Industrial Simulation Report

For
Automobile Development Internship

Submitted by: Group 1 (Boosters)

Submitted to: Ezenith

Acknowledgement
We acknowledge with gratitude, our sincere thanks to Ezenith team for providing us with this
internship opportunity. We are also thankful for Lokmanya Tilak College of Engineering, Navi
Mumbai for providing with their support.

List of figures
Page
Figure 1: Turbocharger.
Figure 2: Variable Valve Timing

Figure 3: Gasoline Direct Injection.

Figure 4: Dual Mass Flywheel..

Figure 5: Catalytic Convertor.

Figure 6: Integrated Exhaust

10

Problem Statement: A passenger car downsized 1L petrol engine with high power to
weight ratio and reduced engine friction.

Target Engine Specifications:

Parameters
Max. Power
Max. Torque
BSFC
Power to weight ratio(BHP/ton)
Emission Norms
Cost
Cold startability

Benchmarking

Engineering Target
123 BHP@6000 RPM
170Nm@1500-4500 RPM
205 g/KwH
98
BS5
Vehicle is for entry level market
-15 deg C

Ford Eco Sport 1L Petrol Eco boost titanium (Rs 8.6 lakh) with turbo charge, variable timing, direct
injection technology and 3 cylinder engine is an example of downsizing done right which reduced
size by 30 Kg less than its non downsized counterpart and has CO2 rating of 114g/km.

Some technologies used for downsizing

Following technologies can be used to downsize an engine:
1.
2.
3.
4.
5.
6.
7.

Turbo Charger
Variable valve (VVT)
Gasoline direct injection (GDI)
Dual Mass Flywheel
Split Cooling
Catalytic Convertor-After treatment, EGR (in cylinder emission)
Integrated Exhaust

1. Turbo Charger
A turbocharger is a turbine-driven forced induction device that increases an internal combustion
engine's efficiency and power output by forcing extra air into the combustion chamber.
Turbocharger improves an engine's volumetric efficiency by increasing density of the intake air and
improves fuel efficiency by lowering pumping losses as well as improving throttle response and lowend torque. The increased power of a turbocharged engine is shown by more torque available at the
engine's crankshaft (at a given rpm within the power band) than an identical engine.
The engine using turbochargers loses 10% weight, saving up to 30% in fuel consumption while
delivering the same power. Modern turbochargers can use waste gates, blow-off valves and variable
geometry for better operation.

Figure 1: Turbocharge

2. Variable Valve Timing

In internal combustion engine, VVT is the process of altering the timing of valve lift event, and is
often used to improve performance, fuel economy or emission. It is increasingly being used in
combination with variable valve lift system.
To optimize the air breathing, an engine would require different valve timings at different speeds. As
the revolution speed
Increases, the duration of the intake and exhaust valves opening would decrease, thus less amount of
fresh air may enter the combustion chambers, while complete exhaust gas cannot exit the combustion
chamber in time. Therefore, varying the Intake timing of an engine could help to produce more power
and, if applied to smaller and lighter engine, it could result in lower fuel as well.
Advantages

Low RPM drivability

Better Fuel Economy
Increasing Torque
Internal Exhaust gas recirculation

Figure 1 Variable valve timing

3. Gasoline Direct Injection

Gasoline direct injection is a process whereby fuel is injected straight into the combustion chamber at
high pressure. This is an effective means of reducing fuel consumption and emissions while greatly
boosting driving dynamics.
The high pressure injection system is especially suitable for engines with a power to-weight ratio
between around 60 and100 kW/liter along with downsizing rates of up to 45 percent in future GDI
injector, pressured to a higher-than-average 200 bar, securing a clean combustion and improving fuel
economy and emissions to fulfill Euro 6 emission standards.

Figure 3. Gasoline Direct Ignition

Advantages

Smaller combustion space, better thermal efficiency.

Cold starting is easier.
Fuel efficiency due to electronically control fuel injection
Ability to accommodate alternative fuels
Less carbon based emission
Better power output and performance than a standard carburetor based vehicle

4. Dual Mass Flywheel

A dual-mass flywheel is essentially two flywheels in one that provides some spring cushioning to
dampen torsional crankshaft vibrations and shock loading when the clutch is engaged. On gasolinepowered passenger car applications, a dual-mass flywheel can provide the same kind of drive train
cushioning and dampening for a smoother, quieter ride. A dual-mass flywheel also helps smooth
clutch engagement in vehicles with high torque output engines.

Figure 4 Dual Mass Flywheel

Advantages

It gives high torque output.

It easily delivers a smooth transfer torque to the road wheels via clutch.
It increases mechanical efficiency

5. Split Cooling
An optimized split-cooling concept manages different temperatures in the cylinder head and block
area using separate circuits. The cylinder block is heated up quickly for lower friction and more
efficient run, while the cylinder head operates at lower temperatures to optimize injection and
combustion. The use of coolant with different coolant in the two circuits provides desired optimal
temperature distribution in the engine which is cooler head and warmer head relative to standard
temperature.
Optimal temperature distribution in engine
Cleaner emission due to rapid and complete combustion of fuel
6. Catalytic Convertor
A catalytic converter is an emissions control device that converts toxic gases and pollutants in exhaust
gas to less toxic pollutants by catalyzing oxidation or reduction. The core is usually a ceramic
monolith with a honeycomb structure. Ceramic is coated with precious metals like platinum,

palladium, rhodium, etc. Honeycomb structure provide larger surface area so that exhaust gases are
converted into less dangerous ones more efficiently.

Figure 5. Catalytic Converter

Advantages

Reduces harmful emissions

Increase in fuel economy

7. Integrated Exhaust manifold

In this technology, to keep the engine unit as small as possible, the exhaust manifold is integrated
within the cylinder head and can therefore be cooled efficiently using the cylinder head water cooling
system. These efforts result in faster warm-up of the catalyst and ultimately in improved real-world
fuel consumption and emissions. By integrating the manifold tracts into the cylinder head the parts
counts is reduced significantly, saving cost throughout the development cycle. Through intelligent
cooling jacket design heat is retained in the engine rather than lost to the engine bay, accelerating
engine warm up so it more quickly reaches optimal efficiency.

Figure 6 Integrated exhausts

Advantages

By integrating the manifold tracts into the cylinder head the parts counts is reduced

significantly,
saving cost throughout the development cycle

8. Precision manufacturing
Methods like metal injection molding can be used to reduce material use in engine and components
manufacturing. It helps to reduce the overall weight of the engine, reduce its cost and make design
more efficient. Simulated analysis can be done before production to reduce physical testing which is
reflected in the price of the engine.
Advantages:
Weight reduction
Better engine response
Conclusion: The above technologies can be used to downsize a petrol engine.