Diploma in Automobile Engineering

automobile-engineering

Syllabus

Faculty: Manas Ranjan Padhi

Diploma Course : Automobile Engineering

Total Course Credit (T-P-P): 20 (7-7-6)

Course Description:

Automobile Engineering is a fascinating branch of Engineering which makes a study of the self-propelled vehicles in the context of purpose, constructional and operational details of different components and their maintenance. The course has been designed for meeting the growing needs of experts in automobile sector.

Type of Course: Diploma Course
Eligibilty: Diploma, B.Tech

Course Objectives

1. To familiarize the students with different systems and subsystems of automobile.
2. To teach basic skill in maintenance of different types of automobiles.
3. To know the operation and maintenance of electric vehicle.

Learning Outcomes

1. Students will gain knowledge about the construction and working of different systems and subsystems of automobile.
2. They will be able to disassemble and assemble major aggregates of the automobile
3. Students will be able to do vehicle trouble shooting

Course Division:

Introduction to Automobile (2-1-0)
Subsystems of Automobile (3-2-0)
Electric Vehicles (2-1-0)
Maintenance of Automobile (0-3-0)
Projects (0-0-6)

Course Syllabus

Introduction to Automobile Engineering

Automobile Architecture:
Definition and Classification of Automobiles, Major Units of the Automobile, Types of Automobile Layouts, Automobile Chassis Types and Components, Automobile Body Types and Components, Automobile Safety Parameters.
Engine:
Classification of Engine, Engine Nomenclature, Components of Engine, Valve Timing Diagram of SI & CI Engines, Variable Valve Timing, Working Principles of Modern Engine Combustion Technologies (CRDI, GDI, HCCI, Dual Fuel Engine, Stratified Charge Engine.
Carburetion:
Air-Fuel Ratio, Mixture Requirements for Different Load Conditions, Factors Affecting Carburetion, Principle of Carburetion, Limitations of Simple Carburettor, Additional Systems in Carburettor, Concept of Electronic Carburettor.
Practice: Model Study of a Solex Carburettor.
Fuel Injection:
BS4 AND BS6 ENGINE SYSTEM, Classification of Injection Systems, Fuel Feed Pump, Injection Pump, Injection Pump Governor, Fuel Injector and Nozzle, Electronic Injection Systems, Multi-Point Fuel Injection (MPFI) System, Direct and Indirect Fuel Injection.
Practice: Study of Fuel Injection System of a Diesel Engine.
Transmission System:
Layout of Power Flow from Engine to Wheels, Brief Construction and Working Principles of - Clutch, Transmissions, Propeller Shaft, Final Drive and Differential, Front and Rear Axles.
Practice:

Study of Transmission System of Automobile.
Model Study of Differential of Automobile.

Cooling and Lubrication System:
Direct Air Cooled and Indirect Liquid Cooled Cooling Systems, Types and Components of Liquid Cooled Cooling System, Engine Coolant and Antifreeze Solution, Desired Properties of Lubricants, Classification, Construction, Working Principles and Components of Various Types of Lubricating Systems.
Practice:

Model Study of Air Cooling System.
Model Study of Liquid Cooling System.

Super Charging &Turbo Charging:
Naturally Aspirated and Forced Induction Engine, Effect of Forced Induction, Method of Supercharging, Types of Super Chargers, Basic Principle and Method of Turbo Charging, Types of Turbo Charging, Concept of Variable Geometry Turbocharging.
Practice:

Study of Working Model of Supercharger.
Study of Working Model of Turbocharger.

Subsystems of Automobile

Engine Emissions:
Sources of Air Pollution from Automobiles and Their Control, Crank Case Emission Control System, Evaporative Emission Control System, Exhaust Emission Control System: Air Injection, EGR, Catalytic Converters, Selective Catalytic Reduction (SCR) Technology, EURO/Bharat Stage Norms: I, II, III, IV, V And VI, Road Map for Implementation of Bharat Stage Norms In India.
Practice:

Identification of Different Sub-Systems of Automobile.
Studies of Exhaust Gas Recirculation System (EGR) in KNOW Vehicle.

Ignition System:
Effect of Spark Timing on Emission and Ignition Timing Controls, Drawbacks of Conventional Ignition Systems, Electronic Ignition Systems (TCI and CDI), Engine Cylinder Numbering Scheme and Firing Order of Multi Cylinder Engines.
Practice:

Study of Battery Ignition and Magneto Ignition System.
Disassembly and Assembly of 6-Cylinder Diesel Engine.

Transmission System:
Power Transmission in Automobile (Front Wheel Drive, Rear Wheel Drive, Four-Wheel Drive, All-Wheel Drive), Clutch System: Key Design Considerations of Clutches, Types of Clutches, Construction and Working Principle of Single Plate Friction Clutch, Diaphragm Clutch, Cone Clutch, Centrifugal Clutch.
Gear Box:
Purpose of Gear Box, Types of Automobile Gear Boxes, Construction and Working Principle of Sliding Mesh, Constant Mesh, Synchronizer Mechanism and Synchromesh Gear Boxes, Planetary Gear Mechanism.
Practice:

Study of Single Plate Friction Clutches (Coil Spring Type And Diaphragm Type).
Study of Synchronizer Mechanism And Synchromesh Gear Box, Continuously Variable Transmission (CVT).

Steering System:
Purpose of Steering System, Components of Steering System, Steering Geometry (Castor, Camber, Toe-In, Toe-Out, King Pin Inclination), Types of Steering Gear Boxes and their Construction and Working Principles
Braking System:
Requirement and Key Design Parameters of Braking System, Classification and Types of Braking Systems, Mechanical Brake, Hydraulic Brake, Air Brake, Vacuum Brake, Disc Brake. Construction, Working Principle and Components of Anti-Lock Braking System (ABS).
Practice:

Study of Steering Gear Box And Hydraulic Power Assisted Steering System.
Identifying the Different Components and Working Of Drum Brake, Disc Brake, Hydraulic Brake, Air Brake System.
Study of Anti-Lock Braking System (ABS) In KNOW Vehicle.

Maintenance of Automobile (Practice)

Safety Precautions in Automobile Maintenance.
Identification and Functions of Various Tools and Equipment used in Automobile Workshop.
Disassembling and Assembling of Engine of a Four Wheeler.
Disassembling and Assembling of Engine of a Two Wheeler.
Engine Troubleshooting.
Nomenclature of a Spark Plug and Spark Plug Reading, Testing and Cleaning of Spark Plug.
Checking and Replenishing Lubricating Oil, Engine Coolant, Power Steering Hydraulic Oil and Wind Screen Wiper Water.
Overhauling and Servicing of Fuel System including Air Filter.
Disassembling and Assembling Of Clutch, Clutch Troubles and Remedies.
Repairing and Adjustment of Brake System.
Disassembling and Assembling of Propeller Shaft.
Inspection and Servicing of Gear Box.
Inspection and Servicing Of CVT.
Tire Change Operation, Wheel Balancing, Wheel Alignment, Tire Inspection (Tubeless & Tube) and Inflation.
Overhauling of Suspension System.
Disassembling and Assembling of Steering System and Adjustment of Drag Link.
Preparation of Electrical Circuits using Switches and Fuses.
Checking of Battery Terminal Voltage, Electrolyte Level and Specific Gravity.
Inspection of Different Electrical Circuits and ECU.
Checking of Ignition System Circuit & Components.

Electric Vehicles

Introduction:
Introduction to Electric Vehicles: Electric Vehicles Advantages and Disadvantages, EV Market and Promotion, Main Components of Electric Vehicle and Its Functions (Electrical and Mechanical).
Electric Vehicle Drive Trains: EV Transmission Configurations, Basic Architecture of Electric Drive Trains, Single and Multi-Motor Drives, In Wheel Drives.
Energy Sources: Working Principle of Battery, Types of Batteries, Lead-Acid Battery, Nickel-Cadmium Battery, Nickel-Metal-Hydride (Nimh) Battery, Lithium Batteries, Battery Parameters, Fuel Cells.
Electric Motors: Classification of Electric Motors, DC Motor, Types of DC Motors, Brushless DC Motor, AC Motor, Types of AC Motors, Induction Motor, Synchronous Motor, Regenerative Braking.
Design Concept of Electric Vehicle: Power and Torque Calculation of Electric Vehicles, Sizing of Components, Initial Acceleration, Maximum Velocity, Maximum Grad ability.
Practice:

Study of Different Components of E-Rickshaw and Assembling Methods.
Working of Circuits in Controllers with respect to Current and Voltage Rating.
Maintenance of Lead Acid Batteries.
Wiring & Harnessing of Battery Circuit.
Study of Different Parts of D.C. Motor and Make Connection.
Performance Characteristics of a Shunt and Series DC Motor.
Load Test on Three Phase Induction Motor.
Speed Control of DC Shunt Motor by Armature and Field Control.
Maintenance of BLDC Motor.

Text Books

Gupta R. B., Automobile Engineering, Satya Prakashan, New Delhi.
Giri N. K., Automobile Technology, Khanna Publishers.
Hussein Iqbal, Electric and Hybrid Vehicles: Design Fundamentals, CRC Press
Chau K. T., Electric Vehicle Machines and Drives: Design, Analysis and Application,Wiley.

References

Gupta H. N., Fundamentals of Internal Combustion Engines, PHI Learning.
Crouse William H and Donald Anglin, Automotive Mechanics, Tata Mcgraw Hill Publications.
Newton K., Steeds W, and Garrett T K, The Motor Vehicle, Butterworth Heinemann
Training Manual Of Four Wheeler Maintenance (Ashok Leyland)
Training Manual Of Two Wheeler Maintenance (Yamaha)
Chan C.C. and Chau K.T., Modern Electric Vehicle Technology, London: Oxford University.

Session Plan

Introduction to Automobile Engineering

Session 1

Automobile Architecture: Definition and Classification of Automobiles, Major Units of the Automobile.
Class Notes: Introduction-to-Automobile-Engineering

Session 2

Types of Automobile Layouts, Automobile Chassis Types and Components
Video: https://www.youtube.com/watch?v=n1cTMnNn-XI

Session 3

Automobile Body Types and Components, Automobile Safety Parameters.
Video: https://www.youtube.com/watch?v=ZuJMtW3xeNQ

Session 4

Engine: Classification of Engine, Engine Nomenclature
Class Notes: Study of engine components their construction, operating principles and functions

Session 5

Components of Engine
Class Notes: I C Engine Cycles, I C Engine Fuels, IC Engine testing, SI engine ignition system
Video: https://spark.adobe.com/page/R8oOfvbN8utQt/

Session 6

Valve Timing Diagram of SI & CI Engines
Class Notes: Study of Engine Valve systems, valve mechanism, Valve timing diagram
Video: https://spark.adobe.com/page/dvrGdqC3rXuej/

Session 7

Variable Valve Timing
Video: https://www.youtube.com/watch?v=glUXDMuQ3Bs

Session 8

Working Principles of Modern Engine Combustion Technologies (CRDI, GDI, HCCI)

Session 9

Working Principles of Modern Engine Combustion Technologies ( Dual Fuel Engine, Stratified Charge Engine)

Session 10

Carburetion: Air-Fuel Ratio
Class Notes: Study of fuels, properties of fuels, calculation of air-fuel ratio

Session 11

Mixture Requirements for Different Load Conditions, Factors Affecting Carburetion

Session 12

Principle of Carburetion, Limitations of Simple Carburetor
Video: https://spark.adobe.com/page/pwbIeVMZ93xV0/

Session 13

Additional Systems in Carburetor, Concept of Electronic Carburetor

Session 14

Model Study of a Solex Carburettor (Practice)

Session 15

Fuel Injection: BS4 AND BS6 ENGINE SYSTEM
Video: https://spark.adobe.com/page/oIeMQPdxu5Lll/

Session 16

Classification of Injection Systems, Fuel Feed Pump
Class Notes: Study of fuel injection system
Video: https://spark.adobe.com/page/SQK1GMaYW6NPw/

Session 17

Injection Pump, Injection Pump Governor

Session 18

Fuel Injector and Nozzle, Electronic Injection Systems

Session 19

Multi-Point Fuel Injection (MPFI) System, Direct and Indirect Fuel Injection

Session 20

Study of Fuel Injection System of a Diesel Engine. (Practice)

Session 21

Transmission System: Layout of Power Flow from Engine to Wheels
Video: https://www.youtube.com/watch?v=Dh7IrZXM2mg

Session 22

Brief Construction and Working Principles of - Clutch, Transmissions, Propeller Shaft

Session 23

Brief Construction and Working Principles of - Final Drive and Differential, Front and Rear Axles
Class Notes: Differential & final drive system
Video: https://spark.adobe.com/page/BribGpetd9akK/

Session 24

Study of Transmission System of Automobile (Practice)

Session 25

Model Study of Differential of Automobile (Practice)

Session 26

Cooling and Lubrication System: Direct Air Cooled and Indirect Liquid Cooled Cooling Systems
Class Notes: Engine cooling system – need, cooling methods and main functional components
Video: https://spark.adobe.com/page/CnhmPnaxGELAD/

Session 27

Types and Components of Liquid Cooled Cooling System

Session 28

Engine Coolant and Antifreeze Solution
Class Notes: Study of need and type of thermostat valves & Additives in the coolant

Session 29

Desired Properties of Lubricants, Classification
Class Notes: Study of lubrication system
Video: https://spark.adobe.com/page/djXKUSNujarTR/

Session 30

Construction, Working Principles and Components of Various Types of Lubricating Systems
Class Notes: Study of lubricants – physical properties, additives and their application

Session 31

Model Study of Air Cooling System (Practice)
Video: https://www.youtube.com/watch?v=Ikdz3wx9iPc&t=4s

Session 32

Model Study of Liquid Cooling System (Practice)
Video: https://www.youtube.com/watch?v=V7inC4lOpGs&t=74s

Session 33

Super Charging &Turbo Charging: Naturally Aspirated and Forced Induction Engine
Video: https://www.youtube.com/watch?v=ImvM5N-H-10

Session 34

Effect of Forced Induction

Session 35

Method of Supercharging, Types of Super Chargers
Video: https://www.youtube.com/watch?v=oHEulOcU7jY

Session 36

Basic Principle and Method of Turbo Charging
Video: https://www.youtube.com/watch?v=DqWKNuTppmU&t=77s

Session 37

Types of Turbo Charging
Video: https://www.youtube.com/watch?v=gN12b-dU2k8

Session 38

Concept of Variable Geometry Turbocharging
Video: https://www.youtube.com/watch?v=CbdY1rymBJg

Session 39

Study of Working Model of Supercharger (Practice)

Session 40

Study of Working Model of Turbocharger (Practice)

Subsystems of Automobile

Session 1

Engine Emissions: Sources of Air Pollution from Automobiles and Their Control
Class Notes: Automobile-Emissions
Video: https://www.youtube.com/watch?v=9jUmOjndVJc

Session 2

Crank Case Emission Control System, Evaporative Emission Control System

Session 3

Exhaust Emission Control System: Air Injection, EGR

Session 4

Catalytic Converters, Selective Catalytic Reduction (SCR) Technology

Session 5

EURO/Bharat Stage Norms: I, II, III, IV, V And VI
Video: https://www.youtube.com/watch?v=OKNUKYDGD1s

Session 6

Road Map for Implementation of Bharat Stage Norms In India

Session 7 & 8

Identification of Different Sub-Systems of Automobile (Practice)

Session 9, 10 & 11

Studies of Exhaust Gas Recirculation System (EGR) in KNOW Vehicle (Practice)

Session 12

Ignition System: Effect of Spark Timing on Emission and Ignition Timing Controls
Video: https://spark.adobe.com/page/KAKWUs2TL1kib/

Session 13

Drawbacks of Conventional Ignition Systems

Session 14

Electronic Ignition Systems (TCI and CDI)

Session 15

Engine Cylinder Numbering Scheme

Session 16

Firing Order of Multi Cylinder Engines

Session 17 & 18

Study of Battery Ignition and Magneto Ignition System (Practice)

Session 19 to 22

Disassembly and Assembly of 6-Cylinder Diesel Engine (Practice)

Session 23 & 24

Transmission System: Power Transmission in Automobile (Front Wheel Drive, Rear Wheel Drive, Four-Wheel Drive, All-Wheel Drive)
Video: https://www.youtube.com/watch?v=rHMDtEPeuQM

Session 25

Clutch System: Key Design Considerations of Clutches, Types of Clutches
Class Notes: CLUTCH
Video: https://spark.adobe.com/page/tzELSpdExApya/
Video: https://www.youtube.com/watch?v=6DL0j0eKD8Y

Session 26

Construction and Working Principle of Single Plate Friction Clutch
Class Notes: Different-subsystems-of-Automobile
Video: https://www.youtube.com/watch?v=HY_PjmHRxuE

Session 27 & 28

Diaphragm Clutch, Cone Clutch, Centrifugal Clutch
Video: https://www.youtube.com/watch?v=QpE-RbZKw1c
Video: https://www.youtube.com/watch?v=tFCo0lGWJGc
Video: https://www.youtube.com/watch?v=HrmWNBwHBQ0

Session 29

Gear Box: Purpose of Gear Box, Types of Automobile Gear Boxes
Class Notes: Gear system
Video: https://spark.adobe.com/page/VZ7yIOuIFxyzz/

Session 30 & 31

Construction and Working Principle of Sliding Mesh, Constant Mesh
Video: https://www.youtube.com/watch?v=9SB5OQh7qYg
Video: https://www.youtube.com/watch?v=eBFyfxTy3nE

Session 32 & 33

Synchronizer Mechanism and Synchromesh Gear Boxes, Planetary Gear Mechanism

Session 34, 35 & 36

Study of Single Plate Friction Clutches (Coil Spring Type And Diaphragm Type) (Practice)

Session 37 to 40

Study of Synchronizer Mechanism And Synchromesh Gear Box, Continuously Variable Transmission (CVT) (Practice)

Session 41

Steering System: Purpose of Steering System, Components of Steering System
Class Notes: Steering System
Video: https://spark.adobe.com/page/S6PShW20AyWqW/

Session 42

Steering Geometry (Castor, Camber, Toe-In, Toe-Out, King Pin Inclination)

Session 43 & 44

Types of Steering Gear Boxes and their Construction and Working Principles

Session 45

Braking System: Requirement and Key Design Parameters of Braking System
Class Notes: Brake system
Video: https://spark.adobe.com/page/AlaweFsPUq8vb/

Session 46

Classification and Types of Braking Systems

Session 47

Mechanical Brake, Hydraulic Brake

Session 48

Air Brake, Vacuum Brake, Disc Brake

Session 49 & 50

Construction, Working Principle and Components of Anti-Lock Braking System (ABS)

Session 51, 52 & 53

Study of Steering Gear Box And Hydraulic Power Assisted Steering System (Practice)

Session 54 to 57

Identifying the Different Components and Working Of Drum Brake, Disc Brake, Hydraulic Brake, Air Brake System (Practice)

Session 58, 59 & 60

Study of Anti-Lock Braking System (ABS) In KNOW Vehicle (Practice)

Maintenance of Automobile

Session 1 & 2

Safety Precautions in Automobile Maintenance (Practice)

Session 3 to 6

Identification and Functions of Various Tools and Equipment used in Automobile Workshop (Practice)

Session 7 to 16

Disassembling and Assembling of Engine of a Four Wheeler (Practice)

Session 17 to 22

Disassembling and Assembling of Engine of a Two Wheeler (Practice)

Session 23 to 30

Engine Troubleshooting (Practice)

Session 31 to 33

Nomenclature of a Spark Plug and Spark Plug Reading, Testing and Cleaning of Spark Plug (Practice)

Session 34 to 36

Checking and Replenishing Lubricating Oil, Engine Coolant, Power Steering Hydraulic Oil and Wind Screen Wiper Water (Practice)

Session 37 to 39

Overhauling and Servicing of Fuel System including Air Filter (Practice)

Session 40 to 44

Disassembling and Assembling Of Clutch, Clutch Troubles and Remedies (Practice)

Session 45 to 47

Repairing and Adjustment of Brake System (Practice)

Session 48 to 55

Disassembling and Assembling of Propeller Shaft (Practice)

Session 56 to 60

Inspection and Servicing of Gear Box (Practice)

Session 61 to 68

Inspection and Servicing Of CVT (Practice)

Session 69 to 73

Tire Change Operation, Wheel Balancing, Wheel Alignment, Tire Inspection (Tubeless & Tube) and Inflation (Practice)

Session 74 to 78

Overhauling of Suspension System (Practice)

Session 79 to 84

Disassembling and Assembling of Steering System and Adjustment of Drag Link (Practice)

Session 85 to 90

Preparation of Electrical Circuits using Switches and Fuses (Practice)

Session 91 to 93

Checking of Battery Terminal Voltage, Electrolyte Level and Specific Gravity (Practice)

Session 94 to 98

Inspection of Different Electrical Circuits and ECU (Practice)

Session 99 & 100

Checking of Ignition System Circuit & Components (Practice)

Electric Vehicles

Session 1

Electric Vehicles: Introduction to Electric Vehicles
Class Notes: Introduction to Electric Vehicles

Session 2

Electric Vehicles Advantages and Disadvantages
Video: https://www.youtube.com/watch?v=sma5T3Ml5tE

Session 3

EV Market and Promotion

Session 4 & 5

Main Components of Electric Vehicle and Its Functions (Electrical and Mechanical)

Session 6

Electric Vehicle Drive Trains: EV Transmission Configurations
Class Notes: Electric Vehicle Drive Trains
Video: https://spark.adobe.com/video/zjH3343Spcs5p

Session 7

Basic Architecture of Electric Drive Trains
Video: https://spark.adobe.com/video/w9I8559F0N8ge

Session 8

Single and Multi-Motor Drives

Session 9

In Wheel Drives
Video: https://spark.adobe.com/video/XBfTgLgbbJprr

Session 10

Energy Sources: Working Principle of Battery
Class Notes: Energy Sources
Video: https://spark.adobe.com/video/K4wlTyc1EUcXl

Session 11

Types of Batteries, Lead-Acid Battery

Session 12

Nickel-Cadmium Battery, Nickel-Metal-Hydride (Nimh) Battery

Session 13

Lithium Batteries

Session 14

Battery Parameters, Fuel Cells

Session 15

Electric Motors: Classification of Electric Motors, DC Motor
Class Notes: Electric Motors

Session 16

Types of DC Motors, Brushless DC Motor
Video: https://www.youtube.com/watch?v=bCEiOnuODac&t=201s

Session 17

AC Motor, Types of AC Motors

Session 18

Induction Motor
Video: https://www.youtube.com/watch?v=AQqyGNOP_3o&t=210s

Session 19

Synchronous Motor, Regenerative Braking
Video: https://www.youtube.com/watch?v=Vk2jDXxZIhs

Session 20 & 21

Design Concept of Electric Vehicle: Power and Torque Calculation of Electric Vehicles
Class Notes: Design Concept of Electric Vehicle

Session 22

Sizing of Components, Initial Acceleration

Session 23

Maximum Velocity

Session 24

Maximum Grad ability

Session 25 to 27

Study of Different Components of E-Rickshaw and Assembling Methods (Practice)

Session 28 to 30

Working of Circuits in Controllers with respect to Current and Voltage Rating (Practice)

Session 31 & 32

Maintenance of Lead Acid Batteries (Practice)

Session 33 to 35

Wiring & Harnessing of Battery Circuit (Practice)

Session 36 to 38

Study of Different Parts of D.C. Motor and Make Connection (Practice)

Session 39 to 41

Performance Characteristics of a Shunt and Series DC Motor (Practice)

Session 42 to 44

Load Test on Three Phase Induction Motor (Practice)
Video: https://www.youtube.com/watch?v=SLXfahyRRdU