Lesson 3: Engine Performance Terminology

Objective: The student will be able to define essential engine performance terminology and calculate engine displacement, compression ratio, and horsepower. References: Glossary of Terms Introduction: To understand diesel engine design and performance, it is necessary to know the terminology and math calculations that apply to diesel engines. LEXQ8150

Lesson 3: Engine Performance Terminology

Unit 1 Lesson 3

1-3-2

Engine Fundamentals

This presentation will review engine performance and engine performance terminology.

Fig. 1.3.1

There are many factors that determine the performance of an engine. The operating conditions that an engine is exposed to and the specific application an engine is placed in can affect the performance of the engine. Many of the determining factors for performance, however, are determined by the manufacturer of the engine. Some of the basic specifications that a manufacturer makes on an engine that affect performance of the engine are: Bore Stroke Displacement Compression Ratio The performance of an engine is typically rated by comparing power output and/or efficiency of the engine. These evaluations can be measured in several different ways. The basis for these measurements and the manufacturers specifications must be known in order to better understand the effects that all of these factors and measurements have on engine performance.

Unit 1 Lesson 3

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Engine Fundamentals

BORE

TDC STROKE

BDC CRANKSHAFT AT TDC

CRANKSHAFT AT BDC

Fig. 1.3.2

Top Dead Center (tdc) Top dead center (tdc) is a term used to describe the position of the piston when the piston is at its highest point in the cylinder. This occurs when the crankshaft and the connecting rod are fully extended and straight with one another. Many events in the operation of the engine are identified by crankshaft position, measured in degrees either before or after tdc. Bottom Dead Center (bdc) Bottom dead center (bdc) is a term used to describe the position of the piston when the piston is at its lowest point in the cylinder. This occurs when the crankshaft and the connecting rod are fully retracted and straight with one another. Bore (B) Bore is a term used to describe the diameter of a single cylinder in an engine. Bore is typically measured in millimeters or inches. Stroke (L) Stroke is a term used to describe the distance that a piston travels in the cylinder of the engine. The stroke is measured as the difference between the position of the piston at BDC to TDC. The amount of stroke is determined by the design of the crankshaft. The stroke is equal to exactly twice the throw of the crankshaft. Stroke is typically measured in millimeters or inches.

Unit 1 Lesson 3

1-3-4

Engine Fundamentals

Engine Displacement The bore, the stroke, and the number of cylinders all determine the displacement of an engine. The displacement of an engine is simply the amount of volume displaced by all cylinders in an engine during one complete rotation. The displacement of an engine can be calculated using the following formula: Displacement = x r2 x L x n Where... r2 radius L n = = = = = 22/7 radius x radius 1/2 bore stroke number of cylinders in the engine
DIESEL ENGINE 17 TO 1

Fig. 1.3.3

Compression Ratio The compression ratio of an engine is determined by the cylinder displacement and the combustion chamber volume. In order to calculate the compression ratio use the following formula: CR = Total Cylinder Volume / Combustion Chamber Volume Typical compression ratios of diesel engines range from 11:1 to 22:1. This is significantly higher than the compression ratio of a typical gasoline engine. Diesel engines utilize higher compression ratios to increase the pressure within the combustion chamber. Higher pressures will cause an increase in the temperature of the air and fuel in the combustion chamber. This high temperature (approximately 1000F) will cause the diesel fuel to ignite without the use of a spark plug.

Unit 1 Lesson 3

1-3-5

Engine Fundamentals

Work Work is defined as a force that is applied over a distance. W = F x D Power Power is defined as the rate at which work is performed P = F x D / t or P = W / t Where t is the time that the work is performed in. The standard measure of power in the metric system is the kilowatt (kW), and in the english system the standard measure of power is the horsepower (HP). 1 HP = 0.746 kW 1 kW = 1.340 HP The term horsepower was originally derived by James Watt, a scottish inventor. Watt observed the ability of a horse in coal mine hoisting coal. He defined 1 HP to be equal to the ability of a horse to raise 33,000 lb of coal a distance of 1 ft in 1 minute. There are several different types of power that are often discussed. Indicated horsepower (IP) is the power that an engine is theoretically able to produce. This is found by multiplying the displacement of the engine by the mean effective pressure in the cylinder in pounds per square inch and dividing it by 33,000. Brake engine horsepower (BP) is the power that is found by physically testing an engine on a dynamometer. A dynamometer is a device that is coupled to an engine for the purpose of measuring the torque and the horsepower output of the engine. Friction power (FP) is the power that an engine requires in order to overcome the frictional losses of bearings, gears, and other moving parts of the engine. Friction power increases as the size and/or the speed of an engine increases. BP = IP - FP

Unit 1 Lesson 3

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Engine Fundamentals

Torque When the engine is running, the combustion that takes place causes the pistons to move downward in the cylinder. This downward piston motion pushes on the connecting rods and causes the crankshaft to be turned. The resulting twisting force produced by the crankshaft is called torque. The torque and the horsepower that an engine produces are related to one another with the following equation: HP = T x RPM / 5252 NOTE: This formula can not be used with metric units. Convert the metric units to english units before performing the calculation. Where... T = Torque (measured in ft lb) 5252 = 33,000 / 2 (constant) The constant of 5252 is derived by dividing the 33,000 lb in Watts horsepower formula by the angular value of one rotation of the crankshaft in radians, 2. Torque is measured in foot-pounds (ft lb) in the english system and in Newton-meters (Nm) in the metric system. 1 ft lb = 1.3558 Nm 1 Nm = 0.7376 ft lb Friction A certain amount of force is required in order to slide the surfaces of two objects against one another. The resistance to this motion is called friction. As the load is increased, friction is increased. For example it requires more effort to slide a heavy object than it does to slide a light object. The condition of the two surfaces in contact also makes a difference. This is why the lubrication system in an engine is so important. The oil film between the moving parts of an engine keep the friction between the two surfaces very low. This not only gives the engine a long service life, but also creates less drag on the engine, reducing the amount of frictional power. This allows the engine to produce more brake power.

Unit 1 Lesson 3

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Engine Fundamentals

Inertia Sir Isaac Newtons first law of motion states that an object in motion tends to stay in motion and an object at rest will tend to stay at rest, until acted upon by an outside force. This phenomenon is due to objects possessing inertia. The amount of inertia an object has is directly proportional to the amount of mass that the object has. For example a car has more inertia than a bicycle. This is why it is harder to move or stop a car than a bicycle. Efficiency The efficiency that a particular engine has is expressed as a percentage of the actual power to the theoretical power of an engine. The actual power produced by an engine is always less than the theoretical power. There are several ways to describe the efficiency of an engine. Volumetric efficiency is defined as how capable an engine is of filling the cylinder with air on the intake stroke compared to the cylinder being completely filled with air at atmospheric pressure. Because air must be sucked into the cylinder with the downward motion of the piston, the engine is never able to fill the cylinder 100%. Brake power is the amount of usable power that an engine actually produces. Indicated power is the amount of theoretical power that an engine should be able to produce. Mechanical efficiency is the ratio of brake power to indicated power. BP / IP = Mechanical Efficiency Thermal efficiency is the degree to which an engine is able to successfully convert the energy in the fuel into heat energy to cause the pistons to turn the crankshaft. Fuel efficiency is defined in several different ways. The most common of which is kilometers per liter (km/L) or miles per gallon (mpg), which would be used to describe the fuel efficiency of an engine in an over the road application such as in a truck. Fuel efficiency for marine or industrial applications may be expressed in liters per hour (Lph) or gallons per hour (gph) at rated speed. Fuel efficiency may also be expressed in brake specific fuel consumption (bsfc). Bsfc is defined as the amount of fuel used per unit of power and time. The bsfc of an engine is expressed in either g / (kW hr) or lb / (hp hr).

Unit 1 Lesson 3

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Engine Fundamentals

Atmospheric Conditions In order to produce the desired levels of power, diesel engines require a large volume of air. Therefore the atmospheric pressure, the ambient air temperature, and the relative humidity of the air play a large role in the performance characteristics of the engine. It is the atmospheric air pressure that is present that forces the air into the engine. Atmospheric pressure is the pressure that is exerted on the earths surface due to the weight of the atmosphere (the air surrounding the earth). Atmospheric pressure is greatest at sea level because there is more air above the air at sea level than there is above the air at the top of a mountain. Refer to figure...
WEIGHT OF AIR ON EARTH'S SURFACE

3657 M. 64.12 kPa 2438 M. 75.15 kPa 1219 M. 87.50 kPa

12,000 FT. 9.3 PSI 8,000 FT. 10.9 PSI 4,000 FT. 12.7 PSI

101.35 kPa SEA LEVEL

SEA LEVEL 14.7 PSI

EARTH'S SURFACE

Fig. 1.3.4

As an example, due to increased pressure at sea level the air is more dense than the air on top of a mountain. The dense air allows for more air molecules to flow into the cylinder. This allows for the fuel to be more completely burned in a diesel engine, which produces more power. This is why engines perform better in lower altitudes, the air is more dense. Ambient air temperature also plays a role in how much air can flow into an engine. The lower the temperature of the air, the more dense the charge of air is that enters the cylinders. The greater the density of the air, the more power that can be produced efficiently in the engine. Humidity is also an important factor in diesel engine combustion. Humidity is a relative measure of the amount of moisture that is suspended in the air. The suspended moisture has a cooling effect on the air as it enters the engine. Therefore, the greater the humidity of the air, the colder the air, the denser the air, the more power that can be produced efficiently in the engine.

Unit 1 Lesson 3, Exercise 1.3.1

Engine Fundamentals

Unit 1, Exercise 1.3.1 Define the following terms: TDC - Top Dead Center: The highest position that a piston reaches in the cylinder. The lowest position that a piston reaches in the cylinder.

BDC - Bottom Dead Center: Bore: Stroke:

The diameter of each cylinder in an engine. The distance travelled by the piston from BDC to TDC. The circular area of one cylinder multiplied by its stroke multiplied by the number of pistons. This is also sometimes referred to as the swept volume. The ratio of total cylinder volume to combustion chamber volume.

Displacement:

Compression Ratio: Work: Power:

A force applied over some distance. The rate at which work is performed. A unit of standard measure for power in the english system.

Horsepower: Kilowatt: Torque:

A unit of standard measure for power in the metric system. The amount of twisting force that is produced by an engine. The amount of power that an engine is theoretically able to produce. A measurement of the actual power that is available for useful work from an engine.

Indicated Horsepower:

Brake Engine Horsepower:

Dynamometer:

A device used to measure the torque and horsepower output of an engine. The ratio of brake power to indicated power. Gives an idea of how much power is lost due to friction in the engine. The degree to which an engine is able to convert the energy in the fuel into heat energy to cause the pistons to turn the crankshaft. The capability of an engine is of filling the cylinder with air on the intake stroke compared to the cylinder being completely filled with air at atmospheric pressure.

Mechanical Efficiency:

Thermal Efficiency:

Volumetric Efficiency:

Instructor Copy: Quiz 1.3.1

Unit 1 Lesson 3, Exercise 1.3.1

Engine Fundamentals

Fuel Efficiency:

In general the amount of production that is accomplished for a given volume of fuel. This could be miles per gallon, liters per hour, pounds per horsepower-hour, etc. The pressure on the earths surface due to the weight of the atmosphere.

Atmospheric Pressure: Friction: Inertia:

Resistance to motion due to the contact of two surfaces. The property of matter which causes it to tend to stay in motion if already moving, or to remain at rest if already motionless.

Unit 1 Lesson 3, Exercise 1.3.1

Engine Fundamentals

Write the equations for calculating the following: Displacement: Displacement = Where... r2 radius = L n Horsepower:

x r2 x L x n

= 22/7 = radius x radius 1/2 bore = stroke = number of cylinders in the engine

HP = T x RPM / 5252

Using the Glossary of Terms, define the following: Force: The action of one body on another tending to change the state of motion of the body acted upon.

Heat:

Form of energy, the addition of which, causes substances to rise in temperature; energy associated with random motion of molecules.

British Thermal Unit (BTU):

The amount of heat required to raise 1 lb of water from ice to water at standard atmospheric pressure.

Brake Mean Effective Pressure (BMEP):

Mean effective pressure acting on the piston which would result in the given brake horsepower output, if there were no losses due to friction, cooling, and exhaust. This is equal to the mean indicated pressure multiplied by the mechanical efficiency of the engine.

Unit 1 Lesson 3, Exercise 1.3.1

Engine Fundamentals

Define the following terms: Bore: Stroke: TDC - Top Dead Center: BDC - Bottom Dead Center: Displacement: Compression Ratio: Work: Atmospheric Pressure: Power: Mechanical Efficiency: Horsepower: Thermal Efficiency: Kilowatt: Indicated Horsepower: Friction: Torque: Brake Engine Horsepower: Dynamometer: Volumetric Efficiency: Inertia: Fuel Efficiency:

Student Copy: Exercise 1.3.1

Unit 1, Exercise 1.3.1

Unit 1 Lesson 3, Exercise 3.1

Engine Fundamentals

Write the equations for calculating the following: Displacement:

Horsepower:

Using the Glossary of Terms, define the following: Force:

Heat:

British Thermal Unit (BTU):

Brake Mean Effective Pressure (BMEP):

Unit 1Instructor Copy Quiz 1.3.1

Engine Fundamentals

CATERPILLAR ENGINE FUNDAMENTALS

Unit 1 Quiz Circle the best answer or fill in the blanks. Name .

1. The crankshaft in a Caterpillar 3406B is: A. hardened at the journals only B. totally hardened 2. Which engines require MSHA certification? A. Marine B. Underground Mining C. On-Highway Truck 3. Which of the following Caterpillar on-highway truck engines are considered medium duty (mid-range) class? A. B. C. D. C-10 3306C 3126B 3406C

4. What three factors are necessary to create combustion? air fuel heat

5. How does the 4 stroke diesel engine combustion process differ from 4 stroke gasoline engines? Ignition process - diesel uses compression, gasoline uses spark to ignite fuel 6. Name the 4 cycles of Caterpillar diesel engine operation. intake power compression exhaust

Instructor Copy: Quiz 1.3.1

Unit 1Instructor Copy Quiz 1.3.1

Engine Fundamentals

7. Four strokes of the piston equal how many revolutions of the crankshaft? A. B. C. D. 1 2 4 8

8. During the four-stroke cycle, the piston is moving toward TDC (Top Dead Center) during what two strokes? A. B. C. D. Compression and exhaust Intake and power Intake and exhaust Compression and power

9. What does this formula represent? RPM x Torque 5252 A. B. C. D. BTU % Torque Rise Horsepower Thermal Efficiency

10. 317 kilowatts is equivalent to how many horsepower? A. 400 B. 425 C. 236 11. In a Caterpillar 3406 engine, when piston #1 is at TDC compression, piston #6 is at: TDC exhaust 12. Horsepower is defined as: A. B. C. D. work done in a given period of time. twisting effort of the crankshaft in an engine. the displacement of an engine in liters. the energy derived from burning dried horse manure

Unit 1Instructor Copy Quiz 1.3.1

Engine Fundamentals

13. Engine displacement is defined as: A. B. C. D. weight of the engine. length of the engine when it is installed. total volume that is displaced by all pistons making one stroke each. moving the engine from one place to another.

14. Compression ratio is defined as: A. ratio of compression pressure to firing pressure. B. ratio of volume in a cylinder with the piston at Bottom Dead Center compared to volume at Top Dead Center. C. ratio of crankcase pressure to atmospheric pressure. D. ratio of turbocharger boost pressure to exhaust backpressure. 15. Explain the difference between "Flywheel Horsepower" and "Wheel Horsepower". Flywheel horsepower is measured at the flywheel, wheel horsepower is measured at the wheels of a vehicle (drivetrain losses will make wheel hresepower less) 16. What section of a Service Manual has step-by-step procedures for setting exhaust valves on a Caterpillar engine? Testing and adjusting 17. An industrial engine application that requires the engine to operate at rated load and speed up to 100% of the time is considered: A. B. C. D. E. A Rating B Rating C Rating D Rating E Rating intake and

18. Which components in a diesel engine convert reciprocating motion to rotary motion? A. B. C. D. Camshaft and crankshaft Connecting rod and crankshaft Piston and crankshaft Crankshaft and flywheel

Unit 1Instructor Copy Quiz 1.3.1

Engine Fundamentals

19. An industrial engine application that requires the engine to operate at rated load and speed for a short time is considered: A. B. C. D. E. A Rating B Rating C Rating D Rating E Rating

20. A "parent bore block" is: A. B. C. D. a cylinder block with removable wet cylinder liners. usually used in heavy duty engine designs. a cylinder block with cylinders bored by your father. a cylinder block where the cylinders are bored directly into the cylinder block material.

Unit 1Student Copy Quiz 1.3.1

Engine Fundamentals

Unit 1 Quiz Circle the best answer or fill in the blanks. Name____________________________

1. The crankshaft in a Caterpillar 3406B is: A. hardened at the journals only B. totally hardened 2. Which engines require MSHA certification? A. Marine B. Underground Mining C. On-Highway Truck 3. Which of the following Caterpillar on-highway truck engines are considered medium duty (mid-range) class? A. B. C. D. C-10 3306C 3126B 3406C

4. What three factors are necessary to create combustion? ________________ _________________ _________________ 5. How does the 4 stroke diesel engine combustion process differ from 4 stroke gasoline engines? ________________________________________________________ ________________________________________________________ 6. Name the 4 cycles of Caterpillar diesel engine operation. _____________________ _____________________ _____________________ _____________________

Student Copy: Quiz 1.3.1

CATERPILLAR ENGINE FUNDAMENTALS

Unit 1Student Copy Quiz 1.3.1

Engine Fundamentals

7. Four strokes of the piston equal how many revolutions of the crankshaft? A. B. C. D. 1 2 4 8

8. During the four-stroke cycle, the piston is moving toward TDC (Top Dead Center) during what two strokes? A. B. C. D. Compression and exhaust Intake and power Intake and exhaust Compression and power

9. What does this formula represent? RPM x Torque 5252 A. B. C. D. BTU % Torque Rise Horsepower Thermal Efficiency

10. Define Torque Rise in a diesel engine. _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ 11. In a Caterpillar 3406 engine, when piston #1 is at TDC compression, piston #6 is at: ______________________________________________________________ 12. Horsepower is defined as: A. B. C. D. work done in a given period of time. twisting effort of the crankshaft in an engine. the displacement of an engine in liters. the energy derived from burning dried horse manure

Unit 1Student Copy Quiz 1.3.1

Engine Fundamentals

13. Engine displacement is defined as: A. B. C. D. weight of the engine. length of the engine when it is installed. total volume that is displaced by all pistons making one stroke each. moving the engine from one place to another.

14. Compression ratio is defined as: A. ratio of compression pressure to firing pressure. B. ratio of volume in a cylinder with the piston at Bottom Dead Center compared to volume at Top Dead Center. C. ratio of crankcase pressure to atmospheric pressure. D. ratio of turbocharger boost pressure to exhaust backpressure. 15. Explain the difference between "Flywheel Horsepower" and "Wheel Horsepower". _____________________________________________________________ _____________________________________________________________

16. What section of a Service Manual has step-by-step procedures for setting intake and exhaust valves on a Caterpillar engine? _____________________________________________________________

17. An industrial engine application that requires the engine to operate at rated load and speed up to 100% of the time is considered: A. B. C. D. E. A Rating B Rating C Rating D Rating E Rating

18. Which components in a diesel engine convert reciprocating motion to rotary motion? A. B. C. D. Camshaft and crankshaft Connecting rod and crankshaft Piston and crankshaft Crankshaft and flywheel

Unit 1Student Copy Quiz 1.3.1

Engine Fundamentals

19. An industrial engine application that requires the engine to operate at rated load and speed for a short time is considered: A. B. C. D. E. A Rating B Rating C Rating D Rating E Rating

20. A "parent bore block" is: A. B. C. D. a cylinder block with removable wet cylinder liners. usually used in heavy duty engine designs. a cylinder block with cylinders bored by your father. a cylinder block where the cylinders are bored directly into the cylinder block material.