Asia Motor Work (AMW) Project

8/10/2019 Asia Motor Work (AMW) Project

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VOCATIONAL TRAINING 2013

A S I A M O R O R W O R K S , B H A G A T M O T O R S , U N A , H I M A C H A L P R A D E S H Page 1

MW

Asia Motor Works

Vocational raining

Project Report

Submitted By:

Abhishek Jumwal

B.Tech. ME

1154337

Guided By:

Mr. Ramesh Sharma

( Workmanager )


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ACKNOWLEDGEMENT

I would like to thank the following people for helping

me in completing the vocational training at Asia Motor

Works. Without them it would not have been possible

for me to get practical knowledge.

I am grateful to Mr. Vivek Bhardwaj, Head - Bhagat

Motors (UNA) for giving me the opportunity to

undergo training in AMW (Bhagat Motors).

Mr. Ramesh Sharma (Work Manager), Chintan

Padhiyar (Senior Engineer) - Bhagat Motors who has

guided me throughout my training period.


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LAYOUT OF AMW WORKSHOP UNA


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MEMBERS OF AMW WORKSHOP UNA

RAMESH SHARMA WORKS MANAGER

VIRENDER BANYAL STORE MANAGER

CHINTAN PADHIYAR SENIOR ENGINEER

MOHAN LAL SUPERVISOR

VARUN SHARMA SUPERVISOR

SHUBAM SHARMA ADVISOR

BALVINDER KUMAR ADVISOR

AKHIL CHOUDHARY MECHANIC

RAKESH KUMAR HEAD MECHANIC

KARAN SHARMA HEAD MECHANIC

JASWINDER KUMAR MECHANIC

MUKESH KUMAR HEAD MECHANIC

AJAY KUMAR ELECTRICIAN

DARSHAN LAL MECHANIC

JAGDISH SINGH MECHANIC

SHASHI PAL HELPER

VINOD KUMAR HELPER

ANKUSH KUMAR HELPER


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CONTENTS

o

INTRODUCTION

o FACILITY AT WORKSHOP

o OVERVIEW OF WORKSHOP

o INVESTIGATION PROJECT


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INTRODUCTIONAsia Motor Works Ltd(AMW) manufactures commercial vehicle, auto components, fully

built vehicles and forged components, inIndia.Founded in 2002. AMW is India's third

largest manufacturer of heavy commercial vehicles, having achieved a unique position in the

country's transportation sector through innovative engineering and customer orientation. We

are the fastest growing truck brand in India with a volume growth of over 100% for the last

three years. Our world classtrucksare manufactured at a state of the art, 50,000 units per

annum plant in Bhuj, Gujarat.

AMW's trucks incorporate some of the best automotive technology from around theworld like a 9-speed gearbox and 380 mm power-assisted clutch.

Engineering Excellence

Providing complete solutions from design to delivery

AMWs vision rests on three pillars providing world class quality, delivering on time

and maximizing the economic advantage of large scale. Our integratedmanufacturing facility at Bhuj is built to optimize on all three.

Customer Satisfaction

Delivering customer satisfaction is our number one priority

At AMW, the customer is the focus of our operations, and delivering customersatisfaction is our number one priority. We aim to do it by delivering products thatscore high on safety and quality, so that the customer enjoys a good drivingexperience and enjoys a high return on investment.

Social Responsibility

Leading with initiatives on employment

AMW is an active participant in the development of the local communities, leadingwith initiatives on employment, community building, health and the environment.
http://en.wikipedia.org/wiki/Indiahttp://www.amwasia.com/truckshttp://www.amwasia.com/truckshttp://www.amwasia.com/truckshttp://www.amwasia.com/truckshttp://en.wikipedia.org/wiki/India


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AMW PRODUCTIONS:

Tippers Tractors

Haulage Transit Mixers Concrete Pumps Fully Built Vehicles

Operations

The manufacturing facility of AMW is located in Bhuj, Gujarat, in the western region of

India. The capacity for commercial vehicles is at 50,000 annually. The company has capacityfor tipper bodies, fabricated components, pressed metal and frames for chassis production.

AMW manufactures components for the automotive and general engineering industries.

AMWs capacity of 15 million wheel rims makes it the largest single location plant in Asia.

The company supplies pressed metal components to the worlds auto and white goods

manufacturers. AMW has over 60 touch points across India.

Type Private company

Industry Automotive and auto components

Founded 2002

Founder(s) Anirudh Bhuwalka

Headquarters Mumbai,Maharashtra, India[1]

Key peopleAnirudh Bhuwalka

(MD & CEO)

Products

Commercial Vehicles

Auto Components

Road Safety Solutions

Forgings

Website www.amwasia.com
http://www.amwasia.com/trucks/tippershttp://www.amwasia.com/trucks/tractorshttp://www.amwasia.com/trucks/haulagehttp://www.amwasia.com/trucks/transit-mixershttp://www.amwasia.com/trucks/concrete-pumpshttp://www.amwasia.com/trucks/fully-built-vehicleshttp://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Automotivehttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Asia_MotorWorks#cite_note-1http://en.wikipedia.org/wiki/Asia_MotorWorks#cite_note-1http://en.wikipedia.org/wiki/Asia_MotorWorks#cite_note-1http://en.wikipedia.org/w/index.php?title=MD_%26_CEO&action=edit&redlink=1http://en.wikipedia.org/wiki/Commercial_Vehicleshttp://en.wikipedia.org/wiki/Forgingshttp://www.amwasia.com/http://www.amwasia.com/http://www.amwasia.com/http://en.wikipedia.org/wiki/Forgingshttp://en.wikipedia.org/wiki/Commercial_Vehicleshttp://en.wikipedia.org/w/index.php?title=MD_%26_CEO&action=edit&redlink=1http://en.wikipedia.org/wiki/Asia_MotorWorks#cite_note-1http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Automotivehttp://en.wikipedia.org/wiki/Types_of_business_entityhttp://www.amwasia.com/trucks/fully-built-vehicleshttp://www.amwasia.com/trucks/concrete-pumpshttp://www.amwasia.com/trucks/transit-mixershttp://www.amwasia.com/trucks/haulagehttp://www.amwasia.com/trucks/tractorshttp://www.amwasia.com/trucks/tippers


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PRODUCTS

Commercial Vehicles

A commercial vehicleis any type ofmotor vehicle used for transporting goods or

paidpassengers.TheEuropean Union defines "commercial motor vehicle" as any

motorized road vehicle, that by its type of construction and equipment is designed for,

and capable of transporting, whether for payment or not: (1) more than nine persons,

including the driver; (2) goods and "standard fuel tanks". This means the tankspermanently fixed by the manufacturer to all motor vehicles of the same type as the

vehicle in question and whose permanent fitting lets fuel be used directly, both for

propulsion and, where appropriate, to power a refrigeration system. Gas tanks fitted to

motor vehicles for the direct use of diesel as a fuel are considered standard fuel tanks.

Contents

1. Commercial classification

In theUnited States a vehicle is designated commercial when it is titled or registered to acompany. This is a broad definition, as commercial vehicles may befleet vehicles,company

cars,or other vehicles used for business. Vehicles that are designed to carry more than 15

passengers are considered a commercial vehicle.

A vehicle may be considered a commercial vehicle if it is:

Belongs to a company or corporation

Used for business, but is in an individual's name, such as asole proprietor

A leased vehicle and in the name of the financial institution that owns it

Exceeds a certain weight or class and therefore is "classified" as commercial even

though it may not be commercially used or commercially owned. A weight rating of26,001 pounds or more is always consider commercial.

Used to haul anyhazardous material

A vehicle can be used for a business, if not exclusively, and remain privately licensed,

depending on the amount of time used for business
http://en.wikipedia.org/wiki/Commercial_Vehicleshttp://en.wikipedia.org/wiki/Motor_vehiclehttp://en.wikipedia.org/wiki/Passengerhttp://en.wikipedia.org/wiki/European_Unionhttp://en.wikipedia.org/wiki/United_Stateshttp://en.wikipedia.org/wiki/Fleet_vehiclehttp://en.wikipedia.org/wiki/Company_carhttp://en.wikipedia.org/wiki/Company_carhttp://en.wikipedia.org/wiki/Sole_proprietorhttp://en.wikipedia.org/wiki/Hazardous_materialhttp://en.wikipedia.org/wiki/Hazardous_materialhttp://en.wikipedia.org/wiki/Sole_proprietorhttp://en.wikipedia.org/wiki/Company_carhttp://en.wikipedia.org/wiki/Company_carhttp://en.wikipedia.org/wiki/Fleet_vehiclehttp://en.wikipedia.org/wiki/United_Stateshttp://en.wikipedia.org/wiki/European_Unionhttp://en.wikipedia.org/wiki/Passengerhttp://en.wikipedia.org/wiki/Motor_vehiclehttp://en.wikipedia.org/wiki/Commercial_Vehicles


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2. Examples of commercial vehicles

1.Truck

2.Semi truck (articulated lorry)

3.Van

4.Coach

5.Bus

6.Taxicab

7.Trailers

8.Box truck (also known as a straight truck)

3. Commercial truck classification

Commercial trucks are classified according to theGross vehicle weight rating (GVWR).

The United StatesDepartment of Transportation classifies commercial trucks with eight

classes:

Class 1- GVWR ranges from 0 to 6,000 pounds (0 to 2,722 kg)

Class 2- GVWR ranges from 6,001 to 10,000 pounds (2,722 to 4,536 kg)



Class 5- GVWR ranges from 16,001 to 19,500 pounds (7,258 to 8,845 kg).



Class 8- GVWR is anything above 33,000 pounds (14,969 kg)
http://en.wikipedia.org/wiki/Truckhttp://en.wikipedia.org/wiki/Semi_truckhttp://en.wikipedia.org/wiki/Vanhttp://en.wikipedia.org/wiki/Coach_(vehicle)http://en.wikipedia.org/wiki/Bushttp://en.wikipedia.org/wiki/Taxicabhttp://en.wikipedia.org/wiki/Trailer_(vehicle)http://en.wikipedia.org/wiki/Box_truckhttp://en.wikipedia.org/wiki/Truck_classificationhttp://en.wikipedia.org/wiki/Gross_vehicle_weight_ratinghttp://en.wikipedia.org/wiki/Department_of_Transportationhttp://en.wikipedia.org/wiki/Department_of_Transportationhttp://en.wikipedia.org/wiki/Gross_vehicle_weight_ratinghttp://en.wikipedia.org/wiki/Truck_classificationhttp://en.wikipedia.org/wiki/Box_truckhttp://en.wikipedia.org/wiki/Trailer_(vehicle)http://en.wikipedia.org/wiki/Taxicabhttp://en.wikipedia.org/wiki/Bushttp://en.wikipedia.org/wiki/Coach_(vehicle)http://en.wikipedia.org/wiki/Vanhttp://en.wikipedia.org/wiki/Semi_truckhttp://en.wikipedia.org/wiki/Truck


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Powered by best-in-class 180 HP & 215 HP Cummins engines, AMW trucks easily handleupward inclines and other tough conditions.

B. GearboxAMW trucks come with a technologically advanced gearbox from ZF, Germany and Eaton.

With a gear ratio of 13.1621 enabling a highly improved start-up, even with very heavy loadsand in difficult conditions.

C. Chassis


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A sturdy frame-in-frame chassis offers high reliability and durability

The chassis of an automobile consist of following components suitably mounted:1. Engine and the radiator2. Transmission system, consisting of the clutch, gearbox, propeller shaft and the rear axle

3. Suspension System4. Road Wheel5. Steering system6. Brakes7. Fuel tank

All the components listed above are mounted in either of the two ways, the conventional construction,in which a separate frame is used and the frameless or unitary construction in which no separateframe is employed. Out of these, the conventional type of construction is being used presently only forheavy vehicle whereas for car the same has been replaced by the frameless type or the monocoquechassis is manufacture, who still find it economical two use frame.

Chassis are classified as :

1. Conventional control chassis2. Semi forward control chassis3. Full forward control chassis

D. Bogey suspension

The unique bogey suspension adds to the vehicles tenacity, and aids comfortable handling even inthe roughest terrain.


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E. Air-conditioned cabin

AMW trucks provide the most comfortable and safe driving experience for the driver. With a world-class ergonomic design, energy absorbing steering wheel for safety, and entertainment facilities like astereo FM and CD player, these vehicles ensure that the driver is comfortable and therefore able togive his best.


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Integrated Manufacturing Facility

The 515 acre plant at Bhuj, Gujarat forms the backbone of the companys truck manufacturingoperations in India. State-of-the-art plants, assembly lines, aspecially designed frame shop, a

completely automated paint shop, in-house R & D facilities, and a modern warehouse ensure thatonly trucks of international quality roll out from these premises.

FRAME SHOPAMW builds robust chassis systems, specially designed for Indian roads. The rock-sturdy in-framechassis is a fine example. The unique, in-frame structure of each truck chassis improves vehiclebalance, handling, ride characteristics, and maneuverability.

ASSEMBLY LINEAMW takes pride in providing high quality and value at every stage of the manufacturing process.After pre-assembly, carriages, bodies, engines and other parts are assembled on a semi-automatedmodern assembly line, where the bare chassis is brought in and leaves as a fully integrated AMW

world-class truck.

CAB WELD SHOPThe automated cab welding facility manufactures a wide range of cabs for different trucks. With thefocus on increased productivity and quality, the cab welding shop is an integral part of AMWstruck manufacturing facility.

FULLY AUTOMATED PAINT SHOPA fully automated paint shop, designed by Durr, Germany offers superior coating and finishproperties. The paint shop has state-of-the-art coating lines for cabs, with advanced equipment andcoating technology.

QUALITYAMW prides itself on employing only world-class technologies and manufacturing practices.At AMW, meeting and exceeding the expectations of valued customers remains the prime focus at alltimes. Quality assurance teams conduct simulated and field trials on every product. AMW has set thehighest standards for quality with TS 16949 ready systems and processes.

SAFETYSafe manufacturing practices are a high priority at the AMW plant in Bhuj. AMWs safety programencompasses Health, Safety and the Environment. Engineers and managers constantly bring inimprovements in manufacturing practices and technology to ensure a hazard-free work place. Anothercritical aspect of the AMW safety program revolves around the driver who is a key factor in anytransport activity. A safe working environment for the driver means higher productivity and loweroperating costs.

Installed Capacity 50,000 vehicles per year


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VRDE Certification and Testing

AMW trucks go through independent validating tests to verify, validate and certify their performance,durability and reliability. This includes variants as well as new features and product improvements.The tests cover all critical parameters such as maximum speed, acceleration through gears, brakingdeceleration, stopping distance, steering effort, pass by and in-cab noise, cooling, grade ability, waterwading, stability etc.

On-road fuel consumption tests are carried out as per pre-determined cycles to predict fuelconsumption under a variety of traffic and terrain conditions. AMW has entered into an agreementwith the Vehicle Research and Development Establishment (VRDE), a Government of IndiaUndertaking, under which validation of the structural durability of vehicles is carried out on theBelgian Pave and Torture Tracks at VRDE, Ahmednagar.

After-sales Service, Spare partsAMWs strong dealership network, authorized service centers and spare parts outlets ensure thatvehicles run with maximum up-time and minimum stoppage of work. AMWs dealer network is one of

the fastest growing networks, spread across the length and breadth of the country. Its authorizedservice centers and spare parts outlets are strategically placed in almost every city to providecustomers sales, service and spare parts support anywhere, anytime.

AwardsCustomer satisfaction is the highest award. Yet, it is satisfying to be recognized by industry expertsand peers. Voted Truck of the year for 2008 by NDTV, AMW leads the way, offering pride ofownership with unmatched commercial value. AMW also won the Innovation of the year award in2010. This was for a very long truck, in which four wheels are turned by the steering wheel; aninnovation that enhances maneuverability, eliminating the need for articulation.

Fully Built VehiclesAMW manufactures a wide range of Fully Built Vehicle Solutions for on-road and off-roadapplications.

The chassis is designed for use as Tippers, concrete mixers, mobile cranes and other special-purpose bodies. The AMW range includes box body and rock body Tippers, Tip-Trailers and Trailers.

TIPPERSAMW Tippers are manufactured in a state-of-the-art plant, with a robotic welding system. They aredesigned for strength, built to high quality standards, and are proven products, ready to meet arduouschallenges.


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TRAILERS

AMW Trailers are built in a technologically advanced facility and go through stringent qualityprocesses. Custom-designed to suit varied applications, AMW Trailers are sturdy, durable vehicles,increasingly sought after by discerning customers. AMW will soon add Transit Mixers, Bulkers andTankers to its already large product portfolio in the near future.

For customers, the AMW range of Fully Built Vehicles allows for immediate revenue, as they can bequickly attached to trucks or prime movers and deployed for work in various areas without anywaiting time for fabrication or modifications.

INSTALLED CAPACITY

Tippers - 12000 per yearTrailers - 4000 per year


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F CILITY T WORKSHOP

Bhagat Motors deals with the sales/services/repairs of the vehicle. There are

enough facilities in the workshop. There are many types of repairs of the

components of the trucks can be done within the workshop. The plant does not

only the repair facility but it also has the facility of spares and parts. All types of

useful parts are available in the spares shop. It also sales the new trucks. They

make sure a better service always made available to customer. For the new

workers, laborers, and trainees, a training department has been established. Aquality assurance department is also there along with marketing department

which takes care of the better service provided for the customers.

Repairs facilities at the workshop

i. Engine service

ii. Gear box repair

iii. Differential repair

iv. Axle alignment

v. Water wash

vi. Denting

vii. Chassis alignment

viii. Body repair


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INVESTIG TION PROJECT

ENGINE WORKING

A diesel engine(also known as a compression-ignition engine) is aninternal combustion

engine that uses theheat of compression to initiateignition to burn thefuel that has

been injected into thecombustion chamber.This contrasts with spark-ignition engines

such as apetrol engine (gasoline engine) orgas engine (using a gaseous fuel as opposed

togasoline), which use aspark plug to ignite an air-fuel mixture.

The diesel engine has the highestthermal efficiency of any standardinternal orexternal

combustion engine due to its very highcompression ratio.Low-speed diesel engines (asused in ships and other applications where overall engine weight is relatively

unimportant) can have a thermal efficiency that exceeds 50%.

Diesel engines are manufactured intwo-stroke andfour-stroke versions. They were

originally used as a more efficient replacement for stationarysteam engines.Since the

1910s they have been used insubmarines and ships. Use in locomotives, trucks,heavy

equipment and electric generating plants followed later. In the 1930s, they slowly began

to be used in a fewautomobiles.Since the 1970s, the use of diesel engines in larger on-

road andoff-road vehicles in the USA increased. According to the British Society of

Motor Manufacturing and Traders, theEU average for diesel cars account for 50% of the

total sold, including 70% in France and 38% in the UK.
http://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Heat_of_compressionhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Diesel_fuelhttp://en.wikipedia.org/wiki/Combustion_chamberhttp://en.wikipedia.org/wiki/Petrol_enginehttp://en.wikipedia.org/wiki/Gas_enginehttp://en.wikipedia.org/wiki/Gasolinehttp://en.wikipedia.org/wiki/Spark_plughttp://en.wikipedia.org/wiki/Thermal_efficiencyhttp://en.wikipedia.org/wiki/Internal_combustionhttp://en.wikipedia.org/wiki/External_combustionhttp://en.wikipedia.org/wiki/External_combustionhttp://en.wikipedia.org/wiki/Compression_ratiohttp://en.wikipedia.org/wiki/Two-strokehttp://en.wikipedia.org/wiki/Four-strokehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Submarinehttp://en.wikipedia.org/wiki/Heavy_equipmenthttp://en.wikipedia.org/wiki/Heavy_equipmenthttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Off-road_vehiclehttp://en.wikipedia.org/wiki/European_Unionhttp://en.wikipedia.org/wiki/File:DieselCycle_PV.svghttp://en.wikipedia.org/wiki/European_Unionhttp://en.wikipedia.org/wiki/Off-road_vehiclehttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Heavy_equipmenthttp://en.wikipedia.org/wiki/Heavy_equipmenthttp://en.wikipedia.org/wiki/Submarinehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Four-strokehttp://en.wikipedia.org/wiki/Two-strokehttp://en.wikipedia.org/wiki/Compression_ratiohttp://en.wikipedia.org/wiki/External_combustionhttp://en.wikipedia.org/wiki/External_combustionhttp://en.wikipedia.org/wiki/Internal_combustionhttp://en.wikipedia.org/wiki/Thermal_efficiencyhttp://en.wikipedia.org/wiki/Spark_plughttp://en.wikipedia.org/wiki/Gasolinehttp://en.wikipedia.org/wiki/Gas_enginehttp://en.wikipedia.org/wiki/Petrol_enginehttp://en.wikipedia.org/wiki/Combustion_chamberhttp://en.wikipedia.org/wiki/Diesel_fuelhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Heat_of_compressionhttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Internal_combustion_engine


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p-V Diagram for the Ideal Diesel cycle. The cycle follows the numbers 1-4 in clockwise

direction. In the diesel cycle the combustion occurs at almost constant pressure and the

exhaust occurs at constant volume. On this diagram the work that is generated for each cycle

corresponds to the area within the loop.

The diesel internal combustion engine differs from the gasoline powered Otto cycle by using

highly compressed hot air to ignite the fuel rather than using a spark plug (compression

ignitionrather thanspark ignition).

In the true diesel engine, only air is initially introduced into the combustion chamber. The air

is then compressed with a compression ratio typically between 15:1 and 22:1 resulting in 40-

bar (4.0 MPa; 580 psi) pressure compared to 8 to 14 bars (0.80 to 1.4 MPa; 120 to 200 psi) in

the petrol engine. This high compression heats the air to 550 C (1,022 F). At about the top

of the compression stroke, fuel is injected directly into the compressed air in the combustion

chamber. This may be into a (typically toroidal) void in the top of the piston or apre-

chamberdepending upon the design of the engine. The fuel injector ensures that the fuel is

broken down into small droplets, and that the fuel is distributed evenly. The heat of the

compressed air vaporizes fuel from the surface of the droplets. The vapor is then ignited by

the heat from the compressed air in the combustion chamber, the droplets continue to

vaporise from their surfaces and burn, getting smaller, until all the fuel in the droplets hasbeen burnt. The start of vaporization causes a delay period during ignition and the

characteristic diesel knocking sound as the vapor reaches ignition temperature and causes an

abrupt increase in pressure above the piston. The rapid expansion of combustion gases then

drives the piston downward, supplying power to the crankshaft.

As well as the high level of compression allowing combustion to take place without a

separate ignition system, a highcompression ratio greatly increases the engine's efficiency.

Increasing the compression ratio in a spark-ignition engine where fuel and air are mixed

before entry to the cylinder is limited by the need to prevent damagingpre-ignition.Since

only air is compressed in a diesel engine, and fuel is not introduced into the cylinder until

shortly before top dead centre (TDC), premature detonation is not an issue and compressionratios are much higher.

Early fuel injection systems

Diesel's original engine injected fuel with the assistance of compressed air, which atomized

the fuel and forced it into the engine through a nozzle (a similar principle to an aerosol

spray). The nozzle opening was closed by a pin valve lifted by the camshaft to initiate the

fuel injection before top dead centre (TDC). This is called an air-blast injection. Driving the

three stage compressor used some power but the efficiency and net power output was more

than any other combustion engine at that time.
http://en.wikipedia.org/wiki/Compression_ratiohttp://en.wikipedia.org/wiki/Pre-ignition#Pre-ignitionhttp://en.wikipedia.org/wiki/Top_Dead_Centerhttp://en.wikipedia.org/wiki/Top_Dead_Centerhttp://en.wikipedia.org/wiki/Top_Dead_Centerhttp://en.wikipedia.org/wiki/Top_Dead_Centerhttp://en.wikipedia.org/wiki/Pre-ignition#Pre-ignitionhttp://en.wikipedia.org/wiki/Compression_ratio


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Diesel engines in service today raise the fuel to extreme pressures by mechanical pumps anddeliver it to the combustion chamber by pressure-activated injectors without compressed air.

With direct injected diesels, injectors spray fuel through 4 to 12 small orifices in its nozzle.

The early air injection diesels always had a superior combustion without the sharp increase in

pressure during combustion. Research is now being performed and patents are being taken

out to again use some form of air injection to reduce the nitrogen oxides and pollution,

reverting to Diesel's original implementation with its superior combustion and possibly

quieter operation. In all major aspects, the modern diesel engine holds true to Rudolf Diesel's

original design, that of igniting fuel by compression at an extremely high pressure within the

cylinder. With much higher pressures and high technology injectors, present-day diesel

engines use the so-called solid injection system applied byHerbert Akroyd Stuart for hishot

bulb engine.Theindirect injection engine could be considered the latest development of these

low speed hot bulbignition engines.

Fuel delivery

A vital component of all diesel engines is a mechanical or electronicgovernor which

regulates the idling speed and maximum speed of the engine by controlling the rate of fuel

delivery. Unlike Otto-cycle engines, incoming air is not throttled and a diesel engine without

a governor cannot have a stable idling speed and can easily over speed, resulting in its

destruction. Mechanically governed fuel injection systems are driven by the engine'sgear

train.These systems use a combination of springs and weights to control fuel delivery

relative to both load and speed. Modern electronically controlled diesel engines control fuel

delivery by use of an electronic control module (ECM) or electronic control unit (ECU). The

ECM/ECU receives an engine speed signal, as well as other operating parameters such as

intake manifold pressure and fuel temperature, from a sensor and controls the amount of fuel

and start of injection timing throughactuators to maximize power and efficiency and

minimize emissions. Controlling the timing of the start of injection of fuel into the cylinder is

a key to minimizing emissions, and maximizingfuel economy (efficiency), of the engine. The

timing is measured in degrees of crank angle of thepistonbefore top dead centre. For

example, if the ECM/ECU initiates fuel injection when the piston is 10 beforeTDC,the start

of injection, or timing, is said to be 10BTDC.Optimal timing will depend on the engine

design as well as its speed and load.

Advancing the start of injection (injecting before the piston reaches to its SOI-TDC) results in

higher in-cylinder pressure and temperature, and higher efficiency, but also results in elevated

engine noise and increasedoxides of nitrogen (NOx) emissions due to higher combustiontemperatures. Delaying start of injection causes incomplete combustion, reduced fuel

efficiency and an increase in exhaust smoke, containing a considerable amount of particulate

matter and unburnedhydrocarbons.

Major advantages

Diesel engines have several advantages over other internal combustion engines:

They burn less fuel than a petrol engine performing the same work, due to the

engine's higher temperature of combustion and greater expansion ratio. Gasoline

engines are typically 30% efficient while diesel engines can convert over 45% of thefuel energy into mechanical energy.
http://en.wikipedia.org/wiki/Herbert_Akroyd_Stuarthttp://en.wikipedia.org/wiki/Hot_bulb_enginehttp://en.wikipedia.org/wiki/Hot_bulb_enginehttp://en.wikipedia.org/wiki/Indirect_injectionhttp://en.wikipedia.org/wiki/Governor_(device)http://en.wikipedia.org/wiki/Gear_trainhttp://en.wikipedia.org/wiki/Gear_trainhttp://en.wikipedia.org/wiki/Electronic_control_unithttp://en.wikipedia.org/wiki/Actuatorhttp://en.wikipedia.org/wiki/Fuel_economy_in_automobileshttp://en.wikipedia.org/wiki/Pistonhttp://en.wikipedia.org/w/index.php?title=Top_Dead_Centre&action=edit&redlink=1http://en.wikipedia.org/wiki/BTDChttp://en.wikipedia.org/wiki/Oxides_of_nitrogenhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Oxides_of_nitrogenhttp://en.wikipedia.org/wiki/BTDChttp://en.wikipedia.org/w/index.php?title=Top_Dead_Centre&action=edit&redlink=1http://en.wikipedia.org/wiki/Pistonhttp://en.wikipedia.org/wiki/Fuel_economy_in_automobileshttp://en.wikipedia.org/wiki/Actuatorhttp://en.wikipedia.org/wiki/Electronic_control_unithttp://en.wikipedia.org/wiki/Gear_trainhttp://en.wikipedia.org/wiki/Gear_trainhttp://en.wikipedia.org/wiki/Governor_(device)http://en.wikipedia.org/wiki/Indirect_injectionhttp://en.wikipedia.org/wiki/Hot_bulb_enginehttp://en.wikipedia.org/wiki/Hot_bulb_enginehttp://en.wikipedia.org/wiki/Herbert_Akroyd_Stuart


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They have no high voltage electrical ignition system, resulting in high reliability andeasy adaptation to damp environments. The absence of coils, spark plug wires, etc.,

also eliminates a source of radio frequency emissions which can interfere with

navigation and communication equipment, which is especially important in marine

and aircraft applications.

The life of a diesel engine is generally about twice as long as that of a petrol engine

due to the increased strength of parts used. Diesel fuel has better lubrication properties

than petrol as well.

Diesel fuel is distilled directly from petroleum. Distillation yields some gasoline, but

the yield would be inadequate withoutcatalytic reforming,which is a more costly

process.

Diesel fuel is considered safer than petrol in many applications. Although diesel fuel

will burn in open air using awick,it will not explode and does not release a large

amount of flammable vapor. The low vapor pressure of diesel is especially

advantageous in marine applications, where the accumulation of explosive fuel-airmixtures is a particular hazard. For the same reason, diesel engines are immune to

vapor lock.

For any given partial load the fuel efficiency (mass burned per energy produced) of a

diesel engine remains nearly constant, as opposed to petrol and turbine engines which

use proportionally more fuel with partial power outputs.

They generate less waste heat in cooling and exhaust.

Diesel engines can accept super- or turbo-charging pressure without any natural limit,

constrained only by the strength of engine components. This is unlike petrol engines,

which inevitably suffer detonation at higher pressure.

The carbon monoxide content of the exhaust is minimal, therefore diesel engines areused in underground mines.

Biodiesel is an easily synthesized, non-petroleum-based fuel (through

transesterification)which can run directly in many diesel engines, while gasoline

engines either need adaptation to runsynthetic fuels or else use them as an additive to

gasoline (e.g.,ethanol added togasohol).

Mechanical and electronic injection

Many configurations of fuel injection have been used over the course of the 20th century.

Most present-day diesel engines use a mechanical single plunger high-pressurefuel pump

driven by the engine crankshaft. For each engine cylinder, the corresponding plunger in the

fuel pump measures out the correct amount of fuel and determines the timing of each

injection. These engines useinjectors that are very precise spring-loaded valves that open and

close at a specific fuel pressure. Separate high-pressure fuel lines connect the fuel pump with

each cylinder. Fuel volume for each single combustion is controlled by a slantedgroove in

the plunger which rotates only a few degrees releasing the pressure and is controlled by a

mechanical governor, consisting of weights rotating at engine speed constrained by springs

and a lever. The injectors are held open by the fuel pressure. On high-speed engines the
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plunger pumps are together in one unit. The length of fuel lines from the pump to eachinjector is normally the same for each cylinder in order to obtain the same pressure delay.

A cheaper configuration on high-speed engines with fewer than six cylinders is to use an

axial-piston distributor pump, consisting of one rotating pump plunger delivering fuel to avalve and line for each cylinder (functionally analogous to points and distributor cap on an

Otto engine).

Many modern systems have a single fuel pump which supplies fuel constantly at high

pressure with acommon rail (single fuel line common) to each injector. Each injector has a

solenoid operated by an electronic control unit, resulting in more accurate control of injector

opening times that depend on other control conditions, such as engine speed and loading, and

providing better engine performance and fuel economy.

Both mechanical and electronic injection systems can be used in eitherdirect orindirect

injection configurations.

Two-stroke diesel engines with mechanical injection pumps can be inadvertently run

in reverse, albeit in a very inefficient manner, possibly damaging the engine. Large

shiptwo-stroke diesels are designed to run in either direction, obviating the need for a

gearbox.

Indirect injection

An indirect injection diesel engine delivers fuel into a chamber off thecombustion

chamber,called a pre-chamber or ante-chamber, where combustion begins and then

spreads into the main combustion chamber, assisted byturbulence created in the

chamber.

Arrow indicates opening from pre-chamber

Main article:Indirect injection
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This system allows for a smoother, quieter running engine, and because combustion is

assisted by turbulence,injectorpressures can be lower, about 100 bar (10 MPa; 1,500 psi),

using a single orifice tapered jet injector. Mechanical injection systems allowed high-speed

running suitable for road vehicles (typically up to speeds of around 4,000 rpm. The pre-

chamber had the disadvantage of increasing heat loss to the engine's cooling system, andrestricting the combustion burn, which reduced the efficiency by 510%. Indirect injection

engines are cheaper to build and it is easier to produce smooth, quiet-running vehicles with a

simple mechanical system. In road-going vehicles most prefer the greater efficiency and

better controlled emission levels of direct injection. Indirect injection diesels can still be

found in the many ATV diesel applications.

Direct injection

Direct injection diesel engines have injectors mounted at the top of the combustion chamber.

The injectors are activated using one of two methods - hydraulic pressure from the fuel pump,

or an electronic signal from an engine controller.

Hydraulic pressure activated injectors can produce harsh engine noise. Fuel consumption is

about 1520% lower than indirect injection diesels. The extra noise is generally not a

problem for industrial uses of the engine, but for automotive usage, buyers have to decide

whether or not the increased fuel efficiency would compensate for the extra noise.

Electronic control of the fuel injection transformed the direct injection engine by allowingmuch greater control over the combustion.

Common rail direct injection

In common rail systems, the separate pulsing high-pressure fuel line to each cylinder'sinjector is also eliminated. Instead, a high-pressure pump pressurizes fuel at up to 2,500 bar

(250 MPa; 36,000 psi), in a "common rail". The common rail is a tube that supplies each

computer-controlled injector containing a precision-machined nozzle and a plunger driven by

asolenoid orpiezoelectric actuator.
http://en.wikipedia.org/wiki/Injectorhttp://en.wikipedia.org/wiki/Fuel_injection#Direct_injectionhttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Piezoelectricityhttp://en.wikipedia.org/wiki/Piezoelectricityhttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Fuel_injection#Direct_injectionhttp://en.wikipedia.org/wiki/Injector


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6 CYLINDER DIESEL ENGINE

A 6 cylinder Engine which produces more power works with two extra cylinders that

create additional piston thrust. The process involves the piston traveling down on the

Intake stroke, up on the compression stroke, down on the Power stroke and up on the

exhaust stroke.

Greater the cylinders more the power, more the horse power and greater fuel consumption.Internal combustion engines are made from various parts. Each part has its own location andfunction for proper working of engine. Someimportant parts and its function is as describedbelow.

01)Cylinder Block

In the bore ofcylinder the fresh charge of air-fuel mixture is ignited, compressed by piston and

expanded to give power topiston.
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02)Cylinder Head

It carries inlet and valve. Fresh charge is admitted through inlet valve and burnt gases are

exhausted from exhaust valve. In case of engine, a spark plug and in case of diesel engine, a

injector is also mounted on cylinder head.

03) Piston

During suction stroke, it sucks the fresh charge of air-fuel mixture throughinlet valve and

compresses during the compression stroke inside the cylinder. This way piston receives power

from the expanding gases after ignition in cylinder. Also forces the burnt exhaust gases out of thecylinder throughexhaust valve.
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04)Piston Rings

-It prevents the compressed charge of fuel-airmixture from leaking to the other side of the piston.

Oil rings, is used for removing lubricating oil from the cylinder after lubrication. This ring prevents

the excess oil to mix with charge.

05)Connecting Rod

It changes the reciprocating motion of piston intorotary motion at crankshaft. This way

connecting rod transmits the power produced at piston to crankshaft.

06)Gudgeon Pin

Connects the piston with small end of connecting rod.
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07)Crank Pin

hand over the power and motion to thecrank shaft which come from piston through connecting

rod.

08) Crank Shaft

Receives oscillating motion from connecting rod and gives a rotary motion to the main shaft. It

also drives the camshaft which actuate the valves of theengine.
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09)Cam Shaft

It takes driving force from crankshaft through gear train or chain and operates the inletvalve as

well as exhaust valve with the help of cam followers, push rod and rocker arms.

10)Inlet Valve & Exhaust Valve

Inlet valve allow the fresh charge of air-fuel mixture to enter the cylinder bore. Exhaust valve

permits theburnt gases to escape from the cylinder bore at proper timing.

11) Governor

It controls the speed of engine at a different load by regulating fuel supply in diesel engine. In

petrol engine, supplying the mixture of air-petrol and controlling the speed at various load

condition.
http://prasannasutrave.hubpages.com/hub/How-Mico-Fuel-Injection-System-Workshttp://prasannasutrave.hubpages.com/hub/How-To-Draw-Valve-Timing-Diagram-For-Four-Stroke-Petrol-Enginehttp://prasannasutrave.hubpages.com/hub/Important-Guidelines-for-Air-Intake-Pipe-of-Air-Compressorhttp://prasannasutrave.hubpages.com/hub/Types-Of-Scavengings-Used-In-Internal-Combustion-Enginehttp://prasannasutrave.hubpages.com/hub/How-To-Increase-Ignition-Timing-In-Petrol-Enginehttp://prasannasutrave.hubpages.com/hub/How-To-Increase-Ignition-Timing-In-Petrol-Enginehttp://prasannasutrave.hubpages.com/hub/Types-Of-Scavengings-Used-In-Internal-Combustion-Enginehttp://prasannasutrave.hubpages.com/hub/Important-Guidelines-for-Air-Intake-Pipe-of-Air-Compressorhttp://prasannasutrave.hubpages.com/hub/How-To-Draw-Valve-Timing-Diagram-For-Four-Stroke-Petrol-Enginehttp://prasannasutrave.hubpages.com/hub/How-Mico-Fuel-Injection-System-Works


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12)Fuel Pump

This device supply the petrol to the carburetor sucking from thefuel tank.

13)Fuel Injector

This device is used in diesel engine only and delivers fuel in fine spray under pressure.
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