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Introduction

Introduction. Team Members Jeffrey Kung Richard Sabatini Steven Ngo Colton Filthaut. Faculty Advisor Jim Mohrfeld Richard Sabatini Steven Ngo Colton Filthaut. Underclassmen Walter Campos Alan Garza Richard Sabatini Steven Ngo Colton Filthaut. Agenda. Goals Prototype Model

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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 Richard Sabatini Steven Ngo Colton Filthaut Underclassmen • Walter Campos • Alan Garza Richard Sabatini Steven Ngo Colton Filthaut

  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 • 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. Animation of Stirling Engine

  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. Hot Cylinder Material Selection http://www.onlinemetals.com/ http://www.onlinemetals.com/ http://www.onlinemetals.com/

  13. Cold Cylinder Material Selection http://www.onlinemetals.com/ http://www.onlinemetals.com/ http://www.onlinemetals.com/

  14. Piston Materials • Displacer Piston • Forged Steel • High in Strength • Retains Heat • Density of 0.279 lb/cu. in. • Power Piston • Forged Aluminum • Light Weight • High in Strength • Density of 0.101 lb/cu. in. http://www.mahle.com/ Ocyaniqueprofessionals.com

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

  16. Alternator Selection Calculation (Mechman) • Selecting an alternator is a key component when designing the stirling engine to reach an output of 2.5kW • Rpms required from engine when using a 3:1 pulley ratio • 900 rpms needed from the engine • 2700 rpms needed from the alternator • 1 hp per 600 watts to run the alternator • To calculate the torque required to spin the shaft http://www.mechman.com/images/products-s-curve-big.png

  17. Cooling Fins • Cooling fins increases efficiency which increases compression energy to run • Materials considered are Aluminum or Copper

  18. Cooling Fins Calculations

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

  20. Calculation Process

  21. 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

  22. Mechanical Analysis First iteration 1:1.5 Piston to Displacer dia. Ratio • Power Piston • Diameter: 4.5” • Connecting Rod Length (L): 5.956” • Crankshaft Arm Length (R): 1.75” • Mass of Piston (M): 1.561 lbm • Displacer Piston • Diameter: 6” (Box Piston) • Connecting Rod Length (L): 8.934” • Crankshaft Arm Length (R): 2.625” • Mass of Piston (M): 10 lbm

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

  24. Mechanical Analysis Required Force • Displacer Piston • Power Piston

  25. Mechanical Analysis Work (N*M) • Displacer piston http://cnx.org/content/m32969/latest/ • Power Piston

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

  27. Mechanical Analysis Torque ; ; -1

  28. Mechanical Analysis Torque Related to Kinetic Energy C D A A E B

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

  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 • =2,029 Pa 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 Design Method • It was not possible to run a second order analysis by simple calculations & equations because of the enormous amount of unknown variables so we built a program in MATLAB capable of running arrays & guess values to arrive at possible values • Our process for the Second Order Design Method. • Build Calculation Sheet On Excel capable of giving us accurate basic parameters • Designed MATLAB program capable of calculating numerous amount of engine variables at different speeds & pressures • Re-Designed Excel sheet to incorporate data from MATLAB program

  34. Second Order Design Method Put in the initial variables calculated from second order excel sheet • Stirling Master MATLAB/FORTAN Program Skeletal Structure The program links the input Functions to the script program which calculates unknown variables

  35. Second Order Design Method • Output calculated variables From the different conditions with respect to speed we can see the optimal conditions we will want

  36. Second Order Design Method • Stirling Master MATLAB/FORTAN Program Skeletal Structure The script that defines the input functions for the program The beginning of the 1st part of the script which helps us find values hard to obtain like that mass of the gas at every angle position Ex. From the ideal Gas law PV=MRT You want to find your mass but can not because you also don’t know your change in temperature, the program will run a series of variable arrays that will coincide with your desired output power and pressure

  37. Second Order Results 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) Output values from Stirling Program imported into Excel Freq. PowerTherm. Eff.TorquePressure

  38. 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

  39. Second Order Results

  40. Second Order Design • Regenerator Design- • The regenerator reduces the heat transferred from expansion cylinder to compression cylinder by incorporating several small tubes & cylinder housing containing a porous mesh material which catches heat • The tubes help dissipate heat by maximizing surface area to help enable the convection of heat. • The tubes also help control the pressure & gas flow by causing a pressure drop which increases the gas velocity • The mesh material not only reduces the heat flow to the compression cylinder but also helps throw heat back into the hot cylinder as the gas flows back.

  41. 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)

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

  43. Cost Analysis

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

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

  46. Gantt Chart

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

  48. Risk Matrix

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