International Journal of Chemical
Engineering and Applications, Vol. 4, No. 3, pp 169-173.
[6] M. R. Parate& S. N. Dandare (2012), “Fault Identification in IC
Engine using DSP and ANN” International Journal of
Computer Applications, pp 59-63.
[7] Naresh Kr. Raghuwanshi (2012), “Failure analysis of
Internal Combustion Engine Valves: A Review” International
Journal of Innovative Research in Science, Engineering and
TechnologyVol. 1, Issue 2, pp 173-181.
[8] M.L. Mathur& R.P. sharma, “Internal Combustion Engines”,
Dhanpat Rai Publications.