Transcript
BASIC DIESEL ENGINE TECHNOLOGY
TRI-CO. YOUNG FARMERS
DECEMBER 4, 2001
Original Power Point created By Joey Wells
Modified by Georgia Agricultural Education
Curriculum Office
June 2002
INTRODUCTION
• THE DIESEL ENGINE IS USED AS A SOURCE OF POWER FOR THOUSANDS OF APPLICATIONS.
WHO INVENTED THE DIESEL ENGINE?
• 1895 – RUDOLPH DIESEL SUCCESSFULLY INVENTED AN ENGINE THAT BURNED COAL DUST INJECTED BY PRESSURIZED AIR. THE DIESEL ENGINE WAS BORN.
WHO DEVELOPED THE FIRST MASS PRODUCED
INJECTION PUMP?
• ROBERT BOSCH IN 1927
USES OF DIESEL ENGINES
TODAY, DIESEL ENGINES ARE USED TO PROVIDE POWER IN A VARIETY OF APPLICATIONS IN
MANY INDUSTRIES
THERE ARE SIX MAJOR USES OF DIESEL ENGINES
AGRICULTURE/FARM
TRANSPORTATION
CONSTRUCTION
FORESTRY
MARINE
ELECTRICAL GENERATION PLANTS
SEVEN ADVANTAGES OF DIESEL ENGINES
• MORE EFFICIENT AND ECONOMICAL TO USE
• FUEL VAPOR IS NOT EXPLOSIVE• EXHAUST GASES ARE LESS
POISONOUS – LESS CARBON MONOXIDE
• GREATER LUGGING POWER AND TORQUE
ADVANTAGES CONTINUED
• ENGINES ARE DURABLE AND IF PROPERLY CARED FOR WILL MAINTAIN THEIR ECONOMY
• FUEL IS LESS VOLATILE – NO VAPOR LOCK PROBLEMS
• CAN USE A VARIETY OF FUELS AND MIXTURES
FIVE DISADVANTAGES OF DIESEL ENGINES
• ENGINES MUST BE STONGER AND HEAVIER BECAUSE OF HIGHER COMPRESSION RATES
• INITIALLY MORE EXPENSIVE• FUEL COULD GEL IN COLDER
CLIMATES• GENERALLY NOISER OPERATION• VERY PUNGENT EXHAUST ODOR
INTERNAL COMBUSTION ENGINE:
AN ENGINE THAT PRODUCES POWER BY BURNING FUEL INSIDE A COMBUSTION CHAMBER WITHIN THE ENGINE
TWO TYPES OF INTERNAL COMBUSTION ENGINES
SPARK IGNITION ENGINE
COMPRESSION IGNITION ENGINE
TRUE OR FALSE: SPARK PLUGS SHOULD BE CHANGED MORE OFTEN IN DIESEL ENGINES THAN IN GASOLINE ENGINES?
FALSE
BASICALLY, HOW DOES A SPARK-IGNITION ENGINE
WORK?
• LIQUID FUEL BROKEN DOWN INTO A FINE SPRAY AND MIXED WITH AIR IN THE CARBURETOR.
• FUEL-AIR MIXTURE PIPED TO THE CYLINDER WHERE IT IS IGNITED BY AN ELECTRIC SPARK FROM THE SPARK PLUG.
HOW DOES A COMPRESSION-IGNITION
ENGINE WORK?
• NO SPARK IS NEEDED• LIQUID FUEL UNDER VERY HIGH
PRESSURE IS INJECTED DIRECTLY INTO THE CYLINDER WHICH IS FILLED WITH HIGHLY COMPRESSED AIR.
• IGNITION BEGINS WHEN THE FUEL HITS THE AIR THAT IS AT A TEMPERATURE OF 777 DEGREES F.
WHAT DOES A COMPRESSION RATIO OF
16:1 MEAN?
THE AIR IN A CYLINDER IS COMPRESSED INTO 1/16 THE
SPACE AT THE TOP OF THE STROKE AS COMPARED TO THE
BOTTOM OF THE STROKE
TRUE OR FALSE: DIESEL ENGINES USE GREATER COMPRESSION RATIOS
THAN GASOLINE ENGINES?
TRUE
DIESEL ENGINES – 16:1 TO 22:1
GASOLINE ENGINES – 8:1
TRUE OR FALSE: DIESEL ENGINES REQUIRE MORE
AIR THAN GASOLINE ENGINES
TRUE
TRUE OR FALSE: DIESEL ENGINES HAVE NO IGNITION SYSTEM
COMPONENTS
TRUE
NO SPARK PLUGS, COIL, MAGNETO, DISTRIBUTOR, OR
WIRING
TRUE OR FALSE: DIESEL ENGINES, LIKE GASOLINE ENGINES, DRAW IN FUEL AND AIR ON THE INTAKE
STROKE?
FALSE
ONLY AIR IN A DIESEL ENGINE
WHAT IS THE PURPOSE OF A TURBOCHARGER ON A
DIESEL ENGINE?
TO INCREASE THE AIR INTAKE INTO THE CYLINDERS
TRUE OR FALSE: DIESEL ENGINES REQUIRE A HIGH
PRESSURE PUMP TO INJECT THE FUEL INTO THE
COMPRESSED AIR IN THE CYLINDER?
TRUE
WHAT IS THE NAME OF THE ENGINE PART THAT SPRAYS FUEL INTO THE CYLINDER
OF A DIESEL ENGINE?
INJECTOR NOZZEL
WHAT TYPE MATERIAL ARE FUEL LINES MADE OF IN A
DIESEL ENGINE? WHY?
STEEL
PRESSURES FROM 5,000 TO 20,000 PSI ARE INVOLVED
TRUE OR FALSE: GASOLINE IS LESS VOLATILE THAN
DIESEL FUELS
FALSE
GASOLINE EVAPORATES READILY AND IS VERY
EXPLOSIVE
TRUE OR FALSE: GASOLINE ENGINES ARE HEAVIER
THAN DIESEL ENGINES OF THE SAME HORSEPOWER?
FALSE
HIGH DIESEL CYLINDER PRESSURES REQUIRE HEAVIER
MATERIALS
HOW IS ENGINE SPEED CONTROLLED IN A DIESEL
ENGINE?
• THE THROTTLE CONTROL REGULATES ONLY THE AMOUNT OF FUEL INJECTED INTO THE CYLINDER
• THE THROTTLE CONTROL IN A GASOLINE ENGINE REGULATES THE AMOUNT OF AIR/FUEL MIXTURE ALLOWED INTO THE CYLINDER
HOW ARE DIESEL ENGINES STOPPED?
• BY SHUTTING OFF THE FUEL TO THE CYLINDERS BY A MANUAL CONTROL OR SOLENOID SWITCH
• GASOLINE ENGINES ARE STOPPED BY CUTTING OFF THE SPARK FROM THE SPARK PLUGS TO THE CYLINDERS
HOW AN ENGINE WORKS
WHAT ARE THE FIVE BASIC PARTS OF ANY ENGINE?
NAME THE TWO BASIC TYPES OF ENGINES
• FOUR STROKE CYCLE ENGINE
• TWO STROKE CYCLE ENGINE
WHAT SEQUENCE OF EVENTS MAKE UP A
CYCLE?• INTAKE
• COMPRESSION
• POWER
• EXHAUST
• WHAT IS A STROKE?
• ONE MOVEMENT OF THE PISTON
FOUR STROKES OF AN ENGINE
HOW MANY TIMES DOES THE CRANKSHAFT
REVOLVE DURING A CYCLE IN A FOUR STROKE CYCLE
ENGINE?
TWO
WHAT ARE THE MAJOR DIFFERENCES IN EACH
STROKE WHEN COMPARING A DIESEL
ENGINE WITH A GASOLINE ENGINE?
• INTAKE – AIR VS. AIR/FUEL MIXTURE
DIFFERENCES CONTINUED
• COMPRESSION STROKE– COMPRESSION RATIO
• POWER STROKE– SPARK PLUG VS. HEAT OF
COMPRESSION
• EXHAUST STROKE– SAME FOR BOTH
TWO-STROKE CYCLE ENGINES
HOW MANY STROKES OF THE PISTON ARE REQUIRED
FOR A CYCLE TO BE COMPLETED IN A TWO
STROKE CYCLE ENGINE?
TWO
WHAT HAPPENS DURING STROKE 1 IN A TWO
STROKE CYCLE GASOLINE ENGINE?
• THE UPSTROKE OF THE PISTON COMPRESSES THE AIR/FUEL MIXTURE. (COMPRESSION STROKE)
• AT THE SAME TIME, A NEW AIR-FUEL MIXTURE IS DRAWN INTO THE CRANKCASE. (INTAKE STROKE)
WHAT HAPPENS DURING STROKE 2 OF A TWO
STROKE CYCLE GASOLINE ENGINE?
• THE DOWNWARD STROKE (POWER STROKE) OF THE PISTON CAUSES THE BURNED GASES TO ESCAPE THROUGH THE EXHAUST PORT. (EXHAUST STROKE)
• NEW FUEL-AIR IS FORCED INTO THE CYLINDER
TWO-STROKE CYCLE GASOLINE ENGINES
WHAT ARE THE DIFFERENCES BETWEEN A
DIESEL AND GASOLINE TWO-STROKE CYCLE
ENGINE?• DIESEL ENGINES INJECT FUEL INTO THE
CYLINDER THROUGH A FUEL INJECTOR• A BLOWER IS OFTEN USED TO FORCE AIR INTO
THE CYLINDER• DIESEL ENGINES HAVE EXHAUST VALVES, GAS
ENGINES HAVE A PORT
TWO-STROKE DIESEL ENGINE
THE DIESEL AIR SYSTEM
BASIC PARTS OF THE DIESEL AIR SYSTEM
WHAT IS A TURBOCHARGER ON A DIESEL ENGINE?
A CENTRIFUGAL BLOWER THAT IS DRIVEN BY EXHAUST GASES WHICH FORCES MORE
AIR INTO THE CYLINDER. INCREASES POWER
HOW IMPORTANT IS KEEPING AIR FILTERS
CLEAN?
VERY IMPORTANT
A DIESEL ENGINE USES 12-15,000 GALLONS OF AIR TO
EACH GALLON OF FUEL
NAME THREE TYPES OF AIR CLEANERS
• OIL-BATH TYPE CLEANER
• PRE-CLEANER
• DRY-TYPE AIR CLEANER
THE DIESEL FUEL SYSTEM
WHAT ARE THE FIVE BASIC PARTS OF A DIESEL FUEL
SYSTEM?
• INJECTION NOZZLES
• INJECTION PUMP
• FILTERS
• TRANSFER PUMP
• FUEL TANK
THE DIESEL FUEL SYSTEM
DIESEL FUEL, LIKE GASOLINE IS A PRODUCT OF
THE DISTILLATION OF-
CRUDE OIL
100 GALLONS OF CRUDE OIL WILL YIELD WHAT
PRODUCTS?
• GASOLINE = 44 GALLONS
• DIESEL FUEL = 36 GALLONS
• MISC. = 9 GALLONS
• KEROSENE = 6 GALLONS
• LUBRICANTS = 3 GALLONS
• LOSS = 3 GALLONS
WHAT ARE THE THREE GRADES OF DIESEL FUEL?
• NUMBER 1 DIESEL FUEL (NO. 1-D)– RECOMMENDED FOR COLD WEATHER.
REMAINS FLUID FOR EASIER STARTING– BUSES, CARS, TRUCKS, FARM TRACTORS
• NUMBER 2 DIESEL FUEL (NO. 2-D)– HEAVY WORK LOADS. BUSES, TRUCKS,
FARM EQUIPMENT
• NUMBER 4 DIESEL FUEL (NO. 4-D)– OCEAN GOING VESSELS WITH LOW-MEDIUM
SPEED ENGINES
THE DIESEL COOLING SYSTEM
WHAT ARE TWO PRIMARY TYPES OF COOLING
SYSTEMS FOR DIESEL ENGINES?
LIQUID COOLING
AIR-COOLING
LIQUID COOLING ENGINE
AIR-COOLED DIESEL ENGINE
WHAT IS THE IDEAL OPERATING TEMPERATURE
FOR MOST DIESEL ENGINES?
165 – 185 DEGREES F.
WHAT ARE SOME EFFECTS OF ENGINE OVERHEATING?
• CYLINDER HEAD AND BLOCK CAN CRACK OR WARP
• RINGS AND VALVES MAY SEIZE OR STICK DUE TO GUMS, LAQUERS, AND VARNISHES FORMING FROM OVERHEATED OIL AND CARBON FORMATION
• BEARINGS MAY BE DAMAGED CAUSING EXCESSIVE WEAR
WHAT ARE SOME EFFECTS OF OVERCOOLING?
• INCREASED ENGINE WEAR
• IMPROPER LUBRICATION
• INCREASED FUEL CONSUMPTION
• INCREASED SLUDGE FORMATION
• INCREASED ENGINE CORROSION– MOISTURE CONDENSES IF BELOW 140
DEGREES IN THE ENGINE CRANKCASE
WHAT ARE SOME ADVANTAGES OF AIR-
COOLED ENGINES• LESS WEIGHT• LESS MAINTENANCE• LESS DOWN-TIME• NO CAVITATION EROSION• NO COOLANT CONCERNS• MORE EFFICIENT USE OF POWER• LESS VULNERABLE TO DAMAGE• LESS BULK• QUICKER WARM-UP
WHAT ARE SOME DISADVANTAGES TO AIR-
COOLED ENGINES?
• LENGTH OF THE ENGINE
• LESS TEMPERATURE CONTROL
• HIGHER OPERATING TEMPERATURES
• GREATER NOISE
• MORE FREQUENT CLEANING
THE DIESEL LUBRICATION SYSTEM
WHAT ARE THE FUNCTIONS FOR THE LUBRICATION
SYSTEM?
• REDUCES SHOCK, WEAR, AND FRICTION
• SEALS COMPRESSION• PROVIDES SOME CLEANING• HELPS COOL THE ENGINE• QUIETS THE ENGINE OPERATION
TRUE OR FALSE: MOST OF THE LUBRICANTS USED IN
DIESEL ENGINES COME FROM PETROLEUM?
TRUE
WHAT ARE LUBRICANTS DERIVED FROM ANIMAL OR VEGETABLE OILS CALLED?
SYNTHETIC OILS
WHAT TWO CHARACTERISTICS ARE
MOST IMPORTANT IN CHOOSING PROPER OIL?
VISCOSITY
SERVICE CLASSIFICATION
WHAT IS VISCOSITY?
• A MEASURE OF A LIQUID’S RESISTANCE TO FLOW
• HIGHER TEMPERATURE – DECREASE IN VISCOSITY
• SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) DEVELOPED NUMBERING SYSTEM
WHAT ARE THE VISCOSITY GRADES?
API ENGINE OIL SERVICE CATEGORIES
AMERICAN PETROLEUM INSTITUTE
TABLE 1: (HANDOUT)
WHAT ARE THE THREE MOST COMMON OIL
ADDITIVES?• OXIDATION INHIBITORS
• CORROSION AND RUST INHIBITORS
• DETERGENT DISPERSANTS
HOW DO DETERGENT ADDITIVES WORK?
PRINCIPLES OF FLUID HYDRAULICS
HYDRAULIC SYSTEMS ON A TRACTOR
WHAT IS PASCAL’S LAW OF HYDRAULICS?
• PRESSURE ON A LIQUID IN A CONTAINER IS TRANSFERRED EQUALLY TO ALL SURFACES
PASCAL’S LAW
PRESSURE TRANSFER IN HYDRAULIC BRAKES
CHANGING THE PRESSURE IN A HYDRAULIC SYSTEM
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