Powertr

ain

Powertrain
The powertrain includes series of components used to transform stored
energy (chemical) into kinetic energy for propulsion purposes.
It includes engine , transmission , drive shafts, differentials, wheels.
Sometimes engine and transmission together referred as powertrain and
drive shafts, differentials, wheels together referred as driveline.
Flow chart showing transfer of power in Vehicle
Engine
Transmission
Drive shafts
Differentials
Axles
Wheels

Engine

Engine
Anengineis amachinedesigned to convertenergyinto
usefulmechanical motion.
Heat engine is a machine where fuel is burnt to createheat which then is
converted to mechanical work.
Classification of Engines:
a) Based on the combustion type :
1) External combustion engines
2) Internal combustion engines
b) Based on fuel used :
1) Diesel engines
2) Petrol engines
3) CNG engines and LPG engines
c) Based on no of strokes:
1) Two stroke
2) Four Stroke

d) Based on cycle of operation:

1) Otto cycle
2) Diesel cycle
e) Based on cooling system :
1) Air cooled engine
2) Liquid cooled engine
f) Based on method of ignition:
1) Spark ignition engine
2) Compression ignition engine.
g) Based on Air intake system:
1) Naturally aspirated.
2) Turbocharged
h) Based on Layout :
1) Inline engines
2) Opposed engines
3) Rotary engine
4) V-engines
5) W engines

1. Inline engines

Engine classification based

on Layout

2. Opposed
Engines

5. W Engines

3. V Engines

3. Rotary
Engines

Components and Construction of

Inline IC Engines.7. Cooling systems
12.Turbocharger
1. Cylinder Block
2. Cylinder Head
3. Crank train
a) Piston Asm
b) Conn Rod Asm
e) Crankshaft
f) Flywheel
4. Valve train
a) Camshaft
b) Intake valve
c) Exhaust valve
d) Roller follower or Tappet Over
Head Cam
e) Lash adjustor
f) Lifter
g) Push rod
Over Head
Valve
h) Rocker arm
5. Intake system
a) Intake manifold
b) Throttle body
c) Air Filter

a) Water Pump
b) Housing water outlet
c) Thermostat
d) Radiator
e) Water hoses
8. Lubricating systems
a) Oil Pan
b) Oil Pump
c) Oil Filter
d) Oil Cooler
9.Fuel and Ignition
systems
a) Fuel Pump
b) Fuel Feed Pipe
c) Fuel Rails
d) Fuel Injectors
e) Ignition coil
f) Spark plug
10. Accessory Drives
a) Drive belt
b) AC Compressor
c) Generator
d) Tensioner pulley

13.EGR Systems
14.Front Cover
15.Rear Cover
16.Cam Cover
17.Engine shield cover
18.Engine lift bracket
19.Torsional vibration
dampener

1. Cylinder Block
A Cylinder Block is an integrated structure
comprising the cylinders and some of their
associated surrounding structures like coolant
passages, oil galleries , crankcase.
It is the core of the engine which houses nearly all of
the components required for the engine to function
properly.
Block is commonly classified into 2 major types
1. Inline Block:
The cylinders are arranged in a line in a
single bank
2. V Block:
The cylinders are arranged in two banks set
at an angle
to one another.
Also Block is categorized as short skirt and
deep skirt.
Usually short skirt will have bedplate mounted
at the bottom and deep skirt with bearing caps.

Inline
with
Deep
Skirt

V with Deep
Skirt

Bed plate

Bearing
cap

Deck Face

Blowby gas passage

Cyl head dowel holes

Oil drain hole

Oil supply hole

Cyl Bore

Manufacturing
methods
1. Green sand mould
casting
2. Lost foam technique

Siamese region

Coolant passage

Cyl head mounting

bolt holes

Materials :
It should have following desirable properties
1. Adequate strength and rigidity in compression , bending,
torsion.
2. It should be relatively cheap.
3. It should readily produce castings with good impressions.
4. It should be easily machined.
5. It should have low thermal expansion,
6. It should have a high thermal conductivity.
7. It should have a relatively low density.
1.Cast iron
Meets most of the above requirements and also it is good in
retaining oil film but
- It has a low thermal conductivity and hence more coolant to
be used for heat
dissipation.
2.Aluminium
Advantages:
- High thermal conductivity
- Light weight
- Good machinability
Disadvantages:

Liner
s in the cylinder bore to prevent it
Liners are replaceable sleeves inserted
from wearing due piston movement .
Material - Usually it is made of cast iron.
Two Types:
1) Dry Liner - It is inserted into the cylinder which remain dry on their
outside surrounded by blocks material.
2) Wet Liner It is fitted into the block by means of rubber rings or
gaskets and are entirely removable. The outer sides of the liner are in
direct contact with the engine coolant.
Dry
Liner

Wet
Liner

Main bearing caps

Functions
1. To hold the crankshaft
2. To support the journal bearings
3. To take up the combustion loads.
It is manufactured using powder
metallurgy technique to have high
localised strength.

bearing
shell

Crankshaft

Oil film
Local strengthen
region

No of Main bearing caps in a Inline

engine
= N+1
No of Main bearing caps in a V
engine
= N/2 + 1

Main bearing cap

2.Cylinder
Head

Cylinder Head is a casting which is assembled on the top of the

cylinder block.
Its major functions are
1. To support the combustion system.
2. To support the valve train.
3. To support fluid flow such as charge(air+fuel) , exhaust gases ,
coolant, lubricant.
4. To support mounting of other engine hardware.

Based on valve and camshaft configurations , Cylinder head

designs are of 3 types
1. Over Head Valve(OHV)(Cam In Block):
Here camshaft is housed in block and valves in head. Push
rod and Rocker arm

2. Over Head Cam(OHC):

Here both camshaft and valves are housed in head. Tappet or
follower is used to transfer motion from camshaft to valves.
3. Dual Over Head Cam( DOHC):
Here two camshafts are mounted in head each one separately to
operate intake and exhaust valves.

OHV

OHC

DOHC

Materials :
It should have following desirable properties
1. Adequate strength and rigidity in compression , bending, torsion.
2. It should be relatively cheap.
3. It should readily produce castings with good impressions.
4. It should be easily machined.
5. It should have low thermal expansion,
6. It should have a high thermal conductivity.
7. It should have a relatively low density.
1. Cast iron
Meets most of the above requirements but
- It has a low thermal conductivity and hence more coolant to be
used for heat
dissipation.
2. Aluminium
Advantages:
- High thermal conductivity
- Light weight
- Good machinability
Disadvantages:
- Less strength compared to CI
- Higher cost
- Corrosion resistant not so good as CI

3.Cranktrain
It is a series of link components which
transfers the combustion energy to
transmissions.
Parts in cranktrain:
1) Piston asm
2) Connecting rod asm
3) Crankshaft
4) Flywheel
Piston Asm:
Piston asm consists of following parts
1. Piston
2. Piston pin or Gudgeon pin
3. Cir clips
4. Compression rings
5. Oil Rings

Piston
I:t is a cylindrical component which reciprocates in the

cylinder bore. Its main function is to convert combustion

energy into mechanical work. It also seals the
combustion gases from crankcase. It also seals the oil
from entering the combustion chamber.
Top portion of the piston gets maximum heat due to
combustion. As the piston absorbs heat , the diameter of
the piston increases slightly. Hence a small gap is
provided between piston and cylinder wall.
Piston
The piston asm accounts
for 50-60% of the mechanical
Nomenclature
dome or crown
Piston
cylinder
losses of the
engine.
CL
Ring
belts

Compression
height

Piston pin
bore
Piston skirt
Piston Pin Bore
CL

Piston pin offset

Materials :
It should have following desirable properties
1. High hot strength
2. High strength to mass ratio.
3. Good resistance to surface abrasion.
4. Good thermal conductivity to keep down piston
temperature.
5. Low thermal expansion to keep minimal piston-cylinder
clearance.
1.Cast iron
2.Aluminium
Molybdenum is coated on piston skirt to avoid wear.

Gudgeon Pin(Piston Pin):

It is a hollow pin that connects the piston to the
small end of the connecting rod.
Cir clips:
It is fitted in the piston to prevent gudgeon pin from
touching the cylinder wall.
Compression rings:
Its function is to seal the space between piston and
cylinder wall so that fresh charge or exhaust gases
cannot escape.
These rings are first installed in the grooves of piston
and then piston is inserted into the cylinder. The
diameter of the ring is slightly greater than that of
cylinder bore and hence press tightly against the
cylinder wall.
Oil rings:
Its function is to distribute the oil film over the whole
cylinder surface and scrape the oil from the wall to
the oil pan.

Connecting rod
asm :
Connecting rod asm consists of
following parts
1. Conn rod
2. Bush
3. Bearing cap
4. Bearing shell
5. Screws bearing cap

Connecting rod :
Its function is to transmit the power from the piston to
crankshaft.
Top end of the connecting rod is called the small end.
The bottom end is called the big end. Small end is
press fitted with a bronze bushing. Big end bearing is
made in two halves. This is fixed to conn rod by means
of a cap , bolts and nuts. Small end reciprocates along
with piston while the big end rotates with the

Conn Rod Nomenclature

Small end
Rod
column
Rod
length

Big end
Material and manufacturing :
-Cast Iron
-Heat treated forged steel
-Aluminium using Powder metallurgy technique .
It allows more precise control of size and weight with less
machining . The cap is
separated from the rod by a fracturing process, which results in
an uneven mating

Crankshaf
t:

Crankshaft Nomenclature

Flywheel
adapter
Main Journal

Nose end
Web
Crankpin

It converts the linear motion of the piston to rotary motion and

transfers it to the transmission.
It is housed in crank bore of the block supported by journal bearings.
It is also used to drive camshaft and other accessory devices.
Materials and manufacturing:
-Forged steel
-Cast iron.
It is manufactured by forging process as well as casting process
After manufacturing process:
Sand blasting or shot blasting is done as a part of surface treatment.
Machining is done on main journal, crank pin , nose end , flywheel
adapter.
It also undergoes heat treatment processes like quenching ,

Flywheel:
It is fitted to the adapter end of the crankshaft.
It stores part of the energy produced by the power
stroke and releases during the idle strokes. Thus
flywheel due to its momentum, helps in the smooth
running of the crankshaft.
The flywheel is fitted with a ring gear which is
engaged by a pinion of starter motor for starting
the engine.

Starter motor:
It is an electric motor used for rotating an engine so as to
initiate the engines operation under its own power.
When the switch is turned on , current from the battery is
supplied
to the solenoid . The solenoid then engages a lever that
pushes the pinion gear on the starter driveshaft to mesh
with the ring gear on
the flywheel.
Once the engine starts, a spring in the solenoid assembly
pulls the

4.Valvetrain

OHV

It is a series of linked components to transfer

motion from camshaft to valves

Rocker
arm

Push
rod

Its primary function is to transform rotary motion

of camshaft to linear motion of valve to control
fluid into and out of the combustion chamber.
Secondary function is to drive fuel pump , vacum
pump, power steering pump.
It is mainly of two types:
1. Over head valve(OHV)
When the camshaft rotates , cam lobe lifts
the
tappet or lifter which then operates the
pushrod.
Push rod causes the one end of the rocker
arm to
oscillate about a pivot. The other end of the
rocker
arm pushes down the valve stem due to
which valve
is opened. As camshaft rotates further the

Camsh
aft

Lifter

Valve

2. Over head cam(OHC)

When the camshaft rotates , cam
projection
pushes the tappet and causes the
valve to
open. As camshaft rotates further
the
tappet
Camshaft:
moves up
due toisvalve
springits
and
Its primary
function
to convert
rotary motion
the
valve movement
is
to linear
of the valves at the designed
now closed.
timings.
It is also used to drive the auxiliary devices like
fuel pump, vacum pump.
It is driven by crankshaft by sprocket and timing
chain arrangement.
Camshaft rotates at half the speed of the
crankshaft.
Materials:
1. Chilled iron castings
- Good choice for high volume production
- High resistance against wear
2. Billet steel
- Used for low volume production and is very
expensive

Valves:
It consists of disk shaped tapered plug and a shaft
called valve stem. It is used to control the quantity and
timing of charge or gases flow into or out from the
engine.
There are two types of valve
Intake valve
Exhaust valve
Valve lift is determined by the shape and position of
the cam and also by the rocker arm ratio.
Materials that are commonly used are carbon steel
alloys,
Rocker arm:
stainless
steels, high-strength
nickel-chromium-iron
Itis an oscillating
lever that conveys
radial movement
alloys
.
from thecamlobe
into linear movement of the valve.
One end is raised or lowered by push rod while the
other end acts on the valve stem.
Rocker arm ratio is the ratio of distance from the
rocker arm's center of rotation to the tip divided by
the distance from the center of rotation to the point
acted
by pushrod.
Push on
Rod:
Generally
ratiorod
willconnected
be 1.5:1 toone
1.8:1
It is a longthis
slender
end to
Lifter and other end to Rocker arm using spherical
joints.
Its function is to transfer motion from camshaft to

Hydraulic lash adjustor:

It is a device for maintaining zero clearance
between valve stem and rocker arm. Conventional
engines without these adjustors, there used to be a
small clearance between valve and rocker arm to
compensate the thermal expansion of valves. This
small clearance will create noise as the parts would
rattle against each other until valves get heated up
and expanded. So these lash adjustors will always
maintain valve in contact with rocker arm or
follower thus leading to quieter operation, longer
engine life.

Valve springs:
It controls the movement of valve( returning of
valve)
It supports and holds the valve in position.

Key Valve
stem

Cap Valve
springs

Valve
springs

5.Intake systems
Intake Manifold:
Intake Manifold:
Inlet manifoldorIntake manifold is the part of anenginethat supplies
thefuel/airmixture to thecylinders.
Functions:
Intake manifold is toevenlydistribute the combustion mixture (or just
air in a direct injection engine) to each intake port in the cylinder
head(s).
Optimize the efficiency and performance of the engine.
Serve as a mount for the carburetor, throttle body, fuel injectors and
other components of the engine.
Material:
Aluminum, Cast iron, composite plastic materials (thermoplastic material
with high thermal andmechanical resistance)

Throttle Body:
A Throttle is the mechanism by which the flow of a fluid is managed by
constriction or
obstruction OR mechanism by which the power or speed of an engine is
regulated.
Functions:
Throttle body also contains a secondary air channel known as the idle
air control (IAC) circuit. The IAC contains a valve that allows the
computer to precisely meter air at idle, which can be important under
extremely hot or cold conditions.
The throttle body may contain a servo to open or control the throttle.
Such servos work in concert with the computer's traction control (TC)
system. If the computer detects wheel spin or power sliding, it will close
the throttle plate somewhat to counteract this.
Material:
aluminum castings,

6.Exhaust
systems

Exhaust manifold:
Collects the exhaust gases from multiple cylinders into one pipe. .
Functions:
The exhaust manifold (or "header" if made of separately welded tubes)
moves spent combustion gases from the engine's exhaust ports to a
central collection point.
When exhaust headers are added into this system, it increases engine
efficiency. These extractors, by converging into a central tube (the
Collector) act as a sort of vacuum that pulls the burnt fuel gas more
quickly out of the engine's cylinders and thus decreases back pressure
that reduces engine power.
Material:
cast iron or stainless steel

Heat Shield:
It is substance from absorbing excessive heat from an outside source by
either dissolving, reflecting or simply absorbing the heat
Functions:
Heat shields are used on most engines to protect components and
bodywork from heat damage
Retain heat in exhaust system,
Ceramic coatings are highly advanced coatings applied via plasma
spray will protect and they will offer significant performance benefits
due to the low thermal conductivity of the ceramic compound
Material:
aluminum sheet or other composites with a ceramic thermal barrier
coating to improve the heat insulation.

7. Cooling System

Water Pump
The water pump is a simple centrifugal pump driven by a belt connected
to the crankshaft of the engine. The pump circulates fluid whenever the
engine is running.
Water pump is an effective and integral part of the process.
Functions:
It keeps engine cool and everything running properly.
The water pump endures constant use inside an engine and allows the
engine to endure the intense heat that internal combustion produces.
When engine is on, the water pump circulates coolant, or antifreeze, in
the cylinder head and the engine block to cool the engine down.
After the coolant passes through the engine it's sent back into the
radiator to be cooled before entering the engine again.
Material:
cast iron (housing),
composite plastic materials (impeller, adapter)

Thermostat:
This device is used to block the flow of coolant to the radiator until the
engine has warmed up. When the engine is cold, no coolant flows through
the engine. Once the engine reaches its operating temperature (generally
about 200 degrees F, 95 degrees C), the thermostat opens. By letting the
engine warm up as quickly as possible,
Engine's overall temperature is monitored by a thermostat which opens
up once the normal operating temperature is surpassed.
Functions:
Thermostat reduces engine wear, deposits and emissions.
The thermostat is designed to control the flow of coolant through the
cooling system while the engine is warming up to operating
temperature
Maintain the engine near its optimum operating temperature by
regulating the flow of coolant to an air-cooled radiator..

Radiators:
Radiators are heat exchangers used to transfer thermal energy from one
medium to another for the purpose of cooling and heating.
Functions:
Are used for cooling internal combustion engines,
Cooling the fluid or coolant supplied to it.
Transfer the bulk of their heat via convection,
Working Principle
When coolant circulates through the tubes, the coolant transfers its heat
to the tubes which, in turn, transfer the heat to the fins that are lodged
between each row of tubes. The fins then release the heat to the ambient
air. Fins are used to greatly increase the contact surface of the tubes to
the air, thus increasing the exchange efficiency.

8.Lubricating system
Primary function is to lubricate various parts in
the engine to reduce friction.
- It also cools the engine.
- Helps in chemical protection of parts.
- Helps in hydraulic actuation.
Lubricating area :
- Piston and block (Cyl bore combustion area)
- Crankshaft and Block (Crank bore area)
- Camshaft and Cyl Head (Cam Bore area)
- Balancer shaft and block ( Balancer bore area)
- Conn Rod and Crankshaft rod journal ( Big end
bore area)
Parts of Lubricating system:
1. Oil pan
2. Oil Pump
3. Oil Filter
4. Oil Cooler
5. Oil galleries
6. Oil

Oil pan:
The container underneath the crankcase is known as
the
sump or Oil Pan
Functions
1. to store the engines lubricating oil.
2. to collect the return oil draining from the sides of
the crankcase
walls.
4. to cool the oil.
4. improves rigidity by taking part of gas loads.
Materials:
- Single sheet steel pressing
- Aluminum-alloy casting
Cast aluminum alloy is much better than pressed
steel in
dissipating heat and it does not cause resonant
(vibration) noise.
Baffle plates:
Windage trays:
It is a series of compartments with walls provided in
It acts as a barrier between crankshaft and other
the oil pan to prevent the oil from moving away from
rotating parts with the oil contained in the oil pan.
the pickup location during high acceleration , sudden

Oil Pump:
It circulates the oil through the engine under
pressure.
It is driven by crankshaft .
It is either submerged in oil pan or mounted to the
block just above the oil pan.
Oil pump used can be of different types
1.Gear pumps
2.Rotor pumps
3.Vane pumps
Oil filter:
It is used to remove the contaminants from the
engine oil.
Filter material used can be of paper type or
synthetic .
Particle size upto 25 microns is filtered.
Oil cooler:
It is a heat exchanger used to cool the oil.

9.Fuel system
Fuel system consists of following
parts
1.Fuel Pump
2.Fuel Filter
3.Fuel Feed Pipe
4.Fuel Rail
5.Fuel Injector
Fuel Injection system are of different
types
1. Throttle body injection
2. Manifold injection
3. Multiport fuel injection
4. Direct injection
Fuel Pump:
It is used to pump the fuel from the tank to
the fuel injection systems at high pressure.
It is driven mainly by camshaft and
sometimes by crankshaft through chain and
sprocket arrangement.

Fuel Feed Pipe:

It is a steel pipe used to carry the fuel from
pump to rail or from rail to injector.

Fuel Rail:
It is a common rail used to deliver fuel to
individual fuel injectors .

Fuel Injector:
It is a device used for admitting the fuel into
the engine.
It atomizes the fuel by forcibly pumping it
through a small nozzle under high pressure.

9.Ignition system
Ignition coil:
It transforms batterys low voltage to high voltage
required to create an electric spark in the spark
plugs to ignite the fuel.
It consists
is used inofpetrol
engines.
It
a primary
coil and large no of
secondary coil.
Current supply from the battery to primary coil
is disrupted by the breaker points. As a result
magnetic field of the primary coil collapses
rapidly. This changing magnetic field induces
current in the secondary coil and high voltage
is developed.
Spark
Plug: It is then fed to the distributor.
It is a device used to ignite the fuel in the
combustion chamber by means of electric
spark.
It is located in the cylinder head.
It consists of a metal threaded shell , a central
electrode and insulator.

10.Accessory

Alternator/Generator:
Drives
An alternator is an electrical
generator that converts mechanical energy
to electrical energy in the form of alternating current.
An automotive charging system is made up of three major components:
thebattery, the voltage regulatorand an alternator.
Functions:
The alternator works with the battery to generate power for the
electrical components of a vehicle, like the interior and exterior lights,
and the instrument panel. An alternator gets its name from the
termalternating current (AC).
Working Principle
Alternators produce AC power throughelectromagnetismformed through
the stator and rotor relationship. The electricity is channeled into the
battery, providing voltage to run the various electrical systems.

AC Compressor:
TheA/C compressoris considered one of the most important parts of
theair conditioning system.
It compresses refrigerant and sends it to the air condenser.
The entire process is powered by engine's drive belt (or belts). The highly
pressurized liquid refrigerant converts to a gas and is circulated into tubes
where the heat from the gas is quickly released, causing it to cool. The
cooled gas then reverts back into liquid form as it returns to the
compressor. The cooled gas is used to chill the car's cabin air.

Drive Belts:
A belt is a loop of flexible material used to mechanically link two or more
rotating shafts.
Functions:
Power transmission is achieved by specially designed belts and pulleys.
They run smoothly and with little noise, and cushion motor and
bearings against load changes,
It helps protect the machinery from overload and jam, and damps and
isolates noise and vibration.
Load fluctuations are shock-absorbed (cushioned).
Different speeds can be obtained by stepped or tapered pulleys.

11.Timing
systems

Timing Chain:
The timing chain controls the timing of car engine valves. It connects the
crankshaft to the camshaft, which in turn controls the opening and
closing of the valves.
A worn timing chain can be diagnosed by a rattling or chattering noise
from the cylinder head. It is important that the timing chain, or timing
belt

12.Turbochar
ger

Turbocharger is a force induction device which increases engine

efficiency and power by forcing extra air into the combustion chamber.
The kinetic energy of the exhaust gases after combustion drives the
turbine.The turbine then drives the centrifugal compressor and hence
compresses the intake air thereby increasing its density and pressure.
This results in greater mass of air entering the combustion chamber
during intake stroke
Main parts of turbocharger are
1. Housing
2. Turbine (radial inflow)
3. Compressors (Centrifugal)

13.Exhaust gas recirculation

(EGR
)
It is a system system
where portion
of exhaust
gases after

EGR Valve

combustion is circulated back to the intake manifold.

EGR is a NOx emissions reduction technique. At high
temperature, nitrogen and oxygen present in intake air
will react to form nitrogen oxides . By mixing intake air
with exhaust gases, reduces the amount of oxygen
molecules in the intake charge. Hence when
compressed results in lower combustion chamber
temperature thereby reducing the formation of nitogen
dioxide.
EGR
system consists of following parts
1. EGR Valve
2. EGR Cooler
3. EGR Pipe

EGR
Cooler

EGR Pipe

Thank
you