DESIGN AND MODIFICATION OF

MORSE TEST

BATCH – 7 OF MECHANICAL ENGINEERING 5TH SEM

[M.N.T.I]
 CONTENTS

 ABSTRACT

 INTRODUCTION

 COMPONENTS REQUIRED

• DIESEL ENGINE AND TEST BENCH

• ENGINE OIL PRESSURE GAUGE

• U-TUBE MANOMETER FOR AIR FLOW RATE

• SPEED INDICATOR – DIGITAL

• TEMPERATURE INDICATOR- DIGITAL

• DIGITAL VOLT METER AND AMMETER

• ACOUSTIC EMMISION ANALYSIS AND CONDITION MONITORING

SYSTEM

• VIBRATION INDICATOR –ACCELEROMETER SENSOR

• DYNAMOMETER

• THROTTLE

• KNIFE SWITCH

• LOAD INDICATOR

• TACHOMETER

• COOLING SYSTEM-RADIATOR

• BATTERY

 CONSTRUCTION AND WORKING

 ADVANTAGES

 LIMITATIONS

 LITERATURE SURVEY

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 ABSTRACT

The design and modification of Morse test rig (diesel engine) is presented in this paper. The

device consists of test bench which supports all the components to be built upon. It has 4-stroke

diesel engine which is coupled with dynamometer which has Prony brake which measures the

load, then the 4 cylinders of the diesel engine connected with 4 spark plugs which is used to

cut off the cylinders, by the help of knife switch. The engine is cooled by the help of cooling

systems. After all manometer is placed to measuring the pressure acting on a column of fluid,

ammeter is used for measure current in circuit of the Morse test, the digital speedometer is an

instrument cluster to measure speed of the running shaft. this all are connected with battery to

power the system.

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 INTRODUCTION

The test rig is designed to provide self-contained facility for teaching Internal Combustion

(spark Ignition) engine principles. The equipment is instrumented so that the following

experiments could be performed.

1). Bhp Measurement

2). Ihp Measurement (By Morse Test Arrangement)

3). Fuel Consumption Measurement

4). Air Intake Measurement

5). Measurement of Heat Rejected to Water Jacket

6). Heat Balance Test

The Engine Test Rig Facilitate to Evaluate the Following

1). Performance (BHP Measurement) from no load to full load

2). Performance at various throttle position

3). Heat Balance Sheet

4). Morse test

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Description

Two main components from main parts of the test rig. Welded steel base plate, complete with

Dynamometer, Drive shaft with safety guard, engine starting battery of 12V capacity and

cooling water arrangement. Panel board positioned over the base plate consisting of fuel

system with flow measurement by burette, air flow measurement system, and temperature

and speed indicator.

The purpose of Morse test is to obtain the approximate indicated power of a Multi cylinder

engine. It consists of running the engine against the dynamo-meter at a particular speed, cutting

out the firing of each cylinder in turn and noting the fall in BP each time while maintaining the

speed constant. When one cylinder is cut off, power developed is reduced and speed of engine

falls. Accordingly, the load on dynamo meter is adjusted so as to restore the speed of the engine.

This is done to maintain FP constant, which is considered to be independent of the load and

proportional to the engine speed. The observed difference in BP between all cylinder firing and

one cylinder cut off is the IP of the cut off cylinder. Summation of IP of the entire cylinder

would then give the IP of the engine under test.

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 COMPONENTS REQUIRED

Test bench:

Test bench is used to simulate the

performance test for the experiment of

Morse test.

Fig 1.0 Diagram of Test Bench

Diesel engine:

The Diesel engine is 1489 cc

and 1995 c, the CNG engine is

1817 cc while the LPG engine

is 1995 cc. produces Bhp @

5000 rpm (ISUZU MADE).

Fig 1.1 Diesel Engine

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Engine oil pressure gauge:

Vehicles have an oil pressure gauge in the dashboard or instrument cluster. Oil pressure is

created by a fluid flow restriction in the outlet line of the pump, not by the pump itself.

U-tube manometer and flow gauge:

A manometer is an instrument that

has a small tube in the shape of

a U that is filled with liquid to measure

pressure or flow.

A flow meter is a device used to

measure the volume or mass of a gas or

liquid.

Fig 1.2 U-tube manometer and Flow Gauge

Speed indicator:

A meter fixed to a vehicle that measures and displays its speed.

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Digital temperature indicator:

Temperature indicators are

installation instruments

which can process signals

from temperature sensors

and show them on the

display.

Fig 1.3 Digital Temperature Indicator

Digital volt meter and ammeter:

An ammeter is a measuring device used to

measure the electric current in a circuit.

A voltmeter is connected in parallel with a

device to measure its voltage, while

an ammeter is connected in series with a

device to measure its current.

Fig 1.4 Digital Volt Meter and Ammeter

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Acoustic emission analysis and condition monitoring system

Fig 1.5 Acoustic emission sensor

Elastic wave, which is formed due to sudden rearrangement of stresses in a material, is

called acoustic emission (AE). It is widely used in non-destructive testing (NDT) of materials

and structures especially in health monitoring of structures for damage detection.

Vibration indicator-sensor

Fig 1.6 Vibration indicator sensor

An accelerometer is a device that measures the vibration, or acceleration of motion of a

structure. The force caused by vibration or a change in motion (acceleration) causes the mass

to "squeeze" the piezoelectric material which produces an electrical charge that is proportional

to the force exerted upon it.

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Dynamometer:

An instrument which measures the power

output of an engine.

Fig 1.7 Dynamometer

Throttle:

A device controlling the flow of fuel or power to an engine.

Fig 1.8 Throttle

Knife switch:

A knife switch is a type of switch used to control the

flow of electricity in a circuit.

Fig 1.9 Knife switch

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Load indicator:

A safe load indicator has the capability of detecting the

angle, weight of load lifted, and ground radius of any lifting

device. It controls the lifting equipment to the level that it

tries to keep the machinery functioning as per the

manufacturer's suggested safety charts.

Fig 1.10 Load indicator

Tachometer:

An instrument which measures the working speed of an engine (especially in a road vehicle),

typically in revolutions per minute.

Cooling system-radiator:

A radiator is a type of heat exchanger. It is designed to transfer heat from the hot coolant that

flows through it to the air blown through it by the fan.

Battery -12V:

A 12V battery means that the voltage that is supplied under nominal load is

12V.12V battery can provide 12V*2A=24W.

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 CONSTRUCTION AND WORKING

As we see in above components listed and

their working, further the construction is

fabricated, for starting we need to build a

basement or rig to fix the components. After

basement the next is to fix the 4-cylinder

diesel engine from ambassador. After that

fixing the dynamometer with the help of

Fig 1.11 construction of Morse test rig

shaft coupled. It has a battery to power the voltmeter, ammeter, load gauge, tachometer,

speedometer, sensors and digital thermometer. The 4 cylinders are operated by knife switch to

cut off and on the cylinders.

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 WORKING

The purpose of Morse Test is to obtain the approximate Indicated Power of a Multi-cylinder

Engine. It consists of running the engine against a dynamometer at a particular speed, cutting

out the firing of each cylinder in turn and noting the fall in BP each time while maintaining the

speed constant.

The more test is carried out to find out the indicated power of only multi cylinder IC engines

with in the tolerance of 10%.This text is performed by measuring the break power of the engine

when all the cylinders working and then turning off the cylinders one by one by stopping fuel

in them and measuring the brake power in each case. The equations are solved to get final

indicated power of engine.

IP (n) = bp1 +bp2...... BP (n)

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 ADVANTAGES

It becomes easy to calculate the performance of the Multicylinder IC engine with the help of

Morse test. In future it may be most useful engine testing technique over any other because of

the increase in the use of high-speed vehicles and the high-speed vehicles mainly contains the

Multicylinder engines. Slow speed vehicles are going to escape very soon as every consumer

demands the high-speed vehicle. And the manufacturers also like to produce the Multicylinder

engines. In that case for the testing of Multicylinder engines, Morse test will be more useful.

In future this manual test rig can be computerized using software’s which would be operator

friendly. Modifications can be made for Morse test and also for specific Fuel consumption

which can be measure by volume difference or by weight difference. Radiator can be

eliminated with direct connection. And flow meter is required to measure mass and flow of

exhaust gas.

LIMITATIONS

Morse test is used to find a close estimate of indicated power of a multi cylinder engine. In this

test the engine is coupled to a suitable brake dynamometer and the brake power is determined

by running the engine at required speeds. Here the different engine speeds are obtained by

interrupting the fuel supply in the constituent cylinders of the engine. Therefore, in a multi

cylinder engine if fuel supply is cut off in any of the cylinders, the other cylinders continue to

run and as a result the output from the engine is obtained. But in case of a single cylinder engine

if the fuel supply is cut off no output is obtained to conduct the performance test.

Hence it is not suitable for single cylinder engine at least two cylinders is required.

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 LITERATURE REVIEW

1.1 Rakopoulos et al (2004) has conducted the review which describes a method to curtail

emissions of smoke and other pollutants from diesel engines is to enhance the oxygen supply

to their combustion chamber. This can be accomplished by enriching either the intake air

stream or the fuel stream with oxygen. Experimental studies concerning the oxygen-enrichment

of intake air, have revealed a large decrease of ignition delay, drastic decrease of soot emissions

as well as reduction of CO and HC emissions while, brake specific fuel consumption (BSFC)

remained unaffected and increasing of power output is feasible.

1.2 Subramanian and Ramesh (2005) have done an experimental Investigation on the Use of

Water Diesel Emulsion with Oxygen Enriched Air in a DI Diesel Engine. In the experiment A

single cylinder, direct injection diesel engine was run on water diesel emulsion at a constant

speed of 1500 rpm under variable load conditions. Tests indicated a considerable reduction in

smoke and NO levels. This was accompanied by an increase in brake thermal efficiency at high

outputs. HC & CO levels, ignition delay and rate of pressure rise went up. The heat release rate

in the premixed burn period was higher. When the oxygen concentration in the intake air was

enhanced in steps up to 25% along with the use of water diesel emulsion, the brake thermal

efficiency was improved and there was a further reduction in the smoke level. HC and CO

levels also dropped. NO emission went up due to increased temperature and oxygen

availability. An oxygen concentration of 24% by volume was optimal as the NO levels were

near about base diesel values. With this percentage of oxygen and water diesel emulsion as

fuel, the smoke level reduced from 5.3 BSU to 1.3 BSU at the maximum output tested. 31 HC

level was lower than diesel values and CO emission showed a similar trend at high outputs.

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1.3 Yuh-Yih Wu and David (2007) experimented to improve the performance of a small

gasoline engine, a part of oxygen is added to the intake air when the engine is operated at wide

open throttle. The combustion process can be enhanced by using an oxidant that contains a

higher proportion of oxygen than that in normal air. Engine testing is performed on a 50 cc

four-stroke, spark-ignition engine with the oxygen concentration in intake air ranging from

21% to 25% by volume. The engine torque increases with increasing oxygen concentration.

The HC and CO emissions are decreased with oxygen enrichment, but the NOx emission is

increased.

1.4 Inge Saanum et al (2008) experimented on HCCI Combustion of Natural Gas and Hydrogen

Enriched Natural Gas Combustion Control by Early Direct Injection of Diesel Oil and RME.

Natural gas and hydrogen enriched natural gas has been tested as fuels together with diesel oil

and RME in a single cylinder Scania research engine. The gas was introduced as port injection

while the diesel was introduced as early direct injection. The experiments revealed that the

combustion phasing could successfully be 33 controlled by the amount of diesel oil injected

for loads between 3.5 and 7.5 bar IMEPg at 1200 rpm. For a given combustion phasing, the

hydrogen was not found to influence the required amount of diesel noticeable. However, a large

difference between the RME and diesel oil could be seen by the necessity to inject more RME

to obtain the same combustion phasing.

1.5 Philip Yaccarino et al (2008) evaluated the effect of oxygenated fuels on CO emissions in

modern, closed-loop vehicles and characterize the 34 effects of altitude and temperature on CO

emissions. Eight vehicles equipped with closed-loop emission control systems were tested with

two oxygenated fuel blends and a base fuel (Indolene). All had Reid Yapor pressure adjusted

to 10 psi. The oxygenated blends, at 3.5% (by mass) oxygen, were 10% ethanol in Indolene

and 20% methyl tertiary-butyl ether (MTBE) in Indolene. Federal Test Procedure (FTP)

exhaust emissions were measured with all eight vehicles at standard conditions of 74°F and

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982 ft. altitude. In addition, one Throttle Body Injection (TBI) vehicle and one Port Fuel

Injection (PFI) vehicle were tested with 10% ethanol at high (4000 ft.) and low (1200 ft.)

altitudes, at 74°F and 40°F. The use of oxygenated blends in current production closed-loop

vehicles, decreases CO emissions. The reduction was less with the Port Fuel Injection system

than with the other fuel systems tested. The effect of temperature on CO emissions was more

critical than the effect of altitude.

1.6 Shi et al (2009) introduced a system in which an oxygen separation system for an engine is

disclosed. The oxygen separation system may include a cathode exposed to inlet air, an anode

configured to direct a flow of substantially pure oxygen to a combustion chamber of the engine,

and a thin film electrolyte located between the anode and the cathode. Cullen et al (2009)

introduced a system, including diagnostics, for providing oxygen enriched air so as to control

emissions of unburned hydrocarbons and carbon monoxide. The system includes the capability

of determining whether the oxygen enrichment system is providing suitable mass flow to the

engine and whether oxygen enrichment is available according to the specifications of the

enrichment device.

1.7 Usman Assad and Ming Zheng (2010) conducted tests on efficiency & Stability

Improvements of Diesel Low Temperature Combustion through Tightened Intake Oxygen

control. Diesel engines operating in the low-temperature combustion (LTC) mode generally

tend to produce very low levels of NOx and soot. However, the implementation of LTC is

challenged by the higher cycle-to-cycle variation with the heavy EGR operation and the

narrower operating corridors. Small variations in the intake charge dilution can significantly

increase the unburnt hydrocarbon and carbon monoxide emissions as well as escalate the

consecutive cyclic fluctuations of the cylinder charge. This in turn adversely affects the

robustness and efficiency of the LTC operation. However, Improvements in the promptness

and accuracy of combustion control as well as tightened control on the intake oxygen

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concentration can enhance the robustness and efficiency of the LTC operation in diesel engines.

In this work, a set of field programmable gate array (FPGA) modules was coded and interlaced

to suffice on-the-fly combustion event modulations on a cycle-by-cycle basis. The cylinder

pressure traces were analysed to provide the necessary feedback for the combustion control

algorithms. The combustion phasing was estimated using a computationally efficient Pressure

Departure Ratio Algorithm that helped to anchor the combustion within a narrow crank angle

window for the best efficiency. The load variations were minimized by regulating the indicated

mean effective pressure that helped to stabilize the LTC cycles. Engine dynamometer tests

demonstrated that such systematic and prompt control algorithms were effective to optimize

the LTC cycles for better fuel efficiency and exhaust emissions. The reported techniques were

in part to establish a model-based control strategy for robust diesel LTC operations.

1.8 Christopher John Polonowski et al (2010) has carried the Effects of Oxygenated Biofuel on

Intake Oxygen Concentration, EGR, and Performance of a 1.9L Diesel Engine. Exhaust gas

recirculation (EGR) has been employed 38 in a diesel engine to reduce NOx emissions by

diluting the fresh air charge with gases composed of primarily N2, CO2, H2O, and O2 from

the engine exhaust stream. The addition of EGR reduces the production of NOx by lowering

the peak cylinder gas temperature and reducing the concentration of O2 molecules, both of

which contribute to the NOx formation mechanism. The amount of EGR has been typically

controlled using an open loop control strategy. When oxygenated bio fuels with lower specific

energy are used, the engine control unit (ECU) will demand a higher fuel rate to maintain power

output, which can alter the volumetric flow rate of EGR. In addition, oxygenated bio fuels

affect the oxygen concentration in the intake manifold gas stream.

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 CONCLUSION

After performing the Morse test, we can conclude that it is the most useful engine test to

calculate the performance of the engine mainly the Multicylinder engines and in future the use

is going to increase and it is very easy to calculate the performance of the engine. We can

calculate the individual power developed by the engine cylinders separately and total indicated

power is also calculated. we can also calculate the brake horse power of the engine It is also

very easy to calculate the frictional losses of each cylinder. The complete design of each

component has been discussed in detail and the same details are used for fabrication. The trail

is carried on the engine and various performance parameters such as Break thermal efficiency,

mechanical.

Efficiency and heat balance at various load conditions.

1. As brake power increases fuel consumption also Increases

2. Brake specific fuel consumption decreases with Increase in brake power

3. Exhaust temperature increases as brake power Increases

4. As brake power increases both brake thermal efficiency and mechanical efficiency increases

our project might be have some its own limitations but an effort has been made to the fullest to

make it successful.

5. Other than this theoretical view, in a real-life scenario, the performance, comfort and fuel

efficiency of a car depends on many other factors starting from the aerodynamics to the

passenger weight.

6. There is no generalization that all three-cylinder ones are fuel efficient and all four-cylinder

ones are better to drive.

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