Major Project on

Spark Plug Testing MachineBy

• B.Shravan(11PQ1A0310)

• M.Prabhakar Reddy(11PQ1A0323)

• R.Sridhar(11PA1A0333)

• B.Ashok(11PQ1A0307)

• Under esteemed guidance of Mr.V.Ganesh

Contents

• Introduction

•Working plan

•Working design

• Specifications

•Defects in spark plug

•Working operation

•Benefits of testing

•Conclusion

Introduction about Spark plug

• A spark plug is a device for delivering electric current

from an ignition system to the combustion chamber of a

spark-ignition engine to ignite the compressed fuel/air

mixture by an electric spark.

• Spark plugs usually require voltage of 12,000–25,000

volts or more to 'fire' properly, although it can go up to

45,000 volts.

Spark plug anatomy

What does the tester do!!

• The Spark plug tester performs the following functions to

check the proper working of the Spark plug.

• Checks if the Spark plug is accepting current from the

wires that go to the spark plug.

• Proper firing of the Spark plug.

•Repairing/cleaning the spark plug.

Block Diagram of Work Plan

Study on Spark Plug

and its Efficiency with

respect to usage and life

Design Solution for

performance

improvement and

efficiency losses

Fabricating the

machine

Designing the machine Operation of the

machine

Working Design

Specifications

• Working Air Pressure : 5kg/cm2 – 16kg/cm2

o For Cleaning the Plug - 5kg/cm2 – 16kg/cm2

o For Electrical Testing of the Plug - 10 kg/cm2 – 16kg/cm2

• Power Supply : Input Voltage 220V AC with earth

o Output Voltage 12kv – 19kv (HT voltage)

• Electronic Vibrator : 220V/12V

Appearance Symptoms Remedy

Carbon

deposits

• Dry sooty deposit on

plug.

• Causes misfiring.

• Use a spark plug with

longer core nose.

Detonation

• Insulators may be

cracked or chipped.

• Leads to piston damage.

• Make sure fuel antiknock

values meet engine

requirements.

Mechanical

Damage

• Caused by foreign object

in combustion chamber.

• Causes a dead cylinder

or damages piston.

• Remove the foreign object

from the engine.

Defects in spark plug and their remedies

Splash

deposits • Causes misfiring

• Replace the plugs with new

ones or clean and reinstall

the originals.

Gap

bridging

• Combustion deposits

lodge between electrodes

and bridge the gap

between them.

• Locate the faulty plug and

remove and remove the

deposits between the

electrodes.

Ash deposits • Light brown deposits

encrusted on the centre

electrodes or both which

may mask the spark

causing misfiring

• Install new valve guides to

prevent seepage of oil into

combustion chamber.

• Also try changing gasoline

brands.

High speed

gazing

• Insulator has yellowish

glazed appearance.

• Causes misfiring at high

speeds.

• Install new plug.

Working operation

• The project which is the modified version of the conventional

method.

• A 230 voltage electric current is supplied and it is stepped down

to 12 voltages which only is compatible with the design of contact

breaker point and it is primary winding.

• Parallelly a motor is connected to a CAM. When the motor rotates

the connected CAM also rotates. The CAM and the contact

breaker point are connected together by an adjusting screw.

• The motor and the rotates and so the electric current is

supplied to the contact breaker point and the contact breaker

point opens and the electric current passes on through

winding.

• Now the 12 voltage is stepped up to 12000 voltages using a

High tension coiled (Secondary winding). Now we could test

the spark plug which is our ultimate objective.

Testing

• In conventional tester there are three ranges.

• If the violet spark appears it is in the good condition.

• If it is appeared in the “Yellow” range, the spark plug

is fair.

• If it appears in the no spark range the spark plug is

poor and is to be discharged.

Cleaning process

Spark plug repair or replacement conditions

STARTING TROUBLE LACK OF ACCELERATION

POOR FUEL ECONOMY ENGINE MISFIRING

Benefits of Testing Spark Plugs

& Replacing if underperforming

• Low harmful emissions.

•Better fuel economy.

•Orderly making of optional combustions.

• Trouble free and dynamic start.

• Keeps engine healthy.

How often should it be replaced

When a routine change persists then do it for every 10,000

kilometers.

Conclusion

Operation of an IC Engine requires 3 pivotal elements.

FUELAIR SPARK

Spark plug plays the major role in the working of IC engine ,so it

should be checked in order to the engine healthy

Thank you