Development of an Experimental Testing Rig and Data Sheets for the Analysis of Performance Parameters of IC Engine

Project Title

Development of an Experimental Testing Rig and Data Sheets for the Analysis of Performance Parameters of IC Engine

Project Area of Specialization Mechanical EngineeringProject Summary

Project Summary:

The title of this project is “development of an experimental testing rig and data sheets for the analysis of performance Parameters of IC engine”. The main objective of this project is to determine the unknown variables of engine for calculating performance and mapping them in excel sheets for comparison with manufacturer’s data. The parts are literature review, engine selection, development of test bench, testing and lab experiments development. A clear idea of what an engine is to what variables are involved in engine including geometric, operating, performance are studied in literature review. This project will help students to understand the key concepts of engine testing and also give them an insight to the modern industry, as to what the current industry is utilizing to tackle the engine performance problems and their solutions.

Project Objectives

Project Objectives:

• Selection of a suitable engine analyzer for the testing of engine.
• Testing the engine and obtaining values of the variables (Variables include performance parameter).
• Development of experimental data sheets for the IC engine.
• Development of experimental engine testing facility for the IC Engine lab.

The main objective of this project is to design a testing facility for the IC Engine lab present in Air University. Testing facility is actually a testing rig designed to test the performance of an engine. This can help students in determining the faults in the engine and how to tackle the low performance ratings of the car.

The low performance means that the car is not performing as it should be and some variable is affecting the outward performance of the car. This testing rig will help determine the variables and when test data sheets are developed, it can determine the cycle parameters of the engine. For making data sheets Microsoft Excel will be utilized.

Project Implementation Method

Project Implementation Method:

The project timeline is as follows

• The first was Literature Review, the first part deals with what variables we are trying to find. This part deals with that, to study different variables required down the road and this enables us to find what variables can be achieved from the engine analyzer, what variables are not achieved and what the possible ways of finding them are. To utilize formulas and plug them in Excel sheets to determine the rest of the parameters.
• After the completion of the Literature Review comes the Market survey. The market survey will give us the answer to the following

1. What engine can be utilized in the project keeping in mind the budget?
2. Which Engine analyzer will be used in the project?
3. How much will be the cost of the Engine, Analyzer and the whole project?

The market survey was done to answer the above mentioned points and after this we were able to find the estimation of the project cost and the required components.

• After market survey, initially the objective was to purchase the engine but due to the Covid-19 restrictions this was not feasible at that time. Then the objective was to Visit Workshops and get a clear idea of what technology is being utilized in the industry currently and to gain an insight of how the engine analyzer is used in the workshops.
• After this the Test Data Sheets were developed, These were not the final data sheets but an insight of what the final data sheets will look like after the completion of engine testing.
• Up to this point the semester has ended, the next problem at hand is the Purchasing of engine from the market, along with the engine the engine analyzer and test stand is also purchased.
• After this step, next is the Developing of Test Bench, in this step the engine is mounted on the test bench, engine analyzer is mounted on the engine and all the components are to be in place to proceed towards the next step.
• The next step is Engine Testing, where variables are obtained from the engine analyzer. A number of experiments can be performed to get different results from the engine.
• The next step is the Development of Engine Data Sheets, where the data from analyzer is utilized in the Excel sheets for calculating the cycle parameters of the engine.
• The Final step will be the Development of the Lab Experiments, to be utilized in the lab.

The following picture is an example of what the final test data sheet will look like.

Benefits of the Project

Benefits of the Project:

There are a number of benefits of completing this project

• First of all testing the IC engines and obtaining values of the performance/thermodynamic/ efficiency variables. This helps the students in understanding the variables in the engine that in terms affect the performance of the engine as a whole.
•  Second is with the help of this project, we can develop the experimental data sheets for the engine.
•  One of the main benefit of this project is to provide our university with the testing facility for the IC engine lab.

This project gives the students an insight to how engine are tested for faults in the modern industry and how the industry tackles all these problems that may arise in a man-made machine.

Technical Details of Final Deliverable

Technical details of final deliverables.

The project will be consisting of an engine, analyzer, and testing stand.

• In this project, first the variables are being collected from the engine using the engine analyzer (Know that the details of the project are already listed in the implementation section), the use of engine analyzer will determine the unknown parameters from the engine like torque, RPM, these values are also known as pick up variables of the engine.
• The next part is to utilize the variables obtained from the analyzer and plug these values in the test data sheets that were established.
• Test data sheets are Microsoft Excel sheets designed to find the unknown parameters of the engine that cannot be found using the engine analyzer, these parameters are found by using the sheets developed in Microsoft excel, by plugging in the formulas for those parameters.
• These data sheets can be used to check for the performance of the car, for that the data found has to compare with the manufacturer data which shows the difference in performance.
• Finally the project completes with making the lab experiments in which some parameters can be changed to observe the performance change in the engine. Those parameters which can be altered with are the AF Mixture, Specific Quantity, Spark timings. These can alter the final performance of the car.

The following is the list of components that are used in the project.

• The first is the engine, the final engine selected was the 1997 Toyota Corolla Engine.
• The final selected engine analyzer is OTC Engine Analyzer.

The test bench is not specific in nature to any car and can be used with any car engine.

The following picture is highlighting the geometric variables of the final selected engine.

Final Deliverable of the Project HW/SW integrated systemCore Industry TransportationOther Industries Education , Manufacturing Core Technology OthersOther Technologies OthersSustainable Development Goals Quality Education, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	80000
Engine	Equipment	1	55000	55000
Engine analyzer	Equipment	1	15000	15000
Engine Test stand	Miscellaneous	1	10000	10000