1

Mixture Formation in IC Engine

Chapter 5
 Mixture formation in spark ignition engine
2
 Mixture formation in spark ignition engine
3
 Mixture formation in Gasoline engine
4
 Mixture formation technology adaptation in SI engine
5

Stringent mandates governing exhaust emissions and fuel economy have led to a
total eclipse of the carburetor in favor of fuel injection.
 Mixture formation techniques in SI
6

External mixture
formation

Internal mixture
formation
 Mixture formation in SI Engine- Carburetor
7

 Carburetor is mechanical devices that use pressure differential to meter

and vaporize fuel for engine demands

 Modern carburetor contains 6 circuits designed to deliver air/fuel mixture

for different operating modes/loads

 Carburetor mounted on top of intake manifold, and receives fuel from

mechanical pump driven by camshaft
 Mixture formation in SI Engine- Carburetor
8

Carburettors are still found in small engines and in older or specialized

automobiles such as ;Racing cars.

However , most cars built since the early 1980s use fuel injection instead of
carburetion.
 Various Load on Engine requires range of mixture
9

 Various Load on Engine requires range of mixture to be

supplied by carburretion

 Idling/starting : Engine runs with out load. Produce power only to

overcome friction between the parts. Rich mixture is required to sustain
combustion.

 Normal power/Cruising /Medium Load: Engine runs for most of the

period. Therefore, fuel economy is maintained. Low fuel consumption for
maximum economy. Requires a lean mixture.

 Maximum Power/Acceleration : Overtaking a vehicle (short period) or

climbing up a hill (extra load). Requires a rich mixture
 Simple carburetor-Updraft
10

 Components of a simple carburettor

1. A float chamber with a float and
needle valve to store fuel and to
adjust its level.
2. A round cylinder with a venturi for
atomization of fuel.
3. Fuel nozzle to atomize and produce
a spray of fuel
4. A throttle valve to supply varying
quantity of the mixture at different
load conditions.
5. A choke valve to control the air
supply in order to provide rich or a
lean mixture
 Simple carburetor-Downdraft
11

Bernoulli’s Equation
𝑃 + 1 2𝜌 𝑉 2 +ρgh =Constant
P1​−P2​=1/2​ρ(v22​−v12​)
Since V2>V1​, then
P2<P1​

Continuity Equation
𝐴1 𝑉1 = 𝐴2 𝑉2
V2​=V1​⋅A1​/A2​
 Mixture formation in SI Engine- Carburetor
12

The process of carburetion is influenced by

 The velocity of incoming air
The velocity of the air stream at the point where the fuel is injected has to be increased.

 The vaporization characteristics of the fuel

Will require a volatile fuel for quick evaporation and mixing with air

 The temperature of the incoming air

 Higher atmospheric air temperature increases the vaporization of fuel and produces
a more homogeneous mixture.

 The design of the carburettor

 Proper design of carburetor elements ensures the supply of desired composition of
the mixture under different operating conditions of the engine.
 Mixture formation in SI Engine - EFI injection
13

 Problems with carburetor icing and fire hazards had lent special impetus to fuel-
injection development work for the aeronautics field.

 Bosch started research on gasoline injection pumps in 1912, the first aircraft
engine featuring Bosch fuel injection, a 1,200-hp unit, entered series production
in 1937

 In 1967 fuel injection took a giant step forward: The first electronic injection
system: the intake-pressure controlled D-Jetronic!

 By the end of 1997, around 64 million Bosch engine-management systems had

been installed in countless types of vehicles since the introduction of the D-
Jetronic in 1967.

 In 1997 alone, the figure was 4.2 million, comprised of 1 million throttle-body
injection (TBI) systems and 3.2 million multipoint fuel injection (MPI) systems.
 Functional requirements of injection system
14

 Beside the central task of supplying fuel to the combustion process,

there are several competing objectives such as:
 Power output
 Fuel efficiency
 Emissions performance
 Ability to accommodate alternative fuels
 Reliability
 Driveability and smooth operation
 Initial cost
 Maintenance cost
 Diagnostic capability
 Range of environmental operation
 Mixture formation in SI Engine- Single point EFI injection
15

The point or location of fuel injection is one way to classify a gasoline injection
system.
 A single point injection system, also called throttle body injection(TBI), has the
injector nozzles in a throttle body assembly on top of the engine.
 Fuel is sprayed in to the top centre of the intake manifold.

Single Point Fuel injection system

1. Fuel
2. Air
3. Throttle valve
4. Intake manifold
5. Injector
6. Engine
 Single point EFI Systems - (Throttle Body Injection - TBI)
16

Single Point Fuel Injection (Throttle Body Injection - TBI)

Injector located inside
throttle body, sits on top
of inlet manifold. Air in

Fuel in
Injector sprays fuel from
Injector
above throttle valve.
Throttle body

ECU controls injector

opening.
Throttle valve

Inlet manifold
 Mixture formation in SI Engine- Multi point EFI Injection
17
 Multipoint EFI Systems
18

Multipoint Fuel Injection

Injector located in each branch
of inlet manifold, below throttle
valve. Air in

Throttle valve
Injectors spray fuel Injectors x
directly into each port. 4, x6, x8
Fuel in etc.
ECU controls opening
of injectors.

Inlet manifold
19
 EFI Multi port Injection System
20

Injector is pressed into the runner(Port) in the intake manifold.

Injector sprays towards an engine intake valve.

Each cylinder has it’s own injector

21
22
 Gasoline Direct Injection-EFI
23

 Gasoline direct injection is a variant of fuel injection employed in

modern two- and four- stroke petrol engines.

 The gasoline is highly pressurized, and injected via a common rail fuel
line directly into the combustion chamber of each cylinder, as opposed to
conventional multi-point fuel injection that happens in the intake manifold

 When the driver turns the ignition key on, the power train control module
(PCM) energizes a relay that supplies voltage to the fuel pump.

 Fuel is drawn into the pump through an inlet tube and mesh filter sock

 The fuel then exits the pump through a one-way check valve and is
pushed toward the engine through the fuel line and filter.
24
 Gasoline Direct Injection System-EFI
25

EFI Direct fuel Injection System

Injectors are pressed into the combustion chamber and spray fuel directly into
the combustion chamber.
 Gasoline Direct Injection-EFI
26

 The fuel filter traps any rust, dirt or other solid contaminants that may have
passed through the pump to prevent such particles from clogging the fuel
injectors.

 The fuel then flows to the fuel supply rail on the engine and is goes to the
individual fuel injectors.

 A fuel pressure regulator on the fuel rail maintains fuel pressure, and re
circulates excess fuel back to the tank.

 The fuel pump runs continuously once the engine starts, and continues to run
as long as the engine is running and the ignition key is on.

 If the engine stalls, the (PCM) will detect the loss of the RPM signal and turn
the pump off.
 Gasoline Direct Injection-EFI
27
 Stratified Versus- homogenous charge operation-EFI
28

 With stratified-charge operation, only the mixture directly adjacent to the spark
plug needs to be ignitable.

 The remainder of the air-fuel charge in the combustion chamber can consist
solely of fresh and residual gases, without unburned fuel.

 This strategy furnishes an extremely lean overall mixture for idling and part-
throttle operation, with equal reductions in fuel consumption.

 Homogenous operation reflects the conditions encountered in external mixture

formation by employing uniform consistency for the entire air-fuel charge
throughout the combustion chamber.

 Under these conditions all of the fresh air within the chamber participates in the
combustion process.

 This operational mode is employed for WOT operation

 Gasoline Direct Injection-EFI
29

 Advantage of DFI-EFI system is

 Gasoline Direct Injection-EFI
30

 Thermodynamic levers to increase thermal efficiency

 Gasoline Direct Injection-EFI
31
 Advantage of fuel injection over carburetor
32

 Uses pressure from an electric fuel pump to spray fuel into the engine
intake manifold.

 Correct air-fuel mixture for specific operating conditions.

 Improved atomization - Fuel is forced into the intake manifold under

pressure that helps break fuel droplets into a fine mist.

 Better fuel distribution - Equal flow of fuel vapors into each cylinder.

 Smoother idle - Lean fuel mixture can be used without rough idle
because of better fuel distribution
 Advantage of fuel injection over carburetor
33

• Lower emissions – Lean, efficient air-fuel mixture

reduces exhaust pollution.

• Better cold weather drivability - Injection provides

better control of mixture enrichment than a carburetor.

• Increased engine power - Precise metering of fuel to

each cylinder and increased air flow can result in more
horsepower output.

• Fewer parts - Simpler, latest model electronic fuel

injection system have fewer parts than modern
computer-controlled carburetors.
 Fuel Injection System Components
34

 Fuel tank

 Electric fuel pump

 Fuel filter

 Electronic control unit

 Common rail and Pressure sensor

 Electronic Injectors

 fuel line
 Fuel tank
35

 Fuel tank is safe container for flammable liquids in which the fuel is
stored and propelled (fuel pump) or released (pressurized gas) into
an engine.

 A fuel tank must allow or provide the following:

 Safe fuel storage, no sparks

 No leakage and limit evaporative emissions

 Gauging (the remaining quantity of fuel in the tank must be measured or

evaluated)

 Venting (if over-pressure is not allowed, the fuel vapors must be

managed through valves)

 Feeding of the engine (through a pump)

 Electric fuel pump
36

 An electric fuel pump is used on engines with fuel injection to pump fuel from
the tank to the injectors.

 Electrical fuel pump must deliver the fuel under high pressure (typically 2 to
6 bar depending on the application) so the injectors can spray the fuel into
the engine.

 Electric fuel pumps are usually mounted inside the fuel tank

 Some vehicles may even have two fuel pumps (a transfer pump inside the
tank, and a main fuel pump outside).

 Electric fuel pumps come in a variety of designs. Some older applications

use a positive displacement "roller cell" pump and modern vehicle uses
“turbine style fuel pump”
 Electric fuel pump
37

 A “turbine" style fuel pump has an impeller ring attached to the motor.
 A “turbine" style fuel pump is not a positive-displacement pump, so it produces
no pulsations, runs very smoothly and quietly.
 It is also less complicated to manufacture and is very durable.
 Fuel filter
38

 The fuel filter is the fuel system's primary line of defense against dirt,
debris and small particles of rust that flake off the inside of the fuel
tank .
 Many filters for fuel injected engines trap particles as small as 10 to 40
microns in size.
 Fuel filter normally made into cartridges containing a filter paper.
 Exploded view diagram of injector
39

Compression Injector Housing

Multiport injector Bushing

Nose Cover Needle Valve Valve Spring

 The electronic fuel injector is normally closed, and opens to inject

pressurized fuel as long as electricity is applied to the injector's solenoid
coil.
 When the injector is turned on, it opens, spraying atomized fuel at the
combustion chamber .
 Depending on engine operating condition ,injection quantity will vary .
 Electronic Injectors
40

 The injectors can survive the excessive temperature and pressure of

combustion by using the fuel that passes through it as a coolant

Fuel
 Fuel Injectors
41

 The fuel injectors are typically ECU-controlled. When the fuel injectors are
electrically activated a hydraulic valve (consisting of a nozzle and plunger) is
mechanically or hydraulically opened and fuel is sprayed into the cylinders at the
desired pressure.

 If the accumulator, pump, and plunger are sized properly, the injection pressure
and rate will be the same for each of the multiple injection events.
 Fuel line hoses
42

 Fuel line hoses carry gasoline from the tank to the fuel pump, to the fuel
filter, and to the fuel injection system.

 Much of the fuel lines are rigid tube, sections of it are made of rubber hose,
which absorb engine and road vibrations.

 There are two basic types of fuel hose: Fuel and oil hoses that meet the SAE
30R7 standard, and fuel injection hose that meets the requirements of SAE
30R9.
 Type of injectors
43
 Pressure regulator and electric fuel pump
44

Pressure Regulator controls the amount

of pressure that enters the injector and any Electrical Fuel Pump draws fuel from
extra fuel is returned to the fuel tank. tank and forces it into the regulator.
 Fuel System Diagrams and Schematics

Fuel System Block Diagrams - 1 System and

subsystem
Each block represents a system. blocks

Lines represent connections

between systems.

Arrows represent direction of flow.

Connection lines
Direction of
information
flow/control
45
 Fuel System Block Diagrams - 2 System and
Connection lines component
Each block represents a blocks
component.

Lines represent connections

between systems.

Arrows represent direction

of flow.

Direction of
information
flow/control

46
 Electronic control unit- ECU
47

 In automotive electronics, electronic control unit (ECU) is a generic term

for any embedded system that controls one or more of the electrical
systems or subsystems in a motor vehicle.

 An engine control unit (ECU), also known as power-train control

module (PCM), or engine control module (ECM) is a type of electronic
control unit that determines the amount of fuel, ignition timing and other
parameters an internal combustion engine needs to keep running.

 ECU control engine activities by reading values from multidimensional

maps which contain values calculated by sensor devices monitoring the
engine.
 Working of ECU
48

Control of fuel injection

• The ECU will inject fuel according to how much air is passing into the
engine.

• If the engine has not warmed up yet, more fuel will be injected .

Control of ignition timing

• An ECU can adjust the exact timing of the spark (called ignition timing) to
provide better power and economy.

• The engine RPM is monitored by the crankshaft position sensor which plays
a primary role in the engine timing functions for fuel injection, spark
events, and valve timing.
 Working of ECU
49

Control of idle speed

• Most engine systems have idle speed control built into the ECU.
• Idle speed is controlled by a programmable throttle stop or an idle air
bypass control stepper motor.
 Common rail and Pressure sensor
50

The term "common rail" refers to the fact that all of the fuel injectors are
supplied by a common fuel rail which is nothing more than a pressure
accumulator where the fuel is stored at high pressure. This accumulator
supplies multiple fuel injectors with high pressure fuel.
 Fuel Injection System
51

Electronic Fuel Injection uses various engine sensors and control module to regulate the
opening and closing of injector valve.

•Air induction system

•Fuel delivery system

•Sensor system
•Computer control system
 Sensor Systems
52

Sensors are electrical devices that change resistance or voltage with change in
condition such as temperature, pressure and position.
Monitors engine operating condition and reports this information to ECM
 Engine Sensors
53

 MAP sensor D- Type EFI

 Air flow meter L-Type EFI
 Coolant temperature sensor
 Intake air temperature sensor
 Oxygen sensor
 Throttle position sensor
 Crank shaft position sensor
 Cam shaft Position Sensor
 Knock sensor
 Vehicle speed sensors …
 Engine Sensors
54
 Manifold Absolute Pressure Sensor (MAP)
55

Measures the pressure, or vacuum inside

the engine intake manifold.

Manifold pressure directly related to

Engine load

High pressure (low intake vacuum) =

High load = Rich mixture  The manifold absolute pressure
sensor (some times referred to as
vacuum sensor ) is used on engines
Low pressure (high intake vacuum) = equipped with D type EFI.
Little load = Lean mixture
 It measures intake air volume by
monitoring changes in manifold
Computer senses the change in resistance absolute pressure ,as a function of
and alters the fuel mixture. engine load
 Oxygen Sensor
56

Oxygen Sensor measures the oxygen content in engine exhaust.

Mounted on the exhaust system before the

catalytic converter.

Voltage out-put of O2 sensor changes with

the change in oxygen content of exhaust.

Lean mixture decreases the voltage.

Rich mixture increases the voltage.

Signal is sent to ECM and the ECM changes the time that an injector is open or close.
 Oxygen Sensor
57

 Oxygen sensors on EFI engine are used to provide air/air fuel ratio

 Feed back information from oxygen sensor to the ECU is used to constantly adjust
the air-fuel ratio to stoichiometry during warm idle and cruise operating conditions.

 When the ECU is using information from oxygen sensor to adjust Air/fuel ratio ,the
system is said to be operating in closed loop
 Oxygen Sensor
58

 The efficiency of oxygen sensor is dependent up on its operating Temperature.

 Oxygen sensor will only generate an accurate signal when it has reached its
minimum operating temperature of 398 degree centigrade

 Oxygen sensor is typically located in the exhaust stream at manifold collector.

 This location is close enough to the exhaust valve to maintain adequate

operating temperature under most driving conditions and allows a
representative exhaust sample for all cylinders.
 Temperature Sensor
59

 The temperature sensor measure the Engine coolant Temperature (ECT),

Intake Air Temperature Sensor (IAT), and Exhaust recirculation gases (EGR),
etc
 A thermistor is a type of resistor whose resistance varies significantly with
temperature more than in standard resistors.
 Engine Temperature Sensor
60

Engine Temperature Sensor

Monitors the operating temperature of the engine.

Exposed to engine coolant.

Engine cold = Low Resistance

Engine Hot = High Resistance

 Engine Coolant Temperature Sensor
61

 The water temperature sensor is required because fuel vaporization is

less efficient when the engine is cold; internal engine friction is also
Higher during cold operation increasing operating load.

 The ECM needs to adjust a Varity of systems based on temperature.

 The ECT sensor is critical to many ECM functions such as fuel injection,
ignition timing, variable valve timing, transmission shifting

 It is critical for proper operation of these systems that the engine reach
operating temperature and the temperature is accurately signalled to
ECM.
 Engine Coolant Temperature Sensor
62

 For example for the proper amount of fuel to be injected the ECM must
know the correct engine temperature.

 The Engine Coolant Temperature Sensor is typically located near the

cylinder head Water outlet.

 It monitors engine coolant temperature by means of an internally

mounted thermistor.

 The thermistor has negative temperature coefficient(NTC) so its resistance

value decrease as coolant temperature rises.
 Mass Air Flow Sensor (MAF)
63

Mass Air Flow Sensor (MAF)

•Measures the amount of outside air entering the engine.

•Contains an air flap or door that operates a variable resistor.

•Helps computer to determine how much fuel is needed.

 Inlet Air Temperature Sensor
64

Inlet Air Temperature Sensor

Measures the temperature of air entering the engine.

Cold air (more dense) = More fuel for proper AF ratio.

The intake air temperature detects the temperature of the incoming air stream.

On vehicles equipped with MAP sensor ,the IAT is located in an air passage
 Position Sensors
65

 In many applications , the ECM needs to know the position of mechanical

components .

 The throttle position sensor (TPS) indicates position of the throttle valve

 Accelerator pedal position sensor (APP) indicates the position of accelerator

pedal.

 A wiper arm inside the sensor is mechanically connected to a moving part,

A wiper arm is connected to resistor, as the wiper arm moves on the resistor
the signal voltage output changes.

 At the point of contact, the available voltage is the signal voltage and this
indicates the position.
 Throttle Position Sensors (TPS)
66

 The TPS is mounted on Throttle body and converts the throttle valve angle in
to an electrical signal. As the throttle opens the signal voltage increases.

 The ECM uses throttle valve position information to know;

1. Engine mode :Idle ,part throttle, wide open throttle

2. Switch off AC and emission controls at wide open throttle (WOT)

3. Air Fuel ratio correction

4. Power increase correction

5. Fuel cut control

 Throttle Position Sensor (TPS)
67

Variable resister connected to the

throttle plate.
Change in throttle angle = change in resistance.
Based on the resistance, ECM richens or leans the
mixture.
The basic TPS requires three wires. Five volt is
supplied to TPS from VC terminal of the ECM

The TPS voltage signal is to VTA terminal. A ground

wire from TPS to the E2 terminal of the ECM
Completes the circuit
 Speed Sensor
68

 Speed sensors provide information to ECM about the speed of the

component, and the change in speed of the component.

 The following sensors provide this data

i. Camshaft position sensor (also called G sensors)

ii. Crank shaft position sensor (also called NE sensor)

iii. Vehicle speed sensor

 Position Sensors
69

As the wiper arm moves the signal voltage out put

changes.

From this voltage the ECM is able to determine

position
 Crankshaft Position Sensor
70

Crankshaft Position Sensor

Detects engine speed.

Changes injector timing and duration.

Higher engine speed = More fuel

 Engine Knock Sensor
71
 Engine Knock Sensor
72