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Introduction

Introduction. Team Members Jeffrey Kung Richard Sabatini Steven Ngo Colton Filthaut. Faculty Advisor Jim Mohrfeld. Industry Advisor Christopher Keller. Underclassmen Walter Campos Alan Garza. Agenda. Goals Prototype Model Component/Material Selection Design Mechanical Design

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Introduction

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  1. Introduction Team Members • Jeffrey Kung • Richard Sabatini • Steven Ngo • Colton Filthaut Faculty Advisor • Jim Mohrfeld Industry Advisor • Christopher Keller Underclassmen • Walter Campos • Alan Garza

  2. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  3. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  4. Goals • To have a working Stirling Engine that will serve as a portable generator capable of producing 2.5 kWh (3.4HP) • To be able to run multiple common household appliances simultaneously

  5. Household Appliances • Appliances (average): • Refrigerator/Freezer = Start up 1500 Watts • Operating = 500-800 Watts • Toaster Oven = 1200 Watts • Space Heater = 1500 Watts • Lights: Most common are 60 Watt light bulbs • Tools (average): • ½” Drill = 750 Watts • 1” Drill = 1000 Watts • Electric Chain Saw 11”-16” = 1100-1600 Watts • 7-1/4” Circular Saw = 900 Watts

  6. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  7. Stirling Engine Prototype Model

  8. Current Model

  9. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  10. Heat Source

  11. Working Gas

  12. Cylinder Material Selection • Melling Cylinder Sleeve • Cast Iron Cylinder • High in Strength • Thermal Conductivity 55 W(m.K) • Would Need to be Bored/Honed

  13. Piston Materials • Displacer Piston • Cummins KT 19 • Forged Aluminum • High in Strength • Density of 0.101 lb/cu. in. • Power Piston • Yamaha Grizzly 660 • Forged Aluminum • High in Strength • Density of 0.101 lb/cu. in.

  14. Alternator Selection http://www.mechman.com/ http://www.ecoair.com/ https://www.dcpowerinc.com/

  15. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  16. Calculation Process

  17. Mechanical Analysis Power and Displacer Piston Crank-Slider mechanism • Variables • Connecting Rod Length (L) • Crankshaft Arm Length (R) • Force on Piston (F) • Mass of Piston (M) • Angular Velocity (ω) • 900 rpm required => (ω)= 94.25 rad/s • ω R L M F

  18. Mechanical Analysis 1.6:1 Piston to Displacer dia. Ratio • Displacer Piston • Diameter: 6.25” (Piston) • Connecting Rod Length (L): 5.375” • Crankshaft Arm Length (R): 1.75” (3.5” Stroke) • Mass of Piston (M): 25 lbm • Power Piston • Diameter: 4” (Piston) • Connecting Rod Length (L): 5.375” • Crankshaft Arm Length (R): 1.75” (3.5” Stroke) • Mass of Piston (M): 1.561 lbm Regenerator Flywheel

  19. Mechanical Analysis Piston Acceleration and Force • Power Piston Acceleration • Displacer Piston Acceleration • Power Piston Force • Displacer Piston Force

  20. Mechanical Analysis Required Force

  21. Mechanical Analysis Work/ Kinetic Energy(N*M) • KEY POINTS • Work being delivered to the system from 0 to 180 degrees (downward direction) • Starting pressure when Θ=0: 221 psi • Displacer piston dia: 6.25” • Power Piston dia: 4” • 20% Mechanical Friction loss • RPM=900 http://cnx.org/content/m32969/latest/

  22. Mechanical Analysis Force Delivered to Force Required Check and Balance

  23. Mechanical Analysis Torque ; ; -1

  24. Mechanical Analysis Torque Related to Kinetic Energy C D A A E B Preferred Method WORK delivered from PRESSURE= 208.333 N*M WORK remaining after FRICTION= 166.664 N*M STORE HALF of the energy to be delivered for UPWARD movement of POWER PISTON (ϴ=180 to 360)

  25. Mechanical Analysis Flywheel is typically set between .01 to .05 for precision

  26. Mechanical Analysis Crankshaft • Sn= Endurance Strength=0.50 (UTS) • Sn’=Fatigue Endurance Strength • Cm= Material Factor= 1.0 • Cst=Type of Stress Factor= 1.0 • Cr= Reliability Factor= 99%= .81 • Cs= Size factor= .88 • N= safety Factor= 2

  27. Mechanical Analysis Overview Pressure= 2.1 MPA (220 PSI) P 20% Energy Loss= 21.7 N*M K.E.=166.7 N*M Storing Half K.E. @ 0º to 180º Deliver K.E. @180 ºto 360º= 83.36 N*M Constant Torque= 26.5 N*M http://enginemechanics.tpub.com/14037/css/14037_90.htm

  28. Mechanical Analysis Manufacturing

  29. Mechanical Analysis Manufacturing Yamaha Grizzly 660 Mazda Miata Rear Drive Hub

  30. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  31. Our Current Design Progress

  32. First Order Design Method Total Volume=MAX(Vexp+Vcomp+Vdead) Total Volume= (7065.3 cm^3) • Average Pressure • =2.02 MPa Total Net Work(Joules) W=dθ W=232.2(Joules) Power Output(Watts) PNet Work *Frequency Power= 232.2(J)*(9.6)Hz Output Power= 2229(watts)

  33. Second Order Results Output values from Stirling Program imported into Excel We have picked 15 Hz (900RPM) because we can achieve a high enough torque to up-gear our engine ratio 3:1 giving us 2700(RPM) at a high output power of 3010 (watts) Freq. (Hz.)Power (Watts) Therm. Eff.%Torque (N.m)Pressure (Pascals)

  34. Second Order Results Wout= net work done by entire engine Pe*dVe= The change in expansion volume as a function of expansion space pressure Pc*dVc=The change in compression volume as a function of compression space pressure Work in expansion space= 7162.2(Joules) Work in compression space= -6961.4(Joules) Pout= (7162.2)(J)+(-6961.4)(J) *(15Hz)=3010 Watts

  35. Methods For Reducing Heat Flow Reduces heat by maximizing surface area, allowing the outside Air to flow more freely over the tubes Reduces heat by the use of porous material, which catches & conducts the hot air as it flows through steel mesh Thin long blades that consist of a more thermally conductive metal will extend out into the environment dissipating heat through convection by air

  36. Methods For Reducing Heat

  37. Methods For Reducing Heat Loss

  38. Second Order Results

  39. FEA ANALYSIS Allowable Yield Stress for ChromMolly AISI 4140 at 600C is 60,400psi or (417MPa) Max Operating pressure is 376 psi Max Hoop Stress Equals= 14,368 psi

  40. Regenerator Design • Regenerator Design- • Reduces heat by a porosity matrix that catches the heat as the helium flows through it • Will store about 60 percent of the heat in the system

  41. Regenerator Design Gasket Material Selection Actual Regenerator Housing The Ideal gasket material we will use A spiral round gasket/ GraphiteFoil mix

  42. Second Order Design • As the swept Volume increases by a factor of “x” the # of tubes must also increase by that factor(if you double the volume you double the tubes)

  43. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  44. Cost Analysis

  45. Sponsorships & Donations

  46. Agenda • Goals • Prototype Model • Component/Material Selection • Design • Mechanical Design • Thermodynamic Design • Cost Analysis • WBS/Gantt Chart • Risk Matrix

  47. WBS 100% 100% 100% 61%-99% 100% 31%-60% 100% 1%-30%

  48. Gantt Chart (Year)

  49. Gantt Chart (Semester II)

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