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The Engine's Heartbeat

An in-depth exploration of internal combustion engines (ICE), covering their history, mechanics, types, fuels, performance, and environmental impact.

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History

Early Innovations

The development of the internal combustion engine spans centuries, with contributions from numerous inventors. Early milestones include John Barber's 1791 gas turbine and Robert Street's 1794 engine utilizing liquid fuel. Jean Joseph Etienne Lenoir patented the first commercially successful gas-fired ICE in 1860. Nicolaus Otto, working with Gottlieb Daimler and Wilhelm Maybach, patented the compressed charge, four-cycle engine in 1876, a foundational design.

Liquid Fuel and Vehicles

Karl Benz patented a reliable two-stroke gasoline engine in 1879 and began the first commercial production of motor vehicles with ICEs in 1886. Rudolf Diesel developed the compression ignition engine in 1892, initially experimenting with vegetable oils. The 20th century saw rapid advancements, including Robert Goddard's 1926 liquid-fueled rocket and the 1939 Heinkel He 178, the world's first jet aircraft.

Evolution of Cycles

Early ICEs often lacked compression, leading to inefficiency. Otto's cycle became dominant, but variations like the Atkinson and Miller cycles emerged for improved fuel efficiency, particularly in hybrid vehicles. Continuous combustion engines, such as gas turbines and jet engines, represent another major class, utilizing different thermodynamic principles.

Etymology

Engine vs. Motor

The term "engine" historically referred to any machinery, while "motor" specifically denotes a machine producing power. Traditionally, electric motors are not called engines, but combustion engines are often referred to as "motors." An "electric engine" typically means an electric locomotive. In marine contexts, engines installed in the hull are "engines," while those mounted externally are "motors."

Applications

Land and Sea Transport

Reciprocating piston engines are the primary power source for most land and water vehicles, including automobiles, motorcycles, ships, and locomotives. Rotary engines like the Wankel are used in some cars, aircraft, and motorcycles. These are collectively known as internal-combustion-engine vehicles (ICEVs).

Aviation and Power Generation

High power-to-weight ratios make ICEs suitable for aircraft, often using reciprocating engines or jet/turboshaft engines (a type of turbine). Gas turbines are crucial for power generation, driving large electric generators in power plants, often in combined-cycle configurations for higher efficiency.

Small Machinery

Smaller engines, typically two-stroke gasoline types, power lawnmowers, chainsaws, leaf blowers, pressure washers, and other light machinery. They are valued for their simplicity and power-to-weight ratio, though often less efficient and more polluting than larger counterparts.

Classification

By Cycle and Ignition

Engines are classified by their operating cycle (e.g., two-stroke, four-stroke, six-stroke) and ignition type. Spark Ignition (SI) engines use a spark plug, while Compression Ignition (CI) engines (diesel) rely on the heat generated during compression. Specialized cycles like Atkinson and Miller are used for enhanced fuel efficiency.

Reciprocating vs. Rotary

The most common type is the reciprocating piston engine. Rotary engines, like the Wankel, use a rotor instead of pistons, offering a different mechanical design and often a higher power-to-weight ratio. Continuous combustion engines, such as gas turbines and jet engines, operate differently by maintaining a constant combustion process.

Continuous Combustion

Gas turbines and jet engines operate on continuous combustion principles. They compress air, mix it with fuel in a combustor, and use the expanding hot gases to drive a turbine or generate thrust. These are distinct from the intermittent combustion found in piston engines.

Reciprocating Engines

Core Structure

The foundation is the engine block, typically cast iron or aluminum, housing cylinders. Pistons move within cylinders, connected via connecting rods to a crankshaft, converting linear motion to rotation. The cylinder head seals the cylinders and contains valves (intake/exhaust) and ignition/fuel systems (spark plug or injector). Lubrication systems (splash or forced) and cooling systems (air or liquid) are essential.

Four-Stroke Cycle

The dominant cycle involves four piston strokes per two crankshaft revolutions: Intake (drawing in air/fuel), Compression (increasing pressure/temperature), Power (combustion forcing the piston down), and Exhaust (expelling burnt gases). Ignition timing is critical and advances with engine speed.

  1. Intake: Piston moves down, intake valve opens, drawing in the charge.
  2. Compression: Both valves close, piston moves up, compressing the charge. Ignition occurs near Top Dead Center (TDC).
  3. Power: Combustion gases expand, pushing the piston down, generating power.
  4. Exhaust: Exhaust valve opens, piston moves up, expelling gases.

Two-Stroke Cycle

Completes the power cycle in two strokes (one crankshaft revolution). It combines intake/exhaust with compression/power strokes using ports in the cylinder wall, often managed by the piston's movement. Crankcase-scavenged two-strokes are mechanically simpler but less efficient and more polluting due to oil burning and charge loss.

Operation: Combines intake, compression, power, and exhaust phases into two strokes. Uses ports instead of valves in some designs. Crankcase acts as a pump. Lubrication is typically mixed with fuel (petrol-oil).

Challenges: Lower thermal efficiency, higher emissions (unburnt fuel, oil), potential for charge loss during scavenging.

Advantages: Simpler construction, higher power-to-weight ratio.

Combustion Turbines

Jet Engines

Jet engines (turbojets, turbofans, turboprops) use continuous combustion. Air is compressed, mixed with fuel, ignited, and expelled through a nozzle or turbine to create thrust. Modern turbofans achieve high efficiencies (up to 48%). Key components include the fan, compressor, combustor, turbine, mixer, and nozzle.

Gas Turbines

Similar to jet engines but optimized to drive a shaft, producing mechanical power. They consist of a compressor, combustion chamber, and turbine. About two-thirds of the work drives the compressor, with the remaining one-third available as output. Combined cycle plants achieve efficiencies exceeding 60%.

Brayton Cycle

Gas turbines operate on the Brayton cycle, characterized by continuous combustion at constant pressure. This contrasts with the Otto cycle's constant volume combustion. The cycle involves compression, combustion, and expansion stages.

Wankel Engines

Rotary Design

The Wankel engine, or rotary engine, replaces pistons with a triangular rotor inside an epitrochoid-shaped housing. It follows the Otto cycle phases (intake, compression, power, exhaust) occurring simultaneously in different locations around the rotor. The rotor orbits the eccentric shaft, resulting in three power pulses per rotor revolution, but only one per eccentric shaft revolution.

Advantages

Wankel engines offer a higher power-to-weight ratio and smoother operation compared to piston engines due to the absence of reciprocating parts. They have been notably used in Mazda vehicles (RX-7, RX-8) and are also found in unmanned aerial vehicles where size and weight are critical.

Forced Induction

Increasing Air Density

Forced induction uses a compressor (driven by a supercharger or exhaust-powered turbocharger) to increase the pressure and density of intake air. This allows more fuel to be burned, significantly boosting engine power and efficiency, especially crucial for aviation engines operating at high altitudes.

Superchargers vs. Turbochargers

Superchargers are mechanically driven by the engine's crankshaft, providing boost directly related to engine speed. Turbochargers use exhaust gases to spin a turbine, which drives the compressor, offering efficiency benefits but potentially introducing lag.

Fuels and Oxidizers

Common Fuels

Most modern ICEs use hydrocarbon fuels derived from fossil fuels, including gasoline (petrol), diesel fuel, natural gas, and LPG (propane). These fuels store significant chemical energy released through combustion with an oxidizer, typically atmospheric oxygen.

Alternative Fuels

Biofuels like ethanol and biodiesel, along with hydrogen, wood gas, and biogas, can also power ICEs, often requiring engine modifications. Hydrogen offers zero carbon emissions during combustion but faces storage challenges. The choice of fuel impacts efficiency, emissions, and engine design.

Oxidizers

While atmospheric air is the most common oxidizer, special applications use compressed air, pure oxygen (liquid or gaseous), nitrous oxide, or hydrogen peroxide. Rockets, for instance, often utilize liquid oxygen as a powerful oxidizer.

Cooling Systems

Preventing Overheating

Cooling is vital to prevent engine failure from excessive heat. Common methods include air cooling (using fins) and liquid cooling (circulating coolant through passages, often called a water jacket). Many engines also employ oil coolers. In some high-performance applications, fuel itself can be used as a coolant.

Starting Mechanisms

Ignition and Rotation

ICEs require initial rotation to start their cycles. This is achieved through various methods: hand cranks (early automobiles), electric starters (most modern vehicles), kick starters (motorcycles), pull-rope mechanisms (small engines), or compressed air starters (large diesel engines).

Ignition Systems

Spark Ignition (SI) engines rely on spark plugs energized by magnetos or battery-based systems (like capacitor discharge ignition - CDI). Compression Ignition (CI) engines rely solely on the heat from high compression, sometimes aided by glow plugs for cold starts.

Performance Measures

Efficiency and Power

Engine performance is measured by energy efficiency (converting fuel energy to work), fuel consumption (e.g., Brake Specific Fuel Consumption - BSFC), power-to-weight ratio, and torque/thrust characteristics. Theoretical efficiencies are limited by thermodynamic cycles (like Carnot), while practical efficiencies are affected by friction, heat loss, and operating conditions.

Fuel Economy

Vehicle fuel economy is measured in miles per gallon (MPG) or liters per 100 kilometers (L/100km). While modern engines incorporate efficiency aids, average thermal efficiency is often around 18-20%, though high-performance and specialized engines can exceed 50%.

Pollution Impact

Air Pollutants

Incomplete combustion releases pollutants like particulate matter (PM), nitrogen oxides (NOx), carbon monoxide (CO), unburnt hydrocarbons, and sulfur dioxide (SO2) if sulfur is present in the fuel. NOx contributes to ground-level ozone formation, while SO2 contributes to acid rain.

Climate Change

The combustion of fossil fuels releases carbon dioxide (CO2), a primary greenhouse gas contributing to climate change. Reducing CO2 emissions involves improving engine efficiency and transitioning to sustainable fuels or alternative powertrains like electric motors.

Noise Pollution

ICEs are significant contributors to noise pollution through exhaust noise, mechanical operation, and intake noise. Aircraft and rocket engines generate particularly intense noise levels.

Idling Emissions

Engines consume fuel and emit pollutants even when idling. Stop-start systems are implemented in many vehicles to reduce idling time and associated emissions.

CO2 Formation

Calculating Emissions

The mass of CO2 produced per liter of fuel can be estimated based on the fuel's carbon content and the stoichiometry of combustion. For diesel (approx. 86% carbon by weight), burning 1 liter produces roughly 2.63 kg of CO2. This calculation highlights the significant carbon footprint of fossil fuel combustion.

Combustion Chemistry

Complete combustion of hydrocarbons yields CO2 and water. Incomplete combustion, due to insufficient oxygen or flame quenching, produces CO, unburnt hydrocarbons, and soot. Increasing air supply reduces incomplete combustion but can increase NOx formation.

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References

References

A full list of references for this article are available at the Internal combustion engine Wikipedia page

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