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

  9. Heat Source

  10. Working Gas

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

  12. 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

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

  14. 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

  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 1.625:1 Displacerto Power dia. Ratio • Displacer Piston • Diameter: 6.5” (Piston) • Connecting Rod Length (L): 8.934” • Crankshaft Arm Length (R): 2.625” • Mass of Piston (M): 10 lbm • Power Piston • Diameter: 4” (Piston) • Connecting Rod Length (L): 5.956” • Crankshaft Arm Length (R): 1.75” • 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: 6.5” • 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 Overview Pressure= 1.5 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

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

  28. Our Current Design Progress

  29. 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)

  30. 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

  31. 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)

  32. 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

  33. Second Order Results

  34. FEA ANALYSIS Allowable Yield Stress for ChromMollyAISI 4140 at 600C is 60,40psi or (417MPa) Max Operating pressure is 376 psi Max Hoop Stress Equals= 14,368 psi

  35. 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

  36. 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)

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

  38. Cost Analysis

  39. Sponsorships & Donations

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

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

  42. Gantt Chart (Year)

  43. Gantt Chart (Semester II)

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

  45. Risk Matrix

  46. Questions? Cot-mect4276.tech.uh.edu/~stngo3

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