CP: Mega Diesel Engine | Exceptional Engineering | Free Documentary

Class Plans
Featured Image

Set the Scene:

Let’s start with some engaging questions to connect your everyday life to the subject of the activity. Have you ever traveled by ship or ferry? What kind of engines do you think power these vessels? Have you ever heard of the MTU Series 8000 Mega Diesel Engine? How do you think it’s used in real-life applications? What do you think are some of the challenges in manufacturing such a powerful engine?

Featured Image Analysis & Prediction:

Look at the featured image of the MTU Series 8000 Mega Diesel Engine. What do you see in the image? What do you think this activity will be about based on this image? Do you think the engine is used for transportation, industry, or something else? What features of the engine can you identify from the image?

Introduction:

Read the introduction to the MTU Series 8000 Mega Diesel Engine and learn about its capabilities and applications. The MTU Series 8000 is one of the most powerful high-speed diesel engines in the world, used to power modern ships, including the catamaran ferry, Jean du Lavalette.

Video Engagement:

Watch the video associated with the activity: https://maestrocursos.com.br/quizzed-esl-activities/mega-diesel-engine-exceptional-engineering-free-documentary/. Pause the video at the following strategic points:

  1. When the video discusses the manufacturing process of the crankcase
  2. When the video shows the assembly of the engine’s components
  3. When the video explains the testing and quality control measures

For each pause point, reflect on or discuss the following questions:

  1. What materials are used to make the crankcase, and why are they important? How does the manufacturing process affect the engine’s performance?
  2. How do the engineers ensure the precise assembly of the engine’s components? What are the challenges they face, and how do they overcome them?
  3. What are the key factors in testing and quality control for the MTU Series 8000 engine? How do these measures ensure the engine’s reliability and efficiency?

Conclusion:

After completing the activity, reflect on what you have learned about the MTU Series 8000 Mega Diesel Engine. How has your understanding of the engine’s manufacturing process, assembly, and testing changed? What do you think are the most critical factors in ensuring the engine’s performance and reliability?

Key Vocabulary:

Term Definition Example Usage
Crankcase The core component of a diesel engine that houses the crankshaft and camshaft. The crankcase is made in a foundry in Bavaria, Germany, using steel scrap, pig iron, and deep drawn sheet metal.
Foundry A factory where metal is melted and cast into shapes. The foundry in Bavaria, Germany, has been molding steel for nearly 600 years.
Casting The process of pouring molten metal into a mold to create a shape. Molten metal is poured into a mold to cast a mega diesel engine, with the temperature strictly maintained above 1400°.
Gantry A type of crane or overhead structure used to lift and move heavy objects. The 16-ton steel block is lifted out of the casting pit using an overhead Gantry.
Camshaft A rod with cams that operate the valves in an engine. The cam shaft, 6M long and weighing 400kg, is assembled with precision, using liquid nitrogen to chill and contract guide pins for a firm fit.
Crankshaft A rod that converts the up-and-down motion of the pistons into rotary motion. The gigantic 6-ton crankshaft is crucial to the engine’s operation and is installed after the engine is turned upside down.
Piston A moving part that transfers force from the expanding gas in the cylinder to the crankshaft. The engine has 20 cylinder pistons, each with a capacity of 17.5 L, which house the combustion process in the power units.
Water Brake A device used to measure the power output of an engine by absorbing its energy and converting it into heat. The engine’s performance is measured with a water brake after it is started with an air starter.
Hydraulic Bolt Tensioning System A system used to tighten bolts using hydraulic pressure. A power unit is removed from a Series 8000 Mega diesel engine using a hydraulic bolt tensioning system and pulleys.
Overhaul A major maintenance or repair operation that involves disassembling and reassembling a machine or engine. The power unit is transported to a special frame for overhaul after being removed from the engine.

Vocabulary Quiz:

  1. What does the term “deep drawn sheet metal” refer to in the context of the MTU Series 8000 engine’s manufacturing process?
    1. A type of steel alloy used in the engine’s crankcase
    2. A process of molding steel into complex shapes
    3. A material used for casting the engine block
    4. A technique for cutting and shaping metal components
  2. Which of the following is a critical aspect of the casting process for the MTU Series 8000 engine’s crankcase?
    1. Maintaining a temperature below 1000°
    2. Using a measuring sleeve to control the metal’s temperature
    3. Ensuring the mold is filled with metal within 70 seconds
    4. Allowing the metal to cool slowly over several days
  3. What is the purpose of using liquid nitrogen in the assembly of the MTU Series 8000 engine’s cam shaft?
    1. To clean the cam shaft of dirt and debris
    2. To chill and contract the guide pins for a firm fit
    3. To lubricate the cam shaft during operation
    4. To test the cam shaft’s performance under extreme temperatures
  4. What is the function of the water brake in the testing of the MTU Series 8000 engine?
    1. To cool the engine during operation
    2. To measure the engine’s performance and output
    3. To test the engine’s durability and reliability
    4. To clean the engine’s components after testing
  5. What is the estimated lifespan of a mega diesel engine like the MTU Series 8000 under typical operating conditions?
    1. Up to 10,000 operating hours
    2. Up to 35,000 operating hours
    3. Up to 72,000 operating hours
    4. Up to 100,000 operating hours

Answer Key:

  1. B
  2. C
  3. B
  4. B
  5. C

Grammar Focus:

The passive voice is a grammatical construction where the subject of a sentence receives the action described by the verb. In technical descriptions, such as those found in the text about the MTU Series 8000 Mega Diesel Engine, the passive voice is often used to focus attention on the action rather than the doer of the action.

Grammar Quiz:

Choose the correct form of the verb in parentheses to complete each sentence in the passive voice.

  1. The MTU Series 8000 engine is designed (design, is designed, designing, to be designed) by engineers to power modern ships.
  2. The crankcase is made (makes, is made, making, to make) in a foundry in Bavaria, Germany.
  3. The engine’s components are measured (measure, are measured, measuring, to measure) with extreme precision to prevent disasters during operation.
  4. The cam shaft is assembled (assembles, is assembled, assembling, to assemble) with precision using liquid nitrogen.
  5. The engine is started (starts, is started, starting, to start) with an air starter, and its performance is measured.

Answer Key:

  1. is designed
  2. is made
  3. are measured
  4. is assembled
  5. is started