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MECH 4020 – Design Project II

Solar Powered Stirling Engine. “The Little Engine the Could...and Did”. MECH 4020 – Design Project II. Team 04 April 9 th , 2009 Andrew McMurray Alex Morash Bryan Neary Kristian Richards Dr. Dominic Groulx. MECH 4020 TEAM 04. Introduction. TABLE OF CONTENTS Introduction

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MECH 4020 – Design Project II

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  1. Solar Powered Stirling Engine “The Little Engine the Could...and Did” MECH 4020 – Design Project II Team 04 April 9th, 2009 Andrew McMurray Alex Morash Bryan Neary Kristian Richards Dr. Dominic Groulx

  2. MECH 4020 TEAM 04 Introduction TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Inspiration • SES Stirling Energy Systems • SunCatcher Unit of Capacity 25 kW • 31.25% solar to electric efficiencies have been realized

  3. MECH 4020 TEAM 04 Introduction Fabrication TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Minimal changes to December Design We built what we designed

  4. MECH 4020 TEAM 04 Fabrication Fabrication - Frame TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions 6061 Aluminum Durable, Lightweight, Easy to Machine Quick assembly/disassembly Clean look with Cap Head Machine Screws

  5. MECH 4020 TEAM 04 Fabrication – Frame Fabrication – Piston Rod Assembly TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Simple Design • Brass chosen for its low sliding coefficient • Minimal moving parts reduce friction • Easy to interchange Piston Rod Length • Crucial for testing phase

  6. MECH 4020 TEAM 04 Fabrication – Piston Rod Assembly Fabrication – Pistons TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Grooved to maintain pressure seal High surface finish to minimize piston/cylinder contact friction Easily connects to piston Rod Assembly with Machine screw

  7. MECH 4020 TEAM 04 Fabrication – Pistons Fabrication - Cylinders TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Cylinders/Cylinder Heads Constructed in two pieces • Offered quick and easy assembly • Trouble shooting capabilities • Fine threads provide adequate pressure seal • Bored, Reamed, Honed to provide high surface finish

  8. MECH 4020 TEAM 04 Fabrication - Cylinders Fabrication - Cranks TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Serve two purposes • Defines Stroke Length (which can be easily modified) • Produces a coupling force to cancel sinusoidal linear motion of pistons • Fastens to shaft via set screw

  9. MECH 4020 TEAM 04 Fabrication - Cranks Fabrication - Flywheel TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Large rotating mass Provides stored energy to power system through phase where no work is produced. Fixed to shaft via key way and two set screws

  10. MECH 4020 TEAM 04 Fabrication - Flywheel Initial Testing Observations TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • All engine components were unmodified • Heat source - propylene torch • (350˚C on hot cylinder head) • Initial operation of the engine was unsuccessful

  11. MECH 4020 TEAM 04 Fabrication - Flywheel How It Works TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Alpha Stirling Engine

  12. MECH 4020 TEAM 04 Initial Testing Observations Design Refinements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Hot Cylinder Insulation 0.125” Hot cylinder insulation. Rapid heat transfer from hot cylinder to aluminum frame. Entire engine became heated Solution: 0.125” gap removed from cylinder clamps to allow for insulation layer Insulation: Teflon header wrap and fiberglass paper

  13. MECH 4020 TEAM 04 Design Refinements Design Refinements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Infrared Image Frame: 65°C Cylinder Head: 550°C Temperatures acquired through use of thermocouples. Image does not represent listed temperatures. Isolation of hot cylinder from frame Cylinder head reaches 550˚C Frame adjacent to cylinder head reaches a max. temperature of 65˚C Frame transfers almost no heat to cold cylinder

  14. MECH 4020 TEAM 04 Design Refinements Design Refinements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Compression Reduction Original position 1.25” Final position 0.5625” 0.375” 0.3125” Crank with modified stroke length. Cylinder Compression caused frame bending. Flywheel not heavy enough to overcome Solution: Reduce stroke length from original 2.5” to 1.75” Stroke length further reduced to 1.125” Cylinder pressure drastically reduced, performance gains achieved

  15. MECH 4020 TEAM 04 Design Refinements Design Refinements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Heat Damage toTransfer Tube Heat Damaged Seal Hot Side Cold Side Copper transfer tube. Unable to perform testing due to heat damage to rubber tube. Solution #1: 0.5” copper pipe sealed to brass fittings with JB weld. Fitting on hot cylinder becomes too hot for solder connection. Problem: Extreme temperatures caused the JB weld to break down, reducing the integrity of the transfer tube.

  16. MECH 4020 TEAM 04 Design Refinements Design Refinements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Heat Damage to Transfer Tube Hot Gas to Cold Cylinder Cool Gas to Hot Cylinder Steel transfer tube. Solution #2: Threaded steel fittings, all joints were threaded, eliminating faulty connections Steel fittings withstood repeated testing without diminished integrity

  17. MECH 4020 TEAM 04 Design Refinements Performance Improvements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Internal Heat Exchangers Modified vehicle radiator. Challenge: Maximize thermal efficiency Solution #1: Internal heat exchangers Modified vehicle radiator fins cut to internal cylinder diameter and positioned adjacent to cylinder head

  18. MECH 4020 TEAM 04 Performance Improvements Performance Improvements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Internal Heat Exchangers Internal Fin Heat Exchangers Internal Heat Exchangers. Fins encased in aluminum sleeve for intimate contact with cylinder walls Heat exchangers in direct path of gas flow Performance increase were noted during testing

  19. MECH 4020 TEAM 04 Performance Improvements Performance Improvements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Regenerator Thermal Mass: Steel Wool Regenerator design. Original design called for the use of a regenerator Regenerator is similar to the economizer of a steam power plant Regenerator design: 0.75” steel pipe with threaded flanged ends Steel wool packed inside steel pipe

  20. MECH 4020 TEAM 04 Performance Improvements Performance Improvements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Regenerator Thermal mass in path of gas flow Regenerator positioning. Steel wool has large surface area for efficient heat transfer with working gas Regenerator strips heat from gas as it flows into cold cylinder and returns much of that heat to the cooled gas as it travels back into the hot cylinder Thermal efficiency of the engine is greatly improved

  21. MECH 4020 TEAM 04 Performance Improvements Final Assembly TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Operational Configuration • Components Engine Configuration. Ice water bath for cooling Regenerator Internal heat exchangers Reduced stroke length (1.125”) Insulated hot cylinder

  22. MECH 4020 TEAM 04 Final Assembly Temperature Acquisition TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Infrared temperature gun – Initial Testing • Type K (CHROMEGA®-ALOMEGA®) thermocouples • Surface - surface temperatures • Probe with compression fitting – Working fluid temperatures • Omega MDSSi8 - Digital thermometer

  23. MECH 4020 TEAM 04 Temperature Acquisition Temperature Acquisition TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Hot cylinder wall Hot Side Cylinder Clamp Hot Cylinder Head Fluid Regenerator Cold Cylinder Head Fluid Cold Cylinder Head Hot Cylinder Head - IR 7

  24. MECH 4020 TEAM 04 Temperature Acquisition Fresnel Lens Testing TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions March23rd, 2009 at 2:00 pm

  25. MECH 4020 TEAM 04 Fresnel Lens Testing Fresnel Lens Testing TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions • Torch – double the heating potential • The engine has the potential to operate using the lens

  26. MECH 4020 TEAM 04 Fresnel Lens Testing Troubleshooting TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Iterative testing process • Evolution of design • Gradual performance improvements • Total of 8 testing configurations were tested • Learning process to understand effects of changing parameters Three performance criteria w/ solutions • Pressure – Compression Ratio • Stroke length reduction 2.5” ↔ 1.75” ↔ 1.125” • Increase dead space low ↔ medium ↔ high • Increase flywheel size • Heat Transfer • Internal heat exchangers • Increase heat input solar ↔ propane ↔ propylene ↔acetylene • Addition of regenerator • Insulation of temperature shorts • High performance working fluid (e.g. Helium) • Friction • Lubrication method oil ↔ dry ↔ graphite • Alignment checks

  27. MECH 4020 TEAM 04 Troubleshooting Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Test #1 – March 30th, 2009 Configuration • 1.125” stroke length • Maximum dead space • No lubrication • Crude regenerator Results • 30 seconds of uninterrupted operation

  28. MECH 4020 TEAM 04 Optimization Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Test #2 – April 1st, 2009 Configuration • 1.125” stroke length • Minimum dead space • No lubrication • ‘True’ regenerator Results • 60 seconds of uninterrupted operation

  29. MECH 4020 TEAM 04 Optimization Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Test #2 – April 1st, 2009

  30. MECH 4020 TEAM 04 Optimization Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Test #3 – Run A – April 4th, 2009 Configuration • Maximum dead space • Graphite lubrication Results • 11 minutes 12 seconds of uninterrupted operation

  31. MECH 4020 TEAM 04 Optimization Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Test #3 – Comparison to Theory

  32. MECH 4020 TEAM 04 Optimization Optimization TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions

  33. MECH 4020 TEAM 04 Optimization Budget TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions

  34. MECH 4020 TEAM 04 Budget Design Requirements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions

  35. MECH 4020 TEAM 04 Design Requirements Design Requirements TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions

  36. MECH 4020 TEAM 04 Design Requirements Final Configuration TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions

  37. MECH 4020 TEAM 04 Final Configuration Sponsors and Thanks TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions Sponsors Individuals Angus MacPherson!! THANKS Albert Murphy Peter Jones Mark MacDonald Dr. Dominic Groulx Dr. Julio Militzer Thank you! Mechanical Engineering Class Notable Recognition Devon Balodis William Easson

  38. MECH 4020 TEAM 04 Sponsors and Thanks Questions TABLE OF CONTENTS Introduction Fabrication Initial Engine Tests How it Works Refinement Improvements Final Assembly Temp Acquisition Lens Testing Troubleshooting Optimization Budget Conclusions Sponsors Questions NO SQUARE PISTONS!

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