Structure The base of a reciprocating internal combustion engine is the
engine block, which is typically made of
cast iron (due to its good wear resistance and low cost) or
aluminum. In the latter case, the cylinder liners are made of cast iron or steel, or a coating such as
nikasil or
alusil. The engine block contains the
cylinders. In engines with more than one cylinder they are usually arranged either in 1 row (
straight engine) or 2 rows (
boxer engine or
V engine); 3 or 4 rows are occasionally used (
W engine) in contemporary engines, and other
engine configurations are possible and have been used.
Single-cylinder engines (or
thumpers) are common for motorcycles and other small engines found in light machinery. On the outer side of the cylinder, passages that contain cooling fluid are cast into the engine block whereas, in some heavy duty engines, the passages are the types of removable cylinder sleeves which can be replaceable. A
ventilation system drives the small amount of gas that escapes past the pistons during normal operation (the blow-by gases) out of the crankcase so that it does not accumulate contaminating the oil and creating corrosion. but they can also be
rotary valves or
sleeve valves. For comparison, the most efficient small four-stroke engines are around 43% thermally-efficient (SAE 900648); size is an advantage for efficiency due to the increase in the ratio of volume to surface area. See the
external links for an in-cylinder combustion video in a 2-stroke, optically accessible motorcycle engine.
Historical design Dugald Clerk developed the first two-cycle engine in 1879. It used a separate cylinder which functioned as a pump in order to transfer the fuel mixture to the cylinder. Day cycle engines are crankcase scavenged and port timed. The crankcase and the part of the cylinder below the exhaust port is used as a pump. The operation of the Day cycle engine begins when the crankshaft is turned so that the piston moves from BDC upward (toward the head) creating a vacuum in the crankcase/cylinder area. The carburetor then feeds the fuel mixture into the crankcase through a
reed valve or a rotary disk valve (driven by the engine). There are cast in ducts from the crankcase to the port in the cylinder to provide for intake and another from the exhaust port to the exhaust pipe. The height of the port in relationship to the length of the cylinder is called the "port timing". On the first upstroke of the engine there would be no fuel inducted into the cylinder as the crankcase was empty. On the downstroke, the piston now compresses the fuel mix, which has lubricated the piston in the cylinder and the bearings due to the fuel mix having oil added to it. As the piston moves downward it first uncovers the exhaust, but on the first stroke there is no burnt fuel to exhaust. As the piston moves downward further, it uncovers the intake port which has a duct that runs to the crankcase. Since the fuel mix in the crankcase is under pressure, the mix moves through the duct and into the cylinder. Because there is no obstruction in the cylinder of the fuel to move directly out of the exhaust port prior to the piston rising far enough to close the port, early engines used a high domed piston to slow down the flow of fuel. Later the fuel was "resonated" back into the cylinder using an expansion chamber design. When the piston rose close to TDC, a spark ignited the fuel. As the piston is driven downward with power, it first uncovers the exhaust port where the burned fuel is expelled under high pressure and then the intake port where the process has been completed and will keep repeating. Later engines used a type of porting devised by the Deutz company to improve performance. It was called the
Schnurle Reverse Flow system. DKW licensed this design for all their motorcycles. Their
DKW RT 125 was one of the first motor vehicles to achieve over 100 mpg as a result.
Ignition Internal combustion engines require ignition of the mixture, either by
spark ignition (SI) or
compression ignition (CI). Before the invention of reliable electrical methods, hot tube and flame methods were used. Experimental engines with
laser ignition have been built.
Spark ignition process The spark-ignition engine was a refinement of the early engines which used Hot Tube ignition. When Bosch developed the
magneto it became the primary system for producing electricity to energize a spark plug. Many small engines still use magneto ignition. Small engines are started by hand cranking using a
recoil starter or hand crank. Prior to
Charles F. Kettering of Delco's development of the automotive starter all gasoline engined automobiles used a hand crank. Larger engines typically power their
starting motors and
ignition systems using the electrical energy stored in a
lead–acid battery. The battery's charged state is maintained by an
automotive alternator or (previously) a generator which uses engine power to create electrical energy storage. The battery supplies electrical power for starting when the engine has a
starting motor system, and supplies electrical power when the engine is off. The battery also supplies electrical power during rare run conditions where the alternator cannot maintain more than 13.8 volts (for a common 12 V automotive electrical system). As alternator voltage falls below 13.8 volts, the lead-acid storage battery increasingly picks up electrical load. During virtually all running conditions, including normal idle conditions, the alternator supplies primary electrical power. Some systems disable alternator field (rotor) power during wide-open throttle conditions. Disabling the field reduces alternator pulley mechanical loading to nearly zero, maximizing crankshaft power. In this case, the battery supplies all primary electrical power. Gasoline engines take in a mixture of air and gasoline and compress it by the movement of the piston from bottom dead center to top dead center when the fuel is at maximum compression. The reduction in the size of the swept area of the cylinder and taking into account the volume of the combustion chamber is described by a ratio. Early engines had
compression ratios of 6 to 1. As compression ratios were increased, the efficiency of the engine increased as well. With early induction and ignition systems the compression ratios had to be kept low. With advances in fuel technology and combustion management, high-performance engines can run reliably at 12:1 ratio. With low octane fuel, a problem would occur as the compression ratio increased as the fuel was igniting due to the rise in temperature that resulted.
Charles Kettering developed a
lead additive which allowed higher compression ratios, which was progressively
abandoned for automotive use from the 1970s onward, partly due to
lead poisoning concerns. The fuel mixture is ignited at different progressions of the piston in the cylinder. At low rpm, the spark is timed to occur close to the piston achieving top dead center. In order to produce more power, as rpm rises the spark is advanced sooner during piston movement. The spark occurs while the fuel is still being compressed progressively more as rpm rises. The necessary high voltage, typically 10,000 volts, is supplied by an
induction coil or transformer. The induction coil is a fly-back system, using interruption of electrical primary system current through some type of synchronized interrupter. The interrupter can be either contact points or a power transistor. The problem with this type of ignition is that as RPM increases the availability of electrical energy decreases. This is especially a problem, since the amount of energy needed to ignite a more dense fuel mixture is higher. The result was often a high RPM misfire.
Capacitor discharge ignition was developed. It produces a rising voltage that is sent to the spark plug. CD system voltages can reach 60,000 volts. CD ignitions use step-up
transformers. The step-up transformer uses energy stored in a capacitance to generate
electric spark. With either system, a mechanical or electrical control system provides a carefully timed high-voltage to the proper cylinder. This spark, via the spark plug, ignites the air-fuel mixture in the engine's cylinders. While gasoline internal combustion engines are much easier to start in cold weather than diesel engines, they can still have cold weather starting problems under extreme conditions. For years, the solution was to park the car in heated areas. In some parts of the world, the oil was actually drained and heated overnight and returned to the engine for cold starts. In the early 1950s, the gasoline Gasifier unit was developed, where, on cold weather starts, raw gasoline was diverted to the unit where part of the fuel was burned causing the other part to become a hot vapor sent directly to the intake valve manifold. This unit was quite popular until electric
engine block heaters became standard on gasoline engines sold in cold climates.
Compression ignition process For ignition, diesel,
PPC and
HCCI engines rely solely on the high temperature and pressure created by the engine in its compression process. The compression level that occurs is usually twice or more than a gasoline engine. Diesel engines take in air only, and shortly before peak compression, spray a small quantity of diesel fuel into the cylinder via a fuel injector that allows the fuel to instantly ignite. HCCI type engines take in both air and fuel, but continue to rely on an unaided auto-combustion process, due to higher pressures and temperature. This is also why diesel and HCCI engines are more susceptible to cold-starting issues, although they run just as well in cold weather once started. Light duty diesel engines with
indirect injection in automobiles and light trucks employ
glowplugs (or other pre-heating: see
Cummins ISB#6BT) that pre-heat the
combustion chamber just before starting to reduce no-start conditions in cold weather. Most diesels also have a battery and charging system; nevertheless, this system is secondary and is added by manufacturers as a luxury for the ease of starting, turning fuel on and off (which can also be done via a switch or mechanical apparatus), and for running auxiliary electrical components and accessories. Most new engines rely on electrical and electronic
engine control units (ECU) that also adjust the combustion process to increase efficiency and reduce emissions.
Lubrication Surfaces in contact and relative motion to other surfaces require
lubrication to reduce wear, noise and increase efficiency by reducing the power wasting in overcoming
friction, or to make the mechanism work at all. Also, the lubricant used can reduce excess heat and provide additional cooling to components. At the very least, an engine requires lubrication in the following parts: • Between pistons and cylinders • Small bearings • Big end bearings • Main bearings • Valve gear (The following elements may not be present): • Tappets • Rocker arms • Pushrods • Timing chain or gears. Toothed belts do not require lubrication. In 2-stroke crankcase scavenged engines, the interior of the crankcase, and therefore the crankshaft, connecting rod and bottom of the pistons are sprayed by the
two-stroke oil in the air-fuel-oil mixture which is then burned along with the fuel. The valve train may be contained in a compartment flooded with lubricant so that no
oil pump is required. In a
splash lubrication system no oil pump is used. Instead the crankshaft dips into the oil in the sump and due to its high speed, it splashes the crankshaft, connecting rods and bottom of the pistons. The connecting rod big end caps may have an attached scoop to enhance this effect. The valve train may also be sealed in a flooded compartment, or open to the crankshaft in a way that it receives splashed oil and allows it to drain back to the sump. Splash lubrication is common for small 4-stroke engines. In a
forced (also called
pressurized)
lubrication system, lubrication is accomplished in a closed-loop which carries
motor oil to the surfaces serviced by the system and then returns the oil to a reservoir. The auxiliary equipment of an engine is typically not serviced by this loop; for instance, an
alternator may use
ball bearings sealed with their own lubricant. The reservoir for the oil is usually the sump, and when this is the case, it is called a
wet sump system. When there is a different oil reservoir the crankcase still catches it, but it is continuously drained by a dedicated pump; this is called a
dry sump system. On its bottom, the sump contains an oil intake covered by a mesh filter which is connected to an oil pump then to an
oil filter outside the crankcase. From there it is diverted to the crankshaft main bearings and valve train. The crankcase contains at least one
oil gallery (a conduit inside a crankcase wall) to which oil is introduced from the oil filter. The main bearings contain a groove through all or half its circumference; the oil enters these grooves from channels connected to the oil gallery. The crankshaft has drillings that take oil from these grooves and deliver it to the big end bearings. All big end bearings are lubricated this way. A single main bearing may provide oil for 0, 1 or 2 big end bearings. A similar system may be used to lubricate the piston, its gudgeon pin and the small end of its connecting rod; in this system, the connecting rod big end has a groove around the crankshaft and a drilling connected to the groove which distributes oil from there to the bottom of the piston and from then to the cylinder. Other systems are also used to lubricate the cylinder and piston. The connecting rod may have a nozzle to throw an oil jet to the cylinder and bottom of the piston. That nozzle is in movement relative to the cylinder it lubricates, but always pointed towards it or the corresponding piston. Typically forced lubrication systems have a lubricant flow higher than what is required to lubricate satisfactorily, in order to assist with cooling. Specifically, the lubricant system helps to move heat from the hot engine parts to the cooling liquid (in water-cooled engines) or fins (in air-cooled engines) which then transfer it to the environment. The lubricant must be designed to be chemically stable and maintain suitable viscosities within the temperature range it encounters in the engine.
Cylinder configuration Common cylinder configurations include the
straight or inline configuration, the more compact
V configuration, and the wider but smoother
flat or boxer configuration.
Aircraft engines can also adopt a
radial configuration, which allows more effective cooling. More unusual configurations such as the
H,
U,
X, and
W have also been used. Multiple cylinder engines have their valve train and crankshaft configured so that pistons are at different parts of their cycle. It is desirable to have the pistons' cycles uniformly spaced (this is called
even firing) especially in forced induction engines; this reduces torque pulsations and makes
inline engines with more than 3 cylinders statically
balanced in its primary forces. However, some
engine configurations require odd firing to achieve better balance than what is possible with even firing. For instance, a 4-stroke
I2 engine has better balance when the angle between the crankpins is 180° because the pistons move in opposite directions and inertial forces partially cancel, but this gives an odd firing pattern where one cylinder fires 180° of crankshaft rotation after the other, then no cylinder fires for 540°. With an even firing pattern, the pistons would move in unison and the associated forces would add. Multiple crankshaft configurations do not necessarily need a
cylinder head at all because they can instead have a piston at each end of the cylinder called an
opposed piston design. Because fuel inlets and outlets are positioned at opposed ends of the cylinder, one can achieve uniflow scavenging, which, as in the four-stroke engine is efficient over a wide range of engine speeds. Thermal efficiency is improved because of a lack of cylinder heads. This design was used in the
Junkers Jumo 205 diesel aircraft engine, using two crankshafts at either end of a single bank of cylinders, and most remarkably in the
Napier Deltic diesel engines. These used three crankshafts to serve three banks of
double-ended cylinders arranged in an equilateral triangle with the crankshafts at the corners. It was also used in single-bank
locomotive engines, and is still used in
marine propulsion engines and marine auxiliary generators.
Diesel cycle for the ideal diesel cycle. The cycle follows the numbers 1–4 in clockwise direction. Most truck and automotive diesel engines use a cycle reminiscent of a four-stroke cycle, but with temperature increase by compression causing ignition, rather than needing a separate ignition system. This variation is called the diesel cycle. In the diesel cycle, diesel fuel is injected directly into the cylinder so that combustion occurs at constant pressure, as the piston moves.
Otto cycle The
Otto cycle is the most common cycle for most cars' internal combustion engines that use gasoline as a fuel. It consists of the same major steps as described for the four-stroke engine: Intake, compression, ignition, expansion and exhaust.
Five-stroke engine In 1879,
Nicolaus Otto manufactured and sold a double expansion engine (the double and triple expansion principles had ample usage in steam engines), with two small cylinders at both sides of a low-pressure larger cylinder, where a second expansion of exhaust stroke gas took place; the owner returned it, alleging poor performance. In 1906, the concept was incorporated in a car built by EHV (
Eisenhuth Horseless Vehicle Company); and in the 21st century
Ilmor designed and successfully tested a 5-stroke double expansion internal combustion engine, with high power output and low SFC (Specific Fuel Consumption).
Six-stroke engine The
six-stroke engine was invented in 1883. Four kinds of six-stroke engines use a regular piston in a regular cylinder (Griffin six-stroke, Bajulaz six-stroke, Velozeta six-stroke and Crower six-stroke), firing every three crankshaft revolutions. These systems capture the waste heat of the
four-stroke Otto cycle with an injection of air or water. The
Beare Head and "piston charger" engines operate as
opposed-piston engines, two pistons in a single cylinder, firing every two revolutions rather than every four like a four-stroke engine.
Other cycles The first internal combustion engines did not compress the mixture. The first part of the piston downstroke drew in a fuel-air mixture, then the inlet valve closed and, in the remainder of the down-stroke, the fuel-air mixture fired. The exhaust valve opened for the piston upstroke. These attempts at imitating the principle of a
steam engine were very inefficient. There are a number of variations of these cycles, most notably the
Atkinson and
Miller cycles.
Split-cycle engines separate the four strokes of intake, compression, combustion and exhaust into two separate but paired cylinders. The first cylinder is used for intake and compression. The compressed air is then transferred through a crossover passage from the compression cylinder into the second cylinder, where combustion and exhaust occur. A split-cycle engine is really an
air compressor on one side with a combustion chamber on the other. Previous split-cycle engines have had two major problems—poor breathing (volumetric efficiency) and low thermal efficiency. However, new designs are being introduced that seek to address these problems. The
Scuderi Engine addresses the breathing problem by reducing the clearance between the piston and the cylinder head through various turbocharging techniques. The Scuderi design requires the use of outwardly opening valves that enable the piston to move very close to the cylinder head without the interference of the valves. Scuderi addresses the low thermal efficiency via firing after top dead center (ATDC). Firing ATDC can be accomplished by using high-pressure air in the transfer passage to create sonic flow and high turbulence in the power cylinder. == Combustion turbines ==