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14012013113436 Air Intake System Essay

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ASSEM BLY AND DI S-ASSEM BLY OF 6-CYLI NDER
COM PRESSI ON I GNI TI ON ENGI NE AND I TS SYSTEM S

M I NI PROJECT REPORT
Submitted in partial fulfillment of the
Requirements for the award of the degree of
Bachelor of Technology
In
M echanical Engineering
By
P.UDAY KI RAN
P.M AHESH BABU
K.CHALAM AI AH
S.V.SRI NI VASA REDDY
B.M ADHU BABU

(07771A0357)
(08775A0325)
(07771A0353)
(07771A0339)
(07771A0306)

Under the esteemed guidance of
M r. P.SURESH BABU Assoc. Prof.

Department Of M echanical Engineering
Rao & Naidu Engineering College - Ongole
(Affiliated to J N T University Kakinada)

2010

ABSTRACT
Engine is one of the most important and costliest part/system of a vehicle, which acts like a heart of the human being, so, we have to keep it in always good condition.
I t consumes around 55% of operating cost of the vehicle, due to which we have to concentrate more on it to reduce the operating cost and to improve the efficiency.
The following main systems of the engine are to be taken care of for optimum performance and long life of the engine.
1. Air intake system.
2. Cooling system.
3. Lubrication system.
4. Fuel injection system.
I n order to observe the above systems, we have done a mini project on ³$VVHPEO\ DQG GLVDVVHPEO\ RI 7$7$ G -F\OLQGHU HQJLQH DQG LW¶V V\VWHPV´ DW µ7$7$027256¶LQ2QJROH

This includes:
¾ Procedure for checking & replacement of air filters, proper maintenance of the turbo charger, proper care of inter cooler etc., of the air intake system. ¾ 'R¶VDQGGRQ¶WVDQGSUHFDXWLRQVRIFRROLQJV\VWHP

¾ 3URFHGXUHV IRU WKH FKDQJH RI RLOV DQG RLO ILOWHUV DORQJ ZLWK GR¶V DQG GRQ¶WV RI engine lubrication system.

¾ FXHO LQMHFWLRQ V\VWHP ZLWK WKH UHSODFLQJ SURFHGXUH RI IXHO ILOWHUV DQG GR¶V DQG GRQ¶WVRIIXHOV\VWHP
¾ I mportant assembly procedure like cylinder head tightening process, taper adjustment, fuel injection pump installation procedure and timing etc., ¾ Trouble VKRRWLQJRIYDULRXVSDUWVRIHQJLQHDORQJZLWK³&KHFNOLVWV´ZKLFKDUH to be carried out for best performance of engine.

AI R I NTAKE SYSTEM
The system consists of Air filter, turbocharger, intercooler and connecting pipe lines.
AI RFI LTER Æ TURBOCHARGERÆ I NTERCOOLERÆI NTAKE M ANI FOLD Dry type air filter :
Requirement of dry type air filter in the system:
As the turbocharger shaft is rotating at a speed more than 1 lakh rpm, he air entering the air compressor of turbocharger should be very clean, lest the compressor blades will get damaged.
Dry type air filter efficiency is upto 99.99%
For checking the the condition of air filter cartridge Service indicator is provided.
Effect of air filter cartridge chocking :
x

Poor pick up.

x

Higher fuel consumption.

x

Higher engine oil consumption due to engine oil is getting sucked from the

turbocharger oil chamber by turbocharger compressor and thrown into air intake of the engine.
PURPOSE OF SERVI CE I NDI CATOR :
Service indicator is provided on air filter to indicate the blockage in the air filter. There is a red band can be seen from the transparent side of the indicator when blockage takes place.

When th red band is seen in service indicator, reset the service indicator by pressing down the black cap. Start the engine and if the red band is seen again then replace the primary cartridge.
Procedure foe checking & replacement air filter cartridge:
™ Primary cartridge should be removed for replacing only red band appears on the vaccum indicator. There is no schedule for replacing the filter cartridge. I f red band appears on service indicator, replace the primary cartridge. THE SECONDARY CARTRI DGE SHOULD NEBER BE

CLEANED BUT ONLY REPLACED AT RECOM M ENDED I NTERVALS
(After every 3 replacements of the primary cartridge ).
PRECAUTI ONS :
Never remove the secondary cartridge , as it is the last barrier for the dust. I t is to be removed only at the time of replacement.
TURBOCHARGER

A turbocharger is a gas compressor that is used for forced-induction of an internal combustion engine. The purpose of the turbocharger is to increase the density of air entering the engine to create more power

WORKI NG PRI NCI PLE :

¾ Turbocharger is mounted on the exhaust manifold. I t contains one turbine wheel, which is coupled to the compressor wheel.
¾ The turbine wheel rotates with the exhaust gas and thereby compressor wheel starts rotating. The inlet air will get compressed and supplied to the intake side of engine at pressure.
¾ With additional amount of air and increased fuel delivery the power of the engine is increased.
M AI NTENANCE OF THE TURBO CHARGER :
x

No specific maintenance services are required for the turbocharger. Ensure correct grade of engine oil used and replace at scheduled interval.

x

Ensure only recommended oil filter cartridge is used for change.

x

Check for oil leakage at inlet and outlet side of turbocharger

LUBRI CATI ON OF TURBOCHARGER :
The rotor assembly of the turbocharger is supported by two floating lead bronze bearings are lubricated wit...

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