Modern ignition systems

Mechanically timed ignition

Most four-stroke engines have used a mechanically timed electrical ignition system. The heart of the system is the distributor which contains a rotating cam running off the engine's drive, a set of breaker points, a condenser, a rotor and a distributor cap. External to the distributor is the ignition coil, the spark plugs, and wires linking the spark plugs and ignition coil to the distributor.

The power source is a lead-acid battery, kept charged by the car's electrical system, which generates electricity using a dynamo or alternator. The engine operates contact breaker points, which interrupt the current flow to an induction coil (known as the ignition coil).

The ignition coil consists of two transformer windings sharing a common magnetic core -- the primary and secondary windings. An alternating current in the primary induces alternating magnetic field in the coil's core. Because the ignition coil's secondary has far more windings than the primary, the coil is a step-up transformer which induces a much higher voltage across the secondary windings. For an ignition coil, one end of windings of both the primary and secondary are connected together. This common point is connected to the battery (usually through a current-limiting resistor). The other end of the primary is connected to the points within the distributor. The other end of the secondary is connected, via the distributor cap and rotor, to the spark plugs.

The ignition firing sequence begins with the points (or contact breaker) closed. A steady current flows from the battery, through the current-limiting resistor, through the coil primary, across the closed breaker points and finally back to the battery. This steady current produces a magnetic field within the coil's core. This magnetic field forms the energy reservoir that will be used to drive the ignition spark.

As the engine turns, so does the cam inside the distributor. The points ride on the cam so that as the engine turns and reaches the top of the engine's compression cycle, a high point in the cam causes the breaker points to open. This breaks the primary winding's circuit and abruptly stops the current flow through the breaker points.

Without the steady current flow through the points, the magnetic field generated in the coil immediately begins to quickly collapse. This rapid decay of the magnetic field induces a high voltage in the coil's secondary windings.

At the same time, current exits the coil's primary winding and begin to charge up the capacitor ("condenser") that lies across the now-open breaker points. This capacitor and the coil’s primary windings form an oscillating LC circuit. This LC circuit produces a damped, oscillating current which bounces energy between the capacitor’s electric field and the ignition coil’s magnetic field. The oscillating current in the coil’s primary, which produces an oscillating magnetic field in the coil, extends the high voltage pulse at the output of the secondary windings. This high voltage thus continues beyond the time of the initial field collapse pulse. The oscillation continues until the circuit’s energy is consumed.

The ignition coil's secondary windings are connected to the distributor cap. A turning rotor, located on top of the breaker cam within the distributor cap, sequentially connects the coil's secondary windings to one of the several wires leading to each engine's spark plugs. The extremely high voltage from the coil's secondary – often higher than 1000 volts -- causes a spark to form across the gap of the spark plug. This, in turn, ignites the compressed air-fuel mixture within the engine. It is the creation of this spark which consumes the energy that was originally stored in the ignition coil’s magnetic field.

High performance engines with 8 or more cylinders that operate at high r.p.m. as in motor racing that demand higher rate and energy of sparks than the simple ignition circuit can provide may use either of these adaptations:

* Two complete sets of coil, breaker and condenser can be provided for each half of the engine which is arranged in V-8 or V-12 configuration. Although the two ignition system halves are electrically independent, they typically share a single distributor which in this case contains two breakers driven by the rotating cam, and a rotor with two isolated conducting planes for the two high voltage inputs.

* A single breaker driven by a cam and a return spring is limited in spark rate by the onset of contact bounce or float at high rpm. This limit can be overcome by substituting for the breaker a pair of breakers that are connected electrically in parallel but spaced on opposite sides of the cam so they are driven out of phase. Each breaker then switches at half the rate of a single breaker and the "dwell" time for current buildup in the coil is maximised since it is shared between the breakers.

The Lamborghini V-12 engine has both these adaptations and therefore uses two ignition coils and a single distributor that contains 4 contact breakers.

Except that more separate elements are involved, a distributor-based system is not greatly different from a magneto system. There are also advantages to this arrangement. For example, the position of the contact breaker points relative to the engine angle can be changed a small amount dynamically, allowing the ignition timing to be automatically advanced with increasing revolutions per minute (RPM) and/or increased manifold vacuum, giving better efficiency. However it is necessary to check periodically the maximum opening gap of the breaker(s), using a feeler gauge, since this mechanical adjustment affects the "dwell" time during which the coil charges, and breakers should be replaced when they have become pitted by electric arcing.

This system was used almost universally until the late 1970s, when electronic ignition systems started to appear.



Electronic ignition

The disadvantage of the mechanical system is the use of breaker points to interrupt the low voltage high current through the primary winding of the coil; the points are subject to mechanical wear where they ride the cam to open and shut, as well as oxidation and burning at the contact surfaces from the constant sparking. They require regular adjustment to compensate for wear, and the opening of the contact breakers, which is responsible for spark timing, is subject to mechanical variations. In addition, the spark voltage is also dependent on contact effectiveness, and poor sparking can lead to lower engine efficiency. A mechanical contact breaker system cannot control an average ignition current of more than about 3 A while still giving a reasonable service life, and this may limit the power of the spark and ultimate engine speed.

Electronic ignition (EI) solves these problems. In the initial systems, points were still used but they only handled a low current which was used to control the high primary current through a solid state switching system. Soon, however, even these contact breaker points were replaced by an angular sensor of some kind - either optical, where a vaned rotor breaks a light beam, or more commonly using a Hall effect sensor, which responds to a rotating magnet mounted on a suitable shaft. The sensor output is shaped and processed by suitable circuitry, then used to trigger a switching device such as a thyristor, which switches a large flow of current through the coil. The rest of the system (distributor and spark plugs) remains as for the mechanical system. The lack of moving parts compared with the mechanical system leads to greater reliability and longer service intervals. For older cars, it is usually possible to retrofit an EI system in place of the mechanical one. In some cases, a modern distributor will fit into the older engine with no other modifications.

Other innovations are currently available on various cars. In some models, rather than one central coil, there are individual coils on each spark plug. This allows the coil a longer time to accumulate a charge between sparks, and therefore a higher energy spark. A variation on this has each coil handle two plugs, on cylinders which are 360 degrees out of phase (and therefore reach TDC at the same time); in the four cycle engine this means that one plug will be sparking during the end of the exhaust stroke while the other fires at the usual time, a so-called "wasted spark" arrangement which has no drawbacks apart from faster spark plug erosion; the paired cylinders are 1/4 and 2/3. Other systems do away with the distributor as a timing apparatus and use a magnetic crank angle sensor mounted on the crankshaft to trigger the ignition at the proper time.

During the 1980s, EI systems were developed alongside other improvements such as fuel injection systems. After a while it became logical to combine the functions of fuel control and ignition into one electronic system known as an engine management system.



Engine management

In an Engine Management System (EMS), electronics control fuel delivery, ignition timing and firing order. Primary sensors on the system are engine angle (crank or Top Dead Center (TDC) position), airflow into the engine and throttle demand position. The circuitry determines which cylinder needs fuel and how much, opens the requisite injector to deliver it, then causes a spark at the right moment to burn it. Early EMS systems used analogue computer circuit designs to accomplish this, but as embedded systems became fast enough to keep up with the changing inputs at high revolutions, digital systems started to appear.

Some designs using EMS retain the original coil, distributor and spark plugs found on cars throughout history. Other systems dispense with the distributor and coil and use special spark plugs which each contain their own coil (Direct Ignition). This means high voltages are not routed all over the engine, they are created at the point at which they are needed. Such designs offer potentially much greater reliability than conventional arrangements.

Modern EMS systems usually monitor other engine parameters such as temperature and the amount of uncombined oxygen in the exhaust. This allows them to control the engine to minimise unburnt or partially burnt fuel and other noxious gases, leading to much cleaner and more efficient engines.