FOREWORD

Welcome to value-conscious company. We are proud of the advanced engineering and

quality construction of each equipment we manufacture.

This manual explains the working of equipment. Please read it thoroughly and have all the
occupants follow the instructions carefully. Doing so will help you enjoy many years of
safe and trouble free operation.

When it comes to service, remember that genius scientific & engg works knows your
equipment best and is interested in your complete satisfaction. We will provide the quality
maintenance and any other assistance you may require.

All the information and specifications in this manual are correct at the time of printing.
However, Because of genius scientific & engg works policy of continual product
improvement we reserve the right to make changes at any time without notice.

Please note that this manual explains all about the equipment including options.
Therefore, you may find some explanations for options not installed on your equipment.

You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability and longer life for the product.

Genius scientific & engg works

 CONTENTS

1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 2

5. Description …………………………………… 3

6. Utilities Required …………………………………… 4

7. Experimental Procedure …………………………………… 4

8. Observation & Calculation …………………………………… 5

9. Nomenclature …………………………………… 7

10. Precautions & Maintenance Instructions …………………………………… 8

11. Troubleshooting …………………………………… 9

12. References …………………………………… 9

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer)
 SINGLE CYLINDER FOUR STROKE DIESEL ENGINE TEST RIG
(WITH ROPE BRAKE DYNAMOMETER)

1. OBJECTIVE:
To study the single cylinder four stroke Diesel engine & its characteristics.

2. AIM:
To determine
Brake Power
Fuel consumption
Specific fuel consumption
Brake thermal efficiency
Heat carried out by water from calorimeter
Heat carried away by engine jacket
Heat carried out by exhaust gases
Air consumption
Swept volume
Volumetric efficiency

3. INTRODUCTION:
A Diesel engine is almost the same as a petrol engine but it burns a different type of
fuel. Diesel is named after its inventor Rudolf Diesel, a German who first developed
this type of fuel in the early 1900’s. Diesel engines have mainly been used in lorries
and buses because of their increased power and their reliability. They tend to be
noisy and smelly compared to a petrol engine but are more economical to run.
In a diesel engine the compression stroke only compresses air and not fuel. On the
ignition stroke the air is compressed to a very high pressure and then fuel is injected into
the engine cylinder with the help of an injector, resulting in generating enormous heat,
which then ignites the fuel that is injected into the combustion chamber at that precise
moment of maximum pressure. There is no need for a spark plug in a diesel engine. The
compressed air is hot enough to cause the fuel to explode. This is because a diesel
engine has a far higher "compression ratio" than does a petrol engine.

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 1
4. THEORY:
THE FOUR-STROKE CYCLE:

The ‘stroke’ is simply when the piston moves all the way either up or all the way
down inside the cylinder. In the four-stroke engine each of the four strokes
accomplishes something different. So, let’s have a look at the four strokes and see
what happens:
INDUCTION:

The first stroke is called Induction. This is when the air is drawn into the cylinder by the
piston going down and producing suction. As the piston travels down the cylinder it
creates a vacuum above it and the air is drawn into the cylinder in the empty space left
by the piston The piston starts at the top, the crankshaft turns and pushes on the tappets
which causes the intake valve to open (on the left), and the piston moves down to let the
engine take in a cylinder full of air. This is called intake stroke.
COMPRESSION:

Compression is the second of the four strokes. This is the stage when the air is
compressed and forced into the top of the cylinder ready for ignition. The crankshaft
has turned, pushed the tappets, which have in turn allowed the inlet valve to return
to the closed position. The piston moves back up and compresses this air.
Compressing the air makes the explosion more powerful. As the valves are both
closed, the cylinder is sealed and the compressed air can’t escape from the cylinder.
IGNITION:

As the piston reaches the top of the compression stroke, the injector injects the fuel
and ignites the highly compressed air. The piston is then forced back down the
cylinder by the resulting explosion, turning the crankshaft and generating the
propulsion for the engine that makes the vehicle to go along the road. The diagram
shows the piston on its way down the cylinder just after the fuel is ignited.
EXHAUST:

This is when the exhaust gases (after the fuel is burnt) are forced out of the engine.
Once the piston hits the bottom of its stroke, the exhaust valve opens (on the right).
The piston travels back up inside the cylinder and this time it ‘pushes’ the exhaust
gases out through the now open exhaust vent. Now the engine is ready for the next
cycle, so it intakes another charge of fresh air and we are back to the intake stroke.

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 2
5. DESCRIPTION:
Single Cylinder, Four Stroke, Diesel Engine Test Rig with Rope Brake
dynamometer arrangement mainly consists of:
1. Loading arrangement
2. A Fuel Input Measuring Arrangement
3. An Arrangement for measuring the heat carried away by cooling water from
engine jacket.
4. An arrangement for measuring the heat carried away by cooling water from
exhaust gas.
LOADING ARRANGEMENT:

A Rope Brake Dynamometer arrangement with a brake drum coupled to the engine
shaft and provided with a cooling water arrangement and spring balances. The load
can be varied by increasing the rope tension on the brake drum with moving the
hand wheel provided on the frame.
FUEL INPUT MEASURING ARRANGEMENT

This arrangement consists of a fuel tank of suitable capacity mounted on a stand.

The fuel goes to the engine through a 50 ml burette. The burette facilitates the
measurement of fuel consumption for a definite period with the help of stopwatch.
ARRANGEMENT FOR MEASURING THE HEAT CARRIED BY COOLING
WATER FROM ENGINE COOLING JACKET.

Suitable pipefitting is provided for circulating the cooling water into the engine
water jacket. For measuring the rate of flow of cooling water, a water meter is
provided. With these entire arrangements, one can find the heat carried away by
cooling water. The temperature of inlet and outlet water can be directly read from
the Digital Temperature Indicator.
ARRANGEMENT FOR MEASURING THE HEAT CARRIED AWAY BY EXHAUST
GASES:

It consists of exhaust gas calorimeter to measure the heat carried away by exhaust
gases. Exhaust gas calorimeter consists of a central tube and an outer jacket.
Exhaust gases passes through central tube and water is circulated in outer jacket to
get the maximum Temperature difference of exhaust gases at inlet and outlet of
calorimeter. The volume of water circulation is measured with the help of water
meter and stopwatch. Thermocouples are provided to get the inlet and outlet
temperature of exhausts gases and water circulated.

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 3
6. UTILITIES REQUIRED:
1. Electricity supply; Single phase , 220V AC, 50Hz, 5-15 Amp socket with earth
connection.
2. Water Supply continuous @ 10 LPM at 1 Bar for engine &5 LPM for exhaust
gas calorimeter cooling.
3. Drain Required.
4. Floor Area Required: 3 m x 2 m.
5. Diesel: 10 Ltrs.
6. Engine oil: Multigrade 20W40 approx 1 ltr.
7. Exhaust Emission.
8. Digital RPM sensor with indicator : For RPM Measurement

7. EXPERIMENTAL PROCEDURE:
1. Fill oil in the oil sump of engine. It should be in between the marks provided on
the oil dipstick. If oil level is reduced, add clean oil (SAE–40) to the crankcase
by opening the cover of valve provided, at the engine.
2. Fill the diesel in diesel tank.
3. Fill the manometer up to half of the height of manometer with water.
4. Fill the burette with diesel by opening the valve provided at the lower side of
burette. Close the valve after filling the burette.
5. Supply the diesel to the engine by opening the valves provided in the fuel supply
line.
6. Open continuous cold water supply to the engine jacket & calorimeter.
7. Switch on the main supply to the panel.
8. Start the engine with starting handle and let it run for 5 minutes under no load
condition.
9. When engine starts running smoothly, firstly load the engine slightly with the
help of rope brake dynamometer and then gradually increase the load.
10. Run the engine for 2 minutes so that it can stabilize.
11. Note the reading of both spring balance and note the RPM of brake drum.
12. Open the valve of burette and close the diesel supply valve of fuel tank. Note
down the time to consume 10ml of diesel. It will give fuel consumption.
13. Now open the diesel supply valve of fuel tank, which refill the burette.
14. Note down the reading of manometer to calculate the air intake by the engine.
Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 4
 15. Note the temperature of inlet and outlet of the water circulating through the
engine jacket and calorimeter. Also note the temperature of exhaust gas at inlet
and outlet of calorimeter.
16. Measure the flow rate of water through engine jacket & calorimeter with the
help of water meter & stop watch.
17. Repeat the experiment for different load.
18. When the experiment is over reduce the load on engine and stop the engine.
19. Then close the fuel and cooling water supply to the engine & calorimeter.

8. OBSERVATION & CALCULATION:

DATA:
do = 0.020 m
D = 0.08 m
L = 0.11 m
dB = 0.3 m
dR = 0.025 m
Nc = 1
n = 2 (for 4 stroke cycle)
Cv = 43500 kJ / kg
o
Cp = 4.186 kJ / kg C
Cd = 0.64
3
ρa = 1.293 kg/m
3
ρw = 1000 kg / m
3
ρf = 804 kg/m
g 2
= 9.81 m/s

OBSERVATION:
o
Ta = ----------- C (Reading of sensor T3 / T4 before starting engine)

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 5
 OBSERVATION TABLE:
V t
S. N h 1, h2, W1, W2, x, t, T1,°C T2,°C T3,°C T4,°C T1ci,°C T5,°C tc, E, E,
No cm cm kg Kg ml sec sec ltrs. sec
1

CALCULATIONS:

R e = dB + 2dR ,m = --------------- M
2
T = (W1 −W2 )× g × Re , N-m = ---------- N-m

BP = 2 × π × N × T ,kW = ------------------- kW
60 ×1000
x ρf
W = × , kg/sec = ------------ kg/sec
f t 106

W sf = Wf ,kg/kW sec = ------------ kg/kW sec

BP
H f = Wf × Cv , kW = ------------------- kW

ηBT = BP ×100 ,% =
H
---------------------
%
f

m = VE ρW , kg/sec = ------------ kg/sec

t
*

ew E 1003
H
= mew *CP *(T2 − T1 ) , kW = -------------------
ecw kW
V
m = c * ρw , kg/sec = ------------ kg/sec
cw tc 103
H
= mcw × CP × (T5 – T1ci ) ,kW=------------------ kW
ccw

mcw × CP × (T5 −T1ci) = mexh × Cexh × (T3 − T4 )

or m exh
× C exh = mcw × Cp × (T5 – T1ci) = -----------------------
(T3 − T4 )
H
exh = mexh × Cexh × (T3 − Ta ) , kW = ------------------- kW
H
un = H f − (BP + Hecw + Hexh ) , kW = ------------------- kW

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 6
 π 2 2
ao = do2 , m = ----------------------- m
4
h−h ρw
H= 1 2
−1 , m = -------------------- m
100 ρa
3 3
Q a = C d × ao 2gH , m /sec = ------------------ m /sec

π × D2 × L× N × Nc 3 3
Vs = , m/sec = ------------------ m /sec
4× 60× n
Qa
η vol. = ×100 ,% = --------------------- %
Vs

9. NOMENCLATURE:
2
ao = Cross-sectional area of orifice, m
BP = Brake power, kW
Cv = Calorific value of fuel, kJ/ kg
Cd = Co-efficient of discharge for orifice.
o
Cexh = Specific heat of exhaust gas, kJ/ kg C
o
Cp = Specific heat of water, kJ/ kg C
D = Diameter of cylinder, m
do = Diameter of orifice, m
dB = Diameter of brake drum, m
dR = Diameter of rope, m
g 2
= Acceleration due to gravity, m/s
H = Head causing flow of air through orifice, m
Hf = Heat supplied, kW
h1, h2 = Manometer reading, cm.
Hccw = Heat carried out by water from calorimeter, kW
Hexh = Heat carried out by exhaust gas, kW
Hun = Heat lost in radiation and unaccounted heat, kW
Hecw = Heat carried out by water from engine cooling jacket, kW
L = Length of stroke, m
mcw = Mass of water entering the calorimeter, kg/sec
mexh = Mass of exhaust gas, kg/sec
mecw = Mass of water entering the engine cooling jacket, kg/sec
Nc = Number of cylinders
Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 7
 n = Number of cycles
N = Revolutions per minute
3
Qa = Air consumption, m /sec
Re = Mean effective radius, m
t = Time taken for x ml, sec
T = Torque, N m
tc = Time for Vc, sec
tE = Time for VE, sec
o
T1 = Temperature of water inlet for Engine jacket, C
o
T2 = Temperature of water outlet from Engine jacket, C
o
T3 = Temperature of exhaust inlet for calorimeter, C
o
T4 = Temperature of exhaust outlet from calorimeter, C
o
T1ci = Temperature of water inlet for calorimeter, C (same as T1 )
o
T5 = Temperature of water outlet from calorimeter, C
o
Ta = Ambient air temperature, C
Vc = Volume of water flows through calorimeter, ltrs.
3
Vs = Swept volume, m /sec
VE = Volume of water flows through the engine cooling jacket, ltrs.
W1 = Spring balance weight, kg
W2 = Dead weight, kg
Wf = Fuel consumption, kg/sec
Wsf = Specific fuel consumption, kg/kW sec
x = Volume of the fuel consumed, ml
3
ρf = Density of fuel, kg/m
ηBT = Brake thermal efficiency
ηvol = Volumetric efficiency
3
ρa = Density of air ,kg/m
3
ρw = Density of water, kg/m

10. PRECAUTIONS & MAINTENANCE INSTRUCTIONS:

1. Always check the oil level in the engine before starting and make sure that
sufficient oil is present in the engine.
2. Change this oil as engine completes 100 hours of total running.
3. Open cold water supply to the engine before starting.

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 8
 4. Fuel tank and fuel line should cleaned and free from foreign particles.
5. If diesel tank was empty before filling the diesel, remove air trapped in fuel line
by opening the vent screw provided at the right side, top of the fuel pump.

11. TROUBLESHOOTING:
1. If the engine heats up, check the water supply to the engine jacket.
2. If engine does not start, check the fuel and fuel supply line. If air found in
pipeline, remove it.

12. REFERENCES:
th
1. M.L.Mathur & R.P. Sharma “A Course in Internal Combustion Engine”, 7 ed.,
Dhanpat Rai Publication Asian Books ltd., ND, 2000, Page 37-42,46-47
nd
2. V Ganesan, “Internal Combustion Engines”, 2 ed, MC Graw- Hill Publishing
Company Ltd., NY, 2003, Page 8-11, 25-34
th
3. R.S Khurmi J.K Gupta, “A Text Book of Thermal Engineering”, 15 ed., S.Chand
& Company LTD., ND, 2007, Page 589-591, 615-617, 626-627

Single Cylinder Four Stroke Diesel Engine Test Rig (With Rope Brake Dynamometer) 9