My first Shortfilm : Oru Naanayam (ഒരു നാണയം)

Posted in Technical by Manu E Nampoothiri on February 25, 2014

This was my first direction venture, As my aim through this creation is to tell the entire story through the visual media.
A visual story telling has many more dimensions, so only natural sounds were used in it.
Natural lighting will add the realistic effect I think.

Please watch and give your valuable suggestions.



Posted in Technical by Manu E Nampoothiri on October 5, 2008

A rising rate of oil is a raising problem in the minds of all human beings and especially in the minds of scientists and engineers for getting a future fuel, which will not raise any more problem. Then they get an unsolved answer, that is the WATER which is the gift of god and is plenty on earth.

How can we use water as a fuel ?

As we study in smaller classes the water can be electrolyzed by using  water, a salt, electrodes, etc. Which will then gives two component gases OXYGEN and HYDROGEN, in the ratio 1 : 2 , that is ONE part of oxygen and TWO part hydrogen.

After the electrolysis in a closed container , if we bring a spark near the nose and open it there will form a combustion of the hydrogen gases, which is collected during electrolysis. If we could use this combustion inside the engine cylinder, then we could gain a vast future in our hand.

Thus there comes the idea of generating OxyHydrogen ( Oxygen-1 + Hydrogen-2) or “HHO“, and using it in right way to produce the required result.

A pure stoichiometric mixture is most easily obtained by water electrolysis, which uses an electric current to dissociate the water molecules:

electrolysis: 2 H2O → 2 H2 + O2
combustion: 2 H2 + O2 → 2 H2O

It says that for a combustion of Hydrogen and Oxygen will produce only water in the form of steam. Where steam having no pollution in the atmosphere.


For cars (gasoline) there is a chance of coversion of normal engine to a OxyHydrogen enabled engine which uses the technique explained above. Besides cars there is also a probability of converting the bikes and also the heavy vehicles to a HHO fueled engine. Since the water andhydrogen is renewable and will not pollute the atmosephere. For aviation turbojet engines the HHO will produce a tremendous change. Low cost of running and maintanance will take the technique to the common man also.

Hydrogen has a LCV(Lower Calorific Value) above that of gasoline and the diesel. It is around 241.8 KJ.

For welding (Gas welding) it had started using HHO as a fuel.

Typical Gas Welding machine uses HHo as a fuel.

Typical Gas Welding machine uses HHo as a fuel.


  • Risk of blaster of hydrogen (If stored as Hydrogen only).
  • Storage of Hydrogen needs low temperature and high pressure. Which makes it difficult to be used in vehicles.

How can we use it in vehicles

By making a chamber for electrolysis of water and a collecting tube which may or may not mix the Hydrogen and Oxygen. Then the collected gas is then stored temporarily in a cylinder for immediate use of the fuel. The Advantage of the HHO is that it can be burned at a HHO percentage ranging from 4%  to 94%. Out of the range it may not burn or may damage the cylinder walls.

Note: The above provided information belongs to the author only, and any clarification will be accepted . © Copyright. COMMENTS PLEASE >

Some tips for extending your car’s life.

Posted in Technical by Manu E Nampoothiri on September 9, 2008

Car is now a part of life and, so it shouldn’t be considered only as a machine but as a friend or our body as such. Care is to be taken over every section of driving and all over the car.
Firstly think that the car is a living thing and so it has pain and will do reaction to our every actions, so do good things to a car. And caring it, will give us more attention on our car and also the attention will reduce damage and misuse of car and also the fuel. In my life car is like a brother or sister , I get pain when I do simple mistakes such as raising it rapidly and running it faster through dump. Also these mistakes pain your car, and these mistakes may lead to uneven wear of moving parts and thus reduces the life of the vehicle.
I am trying to give a simple guidance as what to ‘do’ and ‘do not’.

Driving tips

Driving tips

  • While starting a car look for the fuel level and the A/C switch. If the A/C switch is on, switch it off . The reason is that every IC engines are made to START and STOP on no-load. Do not raise the engine when you start the engine from a cool temperature, because the engine should be gradually heated and the rapid heating may affect the engine material thermally.
  • Air conditioner is an machine which requires more engine power and thus more fuel. So use the air-conditioner if necessary. In most of cars A/C will consume about 20% of fuel in addition. Thus it will affect the fuel efficiency of engine. Kindly don’t use A/C in lower gears and greater speeds, Since lower gears run at low RPM (Revolutions Per Minute) thus require more power to run the A/C. At high speed (above 70Km/hr). the engine will use about 15% of extra fuel. Now imagine, you are running your car at a speed of 75 kmph and the A/C is working, the fuel usage will be 20% + 15% that is 35% extra or 135% of normal rate. The wearing out of the moving parts yet not considered.

While Driving

  • Usually we are not going to a rally or car race, so please do not accelerate rapidly by applying full throttle. Since each and every car will have a maximum limit of acceleration (eg:  0-60 in 11secs). If we apply more fuel the engine will not be able to deliver that much acceleration. Thus wasting the extra amount of fuel supplied. These large amount of fuel will produce huge combustion inside the engine cylinder, which may lead to cracking the walls.
  • After you have completed the needed gear shift, remove immediately your foot from the clutch pedal. If you put legs on the clutch pedal, there will be application of clutch in small percentage. This is enough to reduce the efficiency of transmission and increase the worn out of frictional surface in side the clutch plates. Remember, don’t run vehicles on half clutch for more time.
  • Run the car at a moderate speed of 50-70 Kmph, which is controllable and economical in most of the cars. Thus reduce chance of accidents.
  • Drive carefully so that the CAR, YOU and the PASSENGERS are comfortable. Don’t take risky tasks while driving at high speeds.
  • The Best feature of a good driver is his ability to make the journey much comfortable and also smoother. For that the breaking and shifting of gears should be in a smooth way. Larger breaking speeds will reduce the appeal of passengers on driver. Slow down when a hump or dump is in front, so that the passengers will not get oscillated up and down.
  • Do not turn the vehicle at high speed, since it will drag the passengers through one another and feel lack of comfort.
  • Obey the traffic rules.
  • Take the vehicle to routine service regularly and get advice from the service personnel.
  • Fill the fuel at cool time of the day, so that the fuel quantity will not be less.
  • Change the engine oil, transmission oil at regular periods.
  • Check the air pressure in the four tyre once/twice in a month. Get 1pound extra if the load on the vehicle is increased by 50kg.
  • Check coolant liquid level before going for every drive.
  • Please do not drive on alcohol, since the brain and hand, leg coordination will not be in good condition. Saving a life is better that driving after drinking.
  • Avoid driving at late nights, as our brain may get asleep without our permission.
  • Use indicators and hand signals at required situations.
  • Do not use any accessories that is not genuine. Especially for the machine parts only use genuine spares, since the non genuine parts may increase worn out and adversely affect the machine performance.
  • Do not use any additives in the fuel for increasing fuel efficiency or power, because it will gradually kill the engine parts.
  • Reduce use of the reverse gear, since the reversing will take about 1.5 time a the fuel which is needed for moving forward

Comments and questions are needed for my further post to be excellent.

© this post is owned by the author only. And any reproduction needs the permission of author.

Posted in Car Review, Technical by Manu E Nampoothiri on August 15, 2008

As you know the Hyundai i10 has launched on October 2007 in india. As the car is in mini car segment it is having a sleek and compact design with incorporated luxury in it. In last month the had revised the engine technology in i10 so as to keep challenge against the competitors. The new technology thus introduced is the Kappa engine.

Kappa engine fitted i10

Kappa engine fitted i10

Hyundai´s i10 minicar with a 1.25 liter Kappa engine will deliver a fuel economy rating of 5.0L/100km (47 mpg) in the European combined test cycle––for best in class performance. And Kappa runs cleaner than the competition: In the European combined test cycle, an i10 equipped with the Kappa engine produces just 119g/km of CO2–far less than the Fiat Panda, Fiat Punto, Opel Corsa, Renault Twingo and Nissan Micra.

Kappa also impresses with its high specific torque rating of 9.6kg.m per liter––best in class––for excellent drivability in stop–and–go city traffic. Kappa will also be installed in Hyundai´s i20 due to be revealed at this autumn´s Paris Auto Show.

Developed over a period of 48 months, the Kappa project harnessed all of Hyundai´s engineering know–how in the quest to squeeze more energy out of each droplet of fuel while achieving EURO–4 emissions compliancy.

Kappa puts out 77.8ps@6000rpm––very competitive within the European A–segment––but peak torque is rated best–in–class at 12.0kg.m per 4000rpm––ensuring outstanding acceleration and driving enjoyment.

Kappa adopts a number of weight and friction reducing innovations to achieve its impressive fuel economy.

First, the engine block is made from high pressure die–cast aluminum which results in considerable weight savings: Weighing a mere 82.4kg (1.2 with manual gearbox)?Kappa is the lightest in its class among leading European and Japanese–made engines (using the same measuring criteria across the competitive set).

The Kappa engine

The Kappa Engine

Kappa´s main block features a ladder frame construction for superior structural stiffness while its cylinders are fitted with cast–iron liners for improved abrasion durability. Additional weight was shaved off by integrating the engine support bracket with the timing chain cover.

But probably the most significant engineering innovation is Kappa´s offset crankshaft, an engineering concept first adopted in the Gamma engine introduced last year.

Unlike a conventional engine where the centreline of the cylinder bore is in perfect vertical alignment with the rotating axis of the crankshaft, the Kappa´s centreline is offset by a small distance. By creating this offset distance, engineers have succeeded in minimizing the side force created by the pistons. The net effect is an improvement in fuel consumption and a reduction in noise, vibration and harshness.

Engineers also devised an innovative piston concept to reduce piston mass. The shape of the piston skirt was optimized to reduce its size while the compression height of the piston was also reduced, resulting in precious weight savings.

The optimized piston skirt is also treated with Molybdenum Disulfide (MoS2), a special anti–friction coating.

A highly sophisticated process of Physical Vapor Deposition (PVD) is used to apply an ultra–thin layer of chromium nitride (CrN) to the piston´s oil ring. CrN ensures high wear resistance and a low friction coefficient. CrN–coated piston rings using PVD is an innovative technology borrowed from the Tau V8 engine that Hyundai introduced earlier this year. Friction between the oil ring and cylinder wall has been further minimized by reducing the oil ring tension. The smaller mass and special surface treatment of the piston skirt and oil rings yielded additional savings in fuel consumption.

Kappa is the first Hyundai engine to be fitted with an accessory drive belt which does not require a mechanical auto–tensioning adjustment device, reducing the hardware and further lowering weight and cost. Because it is designed to maintain an ideal tension setting, the belt runs quieter and with proper preventative maintenance and care, the belt will last 100,000 miles.

Kappa uses a new, longer reach spark plug which enabled engineers to enlarge the size of the water jacket to promote more efficient engine cooling around the critically important spark plug and exhaust port area. Cooler operation also prevents engine knocking.

The long reach spark plug (M12 thread) also enabled engineers to enlarge the valve diameter for increased airflow and combustion efficiency.

Kappa´s valvetrain features a number of innovations: roller swing arm lowers friction in the valvetrain thereby helping improve fuel efficiency. Hydraulic lash adjusters ensure clearances between the valve stem and roller swing arm are always perfect: zero, eliminating valve tapping noise.

A new valve spring features an innovative beehive shape and smaller retainer. Its reduced weight and spring load help lower friction and improve fuel economy.

Kappa´s valvetrain is driven by a silent–type steel timing chain that replaces roller–type timing chain: The optimized design greatly reduces impact forces and noise when the gear tooth and chain engage. Moreover, the chain requires absolutely no maintenance.

A lightweight, heat–resistant engineering plastic was specified for the intake manifold. This reduces cost and weight and yields an overall performance improvement.

The fuel delivery pipe assembly is a returnless type (to eliminate evaporative fuel emissions) and is made of SUS (steel use stainless) with an innovative inner structure for the reduction of pulsation noise.

Kappa is controlled by two 16–bit 32Mhz microprocessors for digitally precise control of the ignition timing, idle speed, knocking and emissions.

Kappa is the eleventh in its series of gasoline engines to be independently developed with Hyundai technology. The development story began in 1991 with the introduction of Hyundai´s first proprietary engine, the four–cylinder Alpha (see list below). Kappa will be manufactured in two variants 1.25 litres (EU) and 1.2 litres (Indian market only) at HMI´s No. 2 engine plant, where annual output is forecast to reach 250,000 units per year. With the newly–constructed No. 2 Kappa engine plant, HMI will have a total engine manufacturing capacity of 570,000 units per year, including the existing 320,000 units–per–year No. 1 Epsilon and Alpha engine plant. The Kappa engine plant begins production on July 15.

The information provided above is collected from read it