TE 422A - Automotive Engineering

FUEL
SYSTEM
Francisco, Gallenero, Gonzales BSME 4- B
History
As early as 1806, Nicéphore Niépce ran a single-cylinder riverboat
engine using a mixture of coal dust and moss spores. Then, first gasoline-
fueled, four-stroke cycle engine was built in Germany in 1876. In 1886, Carl
Benz began the first commercial production of motor vehicles with
internal combustion engines. Coal dust made a return appearance in an
early series experimental engine tests by Rudolf Diesel in 1892 before he
settled on his eponymous compression ignition design.
Over the years, changes in the design, size weight and power of
automobiles all contributed to greater gasoline use.
History
The addition of amenities such as air conditioning, power steering,
power breaks, automatic windows and automatic transmissions reduced
fuel economy. And it took several more years for the internal combustion
engine to sweep to America.
Particularly noteworthy in the United states were invented
automotive fuel system between Francis E. and Freeland O. Stanley, who
had been school teachers in Maine. For several years, the "Stanley
Steamer" was the fastest vehicle on the road because of the fuel system.
History
In 1906, the Stanley Rocket set
five world speed records in
Daytona Beach, Florida,
hitting over 127 miles per
hour. After the invention of
automotive fuel system, it
played a major role in
supplying fuel to the engine.
The function of the fuel system is
to store and supply fuel to the
cylinder chamber where it can be
mixed with air, vaporized, and
burned to produce energy.

Classification of Fuels
Fuels are classified:

crude oil based which are gasoline, diesel fuels, and any other gas
and liquid products
non crude oil based which are namely natural gas based fuels-
(compressed natural gas (CNG) and dimethyl-ether) biofuels, like
methanol, ethanol, any other alcohols and different mixtures of them;
biodiesel; biogas oil (mixtures of iso- and n-paraffins from natural
triglycerides).
Fuel Quality
The quality of the fuel mainly depends upon the following properties:

1. Volatility: Volatility of fuel has considerable effect on the performance

of the engine by affecting the following:
(i) Ease of starting the engine.
(ii) Degree of crankcase oil dilution,
(iii) Formation of vapour lock in the fuel system,
(iv) Accelerating characteristics of the engine
(v) Distribution of fuel in multi-cylinder engine.
Fuel Quality
In internal combustion engine, all the liquid fuel must be converted
into vapour fuel before burning. High speed diesel oil is most difficult to
vapourise. Vapourising temperature of high speed diesel oil is higher than
that of the petrol, hence the petrol vapourises quicker than diesel oil in
the engine cylinder. This helps in easy starting of petrol engines.

2. Calorific value: The heat liberated by combustion of a fuel is known as

calorific value or heat value of the fuel. It is expressed in kcal /kg of the
fuel. The heat value of a fuel is an important measure of its worth, since
this is the heat which enables the engine to do the work.
Fuel Quality
3. Ignition quality: Ignition quality refers to ease of burning the oil in
the combustion chamber. Octane number and cetane number are the
measures of ignition quality of the fuel.
(a) Octane number: It is a measure of knock characteristics of a fuel. The
percentage of iso-octane (C8 H18) in the reference fuel consisting of a
mixture of iso-octane and normal heptane (C7H16), when it produces the
same knocking effect as the fuel under test, is called octane number of
the fuel. Iso-octane has excellent antiknock qualities and is given a rating
of 100. Normal heptane would knock excessively and hence it is assigned
a value of zero.
Fuel Quality
(b) Cetane number: The percentage of cetane in a mixture of cetane (C16
H34) and alphamethyl naphthelene (C11 H16) that produces the same
knocking effect as the fuel under test is called cetane number of the fuel.
Diesel fuels are rated according to cetane number which is the indication
of ignition quality of the fuel. The higher the cetane number the better
the ignition quality of the diesel fuel. The commercial diesel fuels have got
cetane rating varying from 30 to 60.
Fuel Quality
Detonation (Knocking): Detonation or engine knocking refers to violent
noises, heard in an engine, giving a pinging sound during the process of
combustion. It occurs during the process of combustion of the mixture
within the cylinder after the ignition has taken place. It is an undesirable
combustion and results in sudden rise in pressure, a loss of power and
overheating of the engine. It is caused by improper combustion chamber,
high compression pressure, early ignition timing, improper fuel and
inadequate cooling arrangement.
Fuel Quality
Pre-ignition: Burning of air-fuel mixture in the combustion chamber
before the piston has reached the top dead centre is called pre-ignition.
Pre-ignition occurs when the charge is fired too far ahead of the top dead
centre of the piston due to excessive spark advance or excessive heat in
the cylinder.
Fuel System Components
Fuel systems vary from engine to engine, they have to supply fuel to
the combustion chamber taking the fuel from tank and control the
amount of fuel supplied in relation to the amount of air.
The fuel system includes all necessary auxiliary/equipment required
to make fuel available for producing the necessary heat. The equipment
required in the fuel system depends on the type of fuel used. The fuel
systen is made up of the fuel tank, pump, filter and injectors or
carburetor, and is responsible for delivering fuel to the engine as
needed.
Fuel System Components
1. Fuel Tank
The storge of fuels in liquid form.
There are many different size and shape
of fuel tanks, designed for a specific
purpose. It must be capable of storing
enough fuel to operatee the engine for
a reasonable length of time. It is located
just about anywhere in the vehicle that
meets the requirement.
Fuel System Components
2. Fuel Filter
Traps foreign material that maybe present in the fuel, preventing it
from entering the carburetor or sensitive fuel injection components. At
least one fuel filter is used in the system.
Fuel System Components
3. Fuel Pump
Used to pump the fuel from the fuel tank, via the fuel lines into the fuel
injectors, which spray the fuel into the combustion chamber- in order to
create combustion. There are two types, mechanical fuel pumps (used in
carburetors) and electronic fuel pumps (used in electronic fuel injection).

Mechanical fuel pumps: these are driven normally by auxiliary belts or

chains from the engine.
Electronic fuel pumps: controlled by the electronic fuel injection system,
these are normally more reliable and have fewer reliability issues than
their mechanical counterparts.
Fuel System Components
3. Fuel Injectors
Sprays a fine mist of fuel into the combustion chamber of each
cylinder or throttle body, depending on the design. The fuel injectors are
driven by the fuel pump and their job is to spray a fuel and air mixture
into the combustion chamber, ready to be ignited to produce power to
the driven wheels. The fuel injectors are basically a nozzle, with a valve
attached, the nozzle creates a spray of fuel and air droplets
(atomization). This can be viewed similar to that of a perfume dispenser
or deodorant can in principle, spraying a fine mist.
Fuel Supply System of Spark
Ignition Engine

The fuel supply system of spark ignition engine consists of:

(i) Fuel tank
(ii) Fuel filter
(iii) Sediment bowl
(iv) Fuel lift pump
(v) Carburettor
(vi) Fuel pipes
(vii) Inlet manifold
Fuel Supply System of Spark
Ignition Engine

In some spark ignition engine, the

fuel tank is placed above the level
of the carburettor. The fuel flows
from the fuel tank to the
carburettor under the action of
gravity. There are one or two filters
between the fuel tank and the
carburettor.
Fuel Supply System of Spark
Ignition Engine

A transparent sediment bowl is

also provided to hold the dust and
dirt of the fuel. If the tank is below
the level of the carburettor, a lift
pump is provided in between the
tank and the carburettor for
forcing fuel from the tank to the
carburettor of the engine.
Fuel Supply System of Spark
Ignition Engine

The fuel comes from the fuel tank

to the sediment bowl and then to
the lift pump. From there the fuel
goes to the carburettor through
suitable pipe. From the carburettor,
the fuel goes to the engine
cylinder, through the inlet manifold
of the engine.
Fuel Supply System of Spark
Ignition Engine

CARBURETTOR: The process of preparing an air-fuel mixture away from

the cylinders of an engine is called carburetion and the device in which
this process take place is called carburettor.

Principle of carburettor: The basic principle of all carburettor design that

when air flows over the end of a narrow tube or jet containing liquid,
some liquid is drawn into the air stream. The quantity of liquid drawn into
the air stream increases as the speed of air flow over the jet increases and
also the quantity is greater if the jet is made larger.
Fuel Supply System of Spark
Ignition Engine
Fuel Supply System of Spark
Ignition Engine

Gasoline, CNG, LNG, LPG, methanol, ethanol, and hydrogen

can be used in vehicles equipped with conventional spark-
ignition (SI) engines.
FUEL SYSTEM OF DIESEL
ENGINE
During engine operation, the fuel is supplied by gravity from fuel
tank to the primary filter where coarse impurities are removed. From the
primary filter, the fuel is drawn by fuel transfer pump and is delivered to
fuel injection pump through second fuel filter. The fuel injection pump
supplies fuel under high pressure to the injectors through high pressure
pipes. The injectors atomise the fuel and inject it into the combustion
chamber of the engine. The fuel injection pump is fed with fuel in
abundance.
FUEL SYSTEM OF DIESEL
ENGINE
The excess fuel is by-passed to the intake side of the fuel transfer
pump through a relief valve. The main components of the fuel system in
diesel engine are:
(1) fuel filter
(2) fuel lift pump
(3) fuel injection pump
(4) atomisers and
(5) high pressure pipe.
FUEL SYSTEM OF DIESEL
ENGINE
FUEL SYSTEM OF DIESEL
ENGINE
Two conditions are essential for efficient operation of fuel system: (i)
The fuel oil should be clean, free from water, suspended dirt, sand or
other foreign matter, (ii) The fuel injection pump should create proper
pressure, so that diesel fuel may be perfectly atomised by injectors and
be injected in proper time and in proper quantity in the engine cylinder.
Fuel should be filtered before filling the tank also. If these precautions are
followed, ninety per cent of diesel engine troubles are eliminated.
FUEL SYSTEM OF DIESEL
ENGINE
FUEL SYSTEM OF DIESEL
ENGINE
IGNITION SYSTEM
There are four different systems of igniting fuel: (a) Ignition by electric
spark i.e. spark ignition (b) Ignition by heat of compression i.e.
compression ignition (c) Ignition by hot tube or hot bulb and (d) Ignition
by open flame. Only the first two are important methods for modern
engines.
FUEL SYSTEM OF DIESEL
ENGINE
SPARK IGNITION
The purpose of spark ignition is to deliver a perfectly timed surge of
electricity across an open spark plug gap in each cylinder at the exact
moment so that the charge may start burning with maximum efficiency.
There are two methods in spark ignition: (a) Battery ignition and (b)
Magneto ignition.
FUEL SYSTEM OF DIESEL
ENGINE
BATTERY IGNITION
Principle of working: Battery ignition system includes two circuits: (i)
Low voltage (primary circuit) and (ii) high voltage (secondary circuit). The
low-voltage circuit consists of: (i) battery (ii) ignition switch (iii) a series
register (iv) primary winding and (v) contact breaker. All are connected in
series. The high voltage circuit consists of: (i) secondary winding (ii)
distributor rotor (iii) high voltage wiring and (iv) spark plugs.
FUEL SYSTEM OF DIESEL
ENGINE
BATTERY IGNITION
When the ignition switch is closed, current flows from the battery through the
primary winding of the ignition coil, provided contact breaker points arc closed.
They produce magnetic field around the winding. When the piston is at the end of
compression stroke, the contact breaker point opens. Thus the flow of current in
primary winding causes the magnetic field to collapse. As the field collapses, its
lines of force cut the wire turnings of the secondary winding. This increases the
voltage across the secondary winding terminals to a value of 20 to 24 thousand
volts. The high-voltage surge is delivered to the centre terminal of the distributor
cap where it is picked up by the rotor and directed to the proper spark plug. A spark
jumps the plug gap and ignites the compressed air-fuel mixture.
FUEL SYSTEM OF DIESEL
ENGINE
FUEL SYSTEM OF DIESEL
ENGINE
BATTERY IGNITION
Ignition circuit: Ignition circuit gets electric current from the battery. When
the distributor points are closed, low voltage current flows through the primary
winding of the ignition coil to the distributor terminal and through the breaker
points to the ground. A strong magnetic field is built up during this period of
operation. When the distributor points are opened, the magnetic field in the coil
starts collapsing. Thus a current is induced in the primary winding of the coil,
which tends to prevent break down of the magnetic field A very high voltage is
produced in the secondary winding due to sudden collapsing of the magnetic
field. This high voltage makes the spark to jump across the gap of the spark plug.
FUEL SYSTEM OF DIESEL
ENGINE
GOVERNOR
Governor is a mechanical device designed to control the speed of an
engine within specified limit used on tractor or stationary engines for: (i)
Maintaining a nearly constant speed of engine under different load
conditions (ii) Protecting the engine and the attached equipments against
high speeds, when the load is reduced or removed.
DIESEL ENGINE
Some list of automobiles made with diesel engines.
1.Isuzu D-Max
DIESEL ENGINE
Some list of automobiles made with diesel engines.
2. Hyundai Accent (Sedan)
DIESEL ENGINE
Some list of automobiles made with diesel engines.
3. Volkswagen Jetta
TDI (Sedan)
Fuel Additives
Automotive uses fuels to combust and produce chemical energy
which is converted into thermal energy, which is further converted into
mechanical work. To increase performance, efficiency, quality and power
of the fuel it is used fuel additives.
Fuel additives are combination of several chemicals. In modem
automotive fuels, a combination of several chemical additives is used in
order to meet the desired performance level of the fuel. These chemical
additives improve properties of fuels that cannot be obtained through
the refining processes.
Fuel Additives
There are six reasons for using additives in fuels:
To improve handling properties and stability of the fuel.
To improve combustion properties of the fuel.
To reduce emissions from fuel combustion.
To provide engine protection and cleanliness.
To increase in the economic use of the fuel.
To establish or enhance the brand image of the fuel.
Fuel Additives Types
1.Deposit Control Additives (Detergent Dispersants)
During combustion all fuels and engine oils form some deposits in the
engine. However, ideal combustion is not possible and some products of
decomposition are formed that are rich in carbon form deposits in the
engines.
Fuel Additives Types
2. Lubricity Improvers
Lubricity improvers and friction modifiers both work through the action
of film formation on the metal surfaces. However, lubricity improvers are
meant for protecting the fuel pump from wear.

3. Combustion Improvers
The combustion of the fuels can be enhanced by the use of a catalyst.
Fuel Additives Types
4. Metal Deactivators
Trace amounts of metals like copper or their soluble compounds
accelerate the oxidation of fuels by catalyzing the reaction, thereby
forming gums and deposits at a faster rate. Copper and its alloys are
extensively used in the chemical processing plants and also in the
distribution and automotive fuel systems.
 Spark Plug
Without the spark plug, there would be no internal combustion
engine. Spark plugs emit a bolt of electricity across a small gap igniting
the fuel and air mixture that puts the pistons in motion and gets your
vehicle up and running. It's a crucial job that spark plugs have because if
they're worn out they won't emit a spark and start your engine or can
even cause significant damage.
History of Spark Plug
The exact date of birth and father of the first real spark plug isn’t
known for sure – some credit Edmond Berger with the invention as far
back as 1839 but it was unpatented and definitely. In 1860 Étienne Lenoir
used an electric spark plug in his gas engine, the first internal combustion
piston engine. Lenoir is generally credited with the invention of the spark
plug.
Early patents for spark plugs included those by Nikola Tesla (in U.S.
Patent 609,250 for an ignition timing system, 1898), Frederick Richard
Simms (GB 24859/1898, 1898) and Robert Bosch (GB 26907/1898).
History of Spark Plug
Only the invention of the first commercially viable high-voltage spark
plug as part of a magneto-based ignition system by Robert Bosch's
engineer Gottlob Honold in 1902 made possible the development of the
spark-ignition engine. Subsequent manufacturing improvements can be
credited to Albert Champion, to the Lodge brothers, sons of Sir Oliver
Lodge, who developed and manufactured their father's idea and also to
Kenelm Lee Guinness, of the Guinness brewing family, who developed
the KLG brand. Helen Blair Bartlett played a vital role in making the
insulator in 1930.
Evolution of Spark Plug
Before the spark plug came into use, manufacturers relied on other sources,
such as car batteries, to generate ignition. However, tapping car batteries seriously
depleted power and in some cases caused fires. The German inventor, Robert
Bosch, developed the first functioning spark plug in 1901, then received a patent
the following year.
Today, spark plugs are a necessary part of the internal combustion, or gas
engine, as they supply ignition for the combustion required to start these vehicles.
On ignition, the air-fuel mixture travels to the engine cylinder where it’s ignited by
the spark created by the spark plug. This is precisely what so many people before
Bosch attempted, but only one individual saw it to a successful conclusion.
Evolution of Spark Plug
Spark Plug Materials
Most spark plugs feature a copper-core center electrode. Copper
is an excellent conductor of electricity and transfers heat faster.
However, copper is soft and has a low melting point so manufacturers
cover it with metals like nickel alloy, platinum and iridium to reduce the
wear caused by high voltage spark. To optimize performance, spark
plugs may have a platinum or iridium tip.
Spark Plug Materials
1.Copper
While almost all spark plugs feature a copper core, many people
refer to the common spark plug as a “copper” spark plug. A standard
spark plug typically features a nickel-alloy outer material fused to the
copper-core electrodes.
Copper spark plugs run cooler and provide more power in
performance driving situations. They are often installed as original
equipment in turbocharged engines and engines with higher
compression ratios. Copper spark plugs are also often used in older (pre-
1980s) vehicles with a distributor-based ignition system.
Spark Plug Materials
2. Platinum
Platinum is much harder than nickel alloy, slowing erosion much longer
than a conventional spark plug. This longevity is a key advantage of platinum
spark plugs. Another advantage of platinum spark plugs is that they run a
little hotter, which burns deposits off the spark plug more efficiently and
helps prevent fouling. This enables the spark plug to wear better.
Platinum spark plugs come in two varieties - single and double platinum. A
single platinum plug is much like a copper spark plug with a platinum disc
welded to the center electrode; a double platinum spark plug has a platinum
disc on both the center and side electrodes.
Spark Plug Materials
3. Iridium
Iridium is said to be six times harder and eight times stronger than
platinum with a 700° higher melting point. Iridium spark plugs have
extremely fine electrodes while retaining excellent wear characteristics.
Thanks to this strength, iridium spark plugs can last up to 25% longer than
comparable platinum spark plugs.
Iridium spark plugs feature a fine wire center electrode that is designed
to conduct electrical energy better and increase firing efficiency. There is a
price for this precious metal; iridium spark plugs are typically more expensive
than copper and platinum spark plugs.
Fuel System Failures
1. The Engine is Sputtering
This often happens the faster you drive. You will hear and feel and
engine as it sputters and struggles to produce power smoothly. This means
there is not a constant stream of fuel being pumped into the engine.

3. Fuel Tank Whining Noise

Any unusual sound in your vehicle is cause for concern. A failing fuel pump
is often heard with a loud whining sound that comes from the fuel tank. It
usually means the vehicle is low on fuel, has contaminated fuel in the
system or the fuel pump isn’t working correctly.
Fuel System Failures
4. Lack of Power
A fuel system issue might also show itself when you are driving the car
under stressful conditions (high temperatures, high altitude, steep uphill
climbs, or carrying an uphill load). The engine may sputter or stall out
completely. It may just lose a lot of power when you need it most, and that’s
often an indicator of a fuel system problem.

5. Loss of Gas Mileage

If you keep diligent track of your gas mileage and notice you aren’t getting
the MPG you are used to, a problem within the fuel system is one of
several issues that could be causing a loss in fuel efficiency.
Fuel System Failures
6. The Car is Surging
Sometimes, a fuel system problem will cause the car to surge while it
is driving. It won’t maintain consistent speed and you’ll feel it struggling
as you press the gas pedal.

7. Fuel is Leaking
A sure sign of a fuel system failure is if you notice that any gasoline or
diesel fuel is leaking from under your vehicle. If you see a fuel leak, don't
drive the car and get it to an auto shop as soon as possible!
Future of Fuels
Article 1:
With gasoline prices hitting uncomfortable highs, consumers
increasingly are looking toward non-gasoline-powered vehicles. But
what ultimately will power those vehicles is far from clear.
Inside the cabin and under the hood, these vehicles will be filled with
semiconductors. Yet what the energy source is for those semiconductors
is the subject of ongoing debate. It could be batteries, hydrogen fuel
cells, or solar, or some combination of any of those. Those decisions may
vary by region, by regulations, and by total cost of ownership.
Future of Fuels

“A lot of people assume the world’s going all-electric, which may or

may not be true,” said David Fritz, vice president of hybrid-physical and
virtual systems, automotive, and mil/aero at Siemens Digital Industries
Software. “But most of the energy in the United States currently today is
generated by burning coal and fossil fuels, so electric cars don’t drive for
free. That energy is generated somewhere to charge up the battery, and
that’s expensive pollution-wise.
Future of Fuels
We’re a long way from 100% renewable energy. Something else is likely to
happen before we get to all-electric, and that easily could be hydrogen. We’re
going to have hydrogen hybrids. Generating hydrogen is pretty cheap. It takes a
lot less energy. You put positive and negative poles into water, then you get
hydrogen and oxygen out. You save the hydrogen, and find a way to distribute
it like propane. Then, as the electric charge goes down, the hydrogen actually
runs a small engine with an alternator that charges you back up. So a hydrogen
hybrid may happen in the future.”

https://semiengineering.com/which-fuel-will-drive-next-generation-autos/
Future of Fuels
Article 2:
Made exclusively with renewable power, green hydrogen is emerging as a
promising alternative to polluting fossil fuels. But this much-touted fuel of
the future may have a pitfall.
Some scientists say the lack of data on leaks and the potential harm they
could cause is a blind spot for the nascent industry.
At least four studies published this year say hydrogen loses its
environmental edge when it seeps into the atmosphere. This is because it
reduces the concentration of molecules that destroy the greenhouse gases
already there, potentially contributing to global warming.
Future of Fuels
If even 10 per cent leaks during its production, transportation, storage or
use, the benefits of using green hydrogen over fossil fuels would be
completely wiped out, two scientists told Reuters.
They say the lack of technology for monitoring hydrogen leaks means there
is a data gap, and more research is needed to calculate its net impact on
global warming before final investment decisions are taken.
Yet governments and energy companies are lining up big bets on green
hydrogen.

https://www.euronews.com/green/2022/12/29/