Design and Investigation of a four stroke Camless Engines using Programmatically controlled actuators
This project focuses on Increasing the Efficiency and Power production of Conventional four stroke Engines. In conventional engines, a camshaft is used to control the flow of air fuel mixture into and out of the combustion cylinder, which have a disadvantage that the quantity of air fuel mixture can
2025-06-28 16:26:25 - Adil Khan
Design and Investigation of a four stroke Camless Engines using Programmatically controlled actuators
Project Area of Specialization Mechanical EngineeringProject SummaryThis project focuses on Increasing the Efficiency and Power production of Conventional four stroke Engines. In conventional engines, a camshaft is used to control the flow of air fuel mixture into and out of the combustion cylinder, which have a disadvantage that the quantity of air fuel mixture can’t be controlled since the camshaft lift is fixed. So, the aim of the project is to gain control over the valve actuation. This goal is achieved by implementing a Programmable Actuator system on the engine to gain greater control over the combustion process in the engine, which allows for better optimization of combustion parameters to make sure that proper time is given for the air-fuel mixture for combustion at higher rpms and lower rpms. By ensuring complete combustion at all rpms of the engine operation, Unburnt fuel and Toxic Exhaust gas emissions such as Carbon Monoxide Emissions can be decreased while preserving Fuel usage thereby increasing Fuel Efficiency and also maximizing the power production at each rpms. Thus, through the use of Modern Programmable Controllers, a conventional Engine is made better, efficient and cleaner.This project focuses on Increasing the Efficiency and Power production of Conventional four stroke Engines. In conventional engines, a camshaft is used to control the flow of air fuel mixture into and out of the combustion cylinder, which have a disadvantage that the quantity of air fuel mixture can’t be controlled since the camshaft lift is fixed. So, the aim of the project is to gain control over the valve actuation. This goal is achieved by implementing a Programmable Actuator system on the engine to gain greater control over the combustion process in the engine, which allows for better optimization of combustion parameters to make sure that proper time is given for the air-fuel mixture for combustion at higher rpms and lower rpms. By ensuring complete combustion at all rpms of the engine operation, Unburnt fuel and Toxic Exhaust gas emissions such as Carbon Monoxide Emissions can be decreased while preserving Fuel usage thereby increasing Fuel Efficiency and also maximizing the power production at each rpms. Thus, through the use of Modern Programmable Controllers, a conventional Engine is made better, efficient and cleaner.
Project ObjectivesThe main Objectives are:
- To implement and evaluate a camless 4-stroke engine using programmatically controlled electronic valve actuators
- To create a functional control system for the electronic valve actuator
- To achieve better fuel efficiency and engine power
The main objective is to implement an electronically controlled valve configuration in place of camshaft of the Bike engine. The first step to achieve this will be the acquisition of the engine and formation of test bench. The test bench will include a throttle body with a butterfly valve to control the throttle of the engine. It will also include a data acquisition system that will measure different engine parameters of the engine such as the rpm and brake power as well as fuel consumption. The next step includes the determination of the control of spark timing to see if it can be adjusted as at higher rpms as early spark timing, theoretically is beneficial for the complete combustion. The measurements of the engine valve head will be taken for the creation of the design of the actuator mounts on SOLIDWORKS prior to their fabrication so that the actuators can sit properly over the valves.
The next steps involve the theoretical simulation of the thermodynamic cycle of the engine to find optimum valve timings and durations depending upon the rpm of the operation of the engine. This data will be required to tune the ECU that will control the actuations of the valve. A number of configurations exists that use electro-mechanical implementations (pneumatic, hydraulic and electromagnetic) for the actuation of valves. Pneumatic actuators need a considerable amount of setup including compressing and master cylinder while hydraulic actuators are slow, electromagnetic actuators are highly reliable and fast processing therefore it is considered better for this implementation. For selecting the correct solenoid actuator for our engine, the minimum force required to operate the valve must be found first by measuring the stiffness of the valve spring and the lift.
The design of the ECU will be done by implementing the logic on a microcontroller. Variety of microcontrollers exists, the popular ones being Arduino and Stm32. Depending upon the availability the respective microcontroller will be used and the actuation timing and duration found in the simulation phase is coded into the microcontroller.
After this final assembly and optimization of the design is done. Multiple iterations might be needed for adequate assembly and performance. The performance parameters are measured from the same test bench and these are then compared with the initial values.
Benefits of the ProjectBy implementing free valve technology to the engine. Following benefits could be obtained.
- Flexible range of rpm of the actuator.
- More power and efficiency.
- Reduction in emissions.
- Reduction in size (weight).
- No camshaft meaning fewer moving parts and ultimately less maintenance.
This project could inspire bike companies to opt the free valve technology keeping in view the benefits.
Technical Details of Final DeliverableThe Final Deliverable of the Project will be a modified 4 stroke engine, which will have a custom mechanism to control the inlet and exhaust valves instead of the conventional cam-follower mechanism. The fuel inlet and outlet will be controlled through a microcontroller based ECU that will change the valve Actuation Parameters for every rpm. These parameters will be optimized and determined through a simulation prior and will be used by ECU in the valve actuation operation.
Final Deliverable of the Project Hardware SystemCore Industry TransportationOther Industries Energy Core Technology Clean TechOther TechnologiesSustainable Development Goals Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 77000 | |||
| 4 – Stroke Engine (CD70) | Equipment | 1 | 30000 | 30000 |
| RPM sensor/meter | Equipment | 1 | 2000 | 2000 |
| Test Bench including throttle body | Equipment | 1 | 4000 | 4000 |
| Manufacturing costs | Miscellaneous | 1 | 6500 | 6500 |
| Power Supply | Equipment | 1 | 2000 | 2000 |
| Battery 12V | Equipment | 1 | 2000 | 2000 |
| Actuators | Equipment | 2 | 7500 | 15000 |
| Microcontroller board | Equipment | 1 | 3000 | 3000 |
| Electrical connections | Equipment | 1 | 500 | 500 |
| Tools | Equipment | 1 | 5000 | 5000 |
| Virtual Oscilloscope LHT00SU1 | Equipment | 1 | 5000 | 5000 |
| Transportation and overheads | Miscellaneous | 1 | 2000 | 2000 |