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At least 37 records · Page 2

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DOE OSTI2020

Fluid-powered linear motor with rotary pistons and motion rectifier

A fluid-powered linear motor with rotary pistons is disclosed. An application is for a downhole motor but it could be used in other applications. Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long (generally up to a maximum length of 30 ft.), a high-torque motor can be produced using this method. A pressurized fluid is used to drive the piston assemblies to produce bit shaft power. This concept employs rotary pistons and a mechanical rectifier to convert the rotational reciprocation produced by a reciprocating rotational piston into continuous rotary motion.

42 ENGINEERING↗

DOE OSTI2022

Fluid-powered linear motor with rotary pistons and motion rectifier and synthetic diamond bearing assemblies

Raymond, David W.↗

DOE OSTI2023

Direct measurement and calculation of rubber bulk modulus by piston-cylinder method using conventional mechanical testing equipment

This article describes a method to directly measure the bulk modulus of rubber using a piston-cylinder type apparatus. The function of the testing apparatus is to reliably transfer load to the water inside the vessel and allow for the accurate and continuous measurement of volumetric displacement as the contents are compressed. During the test, load is applied to a piston-cylinder containing the rubber test sample and water using a conventional mechanical testing load frame. Load and the travel of the piston are recorded by a load cell and extensometer, respectfully. A brass or stainless steel plug of the same dimensions as the test sample is tested as a control sample to isolate the compliance of the system, including the compressibility of water and compliance of the piston-cylinder. The results from this control test are used to disincorporate the compliance of the system from the sample test results. Load-linear displacement data are mathematically converted to pressure-volumetric displacement data, from which bulk modulus is calculated. The test apparatus and method are validated using the known bulk modulus of water. Finally, the bulk modulus for two similar rubbers is evaluated. The validity of the results and limitations of the device are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Spin-piston problem for a ferromagnetic thin film: Shock waves and solitons

In this report the unsteady, nonlinear magnetization dynamics induced by spin injection in an easy-plane ferromagnetic channel subject to an external magnetic field are studied analytically. Leveraging a dispersive hydrodynamic description, the Landau-Lifshitz equation is recast in terms of hydrodynamic-like variables for the magnetization's perpendicular component (spin density) and azimuthal phase gradient (fluid velocity). Spin injection acts as a moving piston that generates nonlinear, dynamical spin textures in the ferromagnetic channel with downstream quiescent spin density set by the external field. In contrast to the classical problem of a piston accelerating a compressible gas, here, variable spin injection and field lead to a rich variety of nonlinear wave phenomena from oscillatory spin shocks to solitons and rarefaction (expansion) waves. A full classification of solutions is provided using nonlinear wave modulation theory by identifying two key aspects of the fluid-like dynamics: subsonic/supersonic conditions and convex/nonconvex hydrodynamic flux. Familiar waveforms from the classical piston problem such as rarefaction waves and shocks manifest in their spin-based counterparts as smooth and highly oscillatory transitions, respectively, between two distinct magnetic states. The spin shock is an example of a dispersive shock wave, which arises in many physical systems. New features without a gas dynamics counterpart include composite wave complexes with “contact” spin shocks and rarefactions. Magnetic supersonic conditions lead to two pronounced piston edge behaviors including a stationary soliton and an oscillatory wave train. These coherent wave structures have physical implications for the generation of high frequency spin waves from pulsed injection and persistent, stable stationary and/or propagating solitons in the presence of magnetic damping. The analytical results are favorably compared with numerical simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Exploring the Effects of Piston Bowl Geometry and Injector Included Angle on Dual-Fuel and Single-Fuel RCCI

Abstract Reactivity control compression ignition (RCCI) is a low-temperature combustion technique that has been proposed to meet the current demand for high thermal efficiency and low engine-out emissions. However, its requirement of two separate fuel systems (i.e., a low-reactivity fuel system and a high-reactivity fuel system) has been one of its major challenges in the last decade. This leads to the single-fuel RCCI concept, where the secondary fuel (reformates of diesel) is generated from the primary fuel (diesel) through catalytic partial oxidation reformation. Following the in-depth analysis of the reformate fuel (reformates of diesel) and its benefit as the low-reactivity fuel with diesel, the effects of the start of injection (SOI) timing of diesel and the energy-based blend ratio were also studied in detail. In this study, the effects of piston profile and the injector included angles were experimentally examined using both conventional fuel pairs (gasoline—diesel and natural gas—diesel) and reformate RCCI. A validated computational fluid dynamics (CFD) model was also used for a better understanding of the experimental trends. Comparing a reentrant bowl piston with a shallow bowl piston at a constant compression ratio and SOI, the latter showed better thermal efficiency, regardless of the fuel combination, due to its 10% lower surface area for the heat transfer. Comparing the 150-degree included angle and 60-degree included angle on the shallow bowl piston, the latter showed better combustion efficiency, regardless of the fuel combination, due to its earlier combustion phasing (at constant SOI timing). The effect was particularly prominent on reformate RCCI because of its incredibly high diluent concentration, which retards the combustion further for the 150-deg injector. Later, using convergecfd, seven different injector included angles were studied at a constant SOI. With the change in injector included angle, the region of the cylinder targeted by the fuel spray varies significantly, and it was found to have a significant impact on the combustion efficiency and the engine-out emissions. As the injector included angle changed from 60-deg to 150-deg, the combustion efficiency increased by 15% and the CO, NOx, and HC emissions decreased by 96%, 70%, and 86%, respectively.

Engineering↗

DOE OSTI2020

Opposed-piston engine in a light-duty truck

An opposed-piston engine is configured to fit in an engine compartment of a light-duty truck without compromising engine operations or the integrity of the engine compartment. The opposed-piston engine includes an air handling system and can be configured so that a cylinder assembly of the engine is tilted. The tilt of the cylinder assembly can allow for all of the components of the engine's air handling system to be located on one side of the opposed-piston engine. The air handling system of the opposed-piston engine can be configured with a cobra-head shaped intake duct assembly.

Warlick, Jr., Richard D.↗

DOE OSTI2022

Internal combustion engine and piston having stepped combustion bowl with non-axisymmetric profile

An internal combustion engine system includes an engine housing having a combustion cylinder, and a piston movable within the combustion cylinder to increase a pressure therein to an autoignition threshold for injected fuel. The piston includes a piston crown having a combustion face forming a combustion bowl, and varied in profile to form jet-jet interaction limiters at locations offset from fuel spray jet paths from a fuel injector. The jet-jet interaction limiters include a bowl component and a step component protruding, respectively, within the combustion bowl and a step located transitioning between the combustion bowl and a circumferential rim of the piston. Limiting jet-jet interaction limits soot production in exhaust produced by the engine.

Anders, Jonathan William↗

DOE OSTI2022

Free piston linear motor compressor and associated systems of operation

A linear motor compressor including a compressor housing and a cylinder housing having a plurality of opposing compression chambers. A piston freely reciprocates within the cylinder housing using a linear electric motor. A piston position feedback control system provides adaptive current output as a function of position feedback and/or velocity feedback from the piston and/or the electric motor, to directly power and control the electric motor, wherein the piston reciprocates without assistance from a mechanical spring or other equivalent centering force.

Stair, Jason↗

DOE OSTI2024

Development of a near-isothermal transcritical CO 2 compression system with a liquid piston compressor

Compressors are critical components in vapor compression cycle systems, significantly contributing to energy consumption. As global demand for HVAC&R systems rises, enhancing compressor efficiency becomes increasingly vital. This paper introduces a novel liquid piston compressor integrated with a gas cooler for the transcritical CO 2 refrigeration cycle. The liquid piston enables CO 2 refrigerant compression within various types of heat exchangers, facilitating the transfer of compression heat to the heat transfer fluid. By releasing significant heat, this compressor allows for removing or downsizing the traditional gas cooler in the refrigeration system. This paper presents the experimental performance of the first near-isothermal compressor utilizing a liquid piston in a vapor compression cycle. The critical parameters affecting heat transfer are analyzed by using a 1-D simulation model to achieve a near-isothermal compression process. The results show that the developed prototype successfully reduced the compression temperature increase from 95 K to 10 K, achieving 90 % isothermal efficiency. Furthermore, the 1-D simulation results suggest the smaller internal diameter tubes benefit the isothermal efficiency the most.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Kinetic simulations of piston-driven collisionless shock formation in magnetized laboratory plasmas

Laboratory laser experiments offer a novel approach to studying magnetized collisionless shocks, and a common method in recent experiments is to drive shocks using a laser-ablated piston plasma. However, current experimental capabilities are still limited to spatio-temporal scales on the order of shock formation, making it challenging to distinguish piston and shock dynamics. We present quasi-1D particle-in-cell simulations of piston-driven, magnetized collisionless shock formation using the code psc , which includes a model of laser-driven plasmas that can be well-matched to experimental conditions. The simulations cover a range of upstream and ablation parameters and yield several robust signatures of shock formation that can provide a reference for experimental results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Initial Results on a New Light-Duty 2.7-L Opposed-Piston Gasoline Compression Ignition Multi-Cylinder Engine

Abstract Gasoline compression ignition (GCI) is a cost-effective approach to achieving diesel-like efficiencies with low emissions. The fundamental architecture of the two-stroke Achates Power Opposed-Piston (OP) Engine enables GCI by decoupling piston motion from cylinder scavenging, allowing for flexible and independent control of cylinder residual fraction and temperature leading to improved low-load combustion. In addition, the high peak cylinder pressure and noise challenges at high-load operation are mitigated by the lower brake mean effective pressure (BMEP) operation and faster heat release for the same pressure rise rate of the OP Engine. These advantages further solidify the performance benefits of the OP Engine and demonstrate the near-term feasibility of advanced combustion technologies, enabled by the opposed-piston architecture. This paper presents initial results from steady-state testing on a brand new 2.7-L OP GCI multi-cylinder engine (MCE) designed for light-duty truck applications. Successful GCI operation calls for a high compression ratio (CR), leading to higher combustion stability at low loads, higher efficiencies, and lower cycle HC + NOX emissions. Initial results show a cycle average brake thermal efficiency (BTE) of 31.7%, which is already greater than 11% conventional engines, after only ten weeks of testing. Emissions results suggest that Tier 3 Bin 160 levels can be achieved using a traditional diesel after-treatment system. Combustion noise was well controlled at or below the United States Council for Automotive Research limits. In addition, initial results on catalyst light-off mode with GCI are also presented.

Energy & Fuels↗

DOE OSTI2023

The Durability of Piston Seals in Hydraulic Power Take-off Systems in Wave Energy Converters

Hydraulic cylinder seals are a critical component of hydraulic power take-off (PTO) systems in wave energy converters (WECs). Primary hydraulic piston seal wear is a major concern for the longevity of hydraulic PTOs, especially in the context of the effort and expense associated with seal replacement. Piston seals, made from polymeric elastomers, are used to contain and isolate high pressure fluids within PTO systems. A specific challenge for WEC designers is knowing, with confidence, the relative expected lifetimes of commercially available seals and seal materials for the unique long travel and continuous use case of WEC hydraulic systems. This information is critical to accurately determine operating expense (OPEX) and levelized cost of electricity (LCOE). If failures of seals occur earlier than their designed lifetime, the estimated operations, and maintenance (O&M) and LCOE costs may double based on estimation. Unfortunately, information from seal manufacturers on longevity in these applications is not generally available and quantitative performance comparison between different manufacturers is not available, creating significant uncertainty on use of hydraulic PTO system in wave power generation. In this project, PNNL, with advice from different WEC device and seal manufacturers, has created a framework to address the industry need for available, dependable and comparative data for seals and seals materials for WEC hydraulic applications including piston seals, glide rings, and shaft seals. Commonly used and candidate seal materials were identified and available information on the materials such as mechanical and fatigue performance, chemical (fluid) compatibility, and cost has been compiled. Hardware and strategy for bench scale measurement of key materials and seal performance and pathway for publicly available library of hydraulic seal materials, properties, suppliers, and options have also been identified for future implementation. The results of this project were presented at WPTO Seedling Symposium 2023 and OCEANS 2023. The results of the literature review including identified polymer seals and ideal operating conditions were summaried and compiled to a database WEC-SealsDB hosted locally at PNNL.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Measurement of Piston Deposit Thickness Using Laser Profilometer

In this work, a novel method of measuring the thickness of deposits on engine pistons, including within ring grooves, is described. A laser profilometer is used in conjunction with a rotary stage to measure a continuous profile of the piston with deposits, and the measurement is repeated after cleaning the deposits from the piston. Algorithms for aligning the scans and determining the differential thickness are described, and results are compared to deposit thickness measurements using a contact-type magnetic induction coating thickness gauge. This method allows continuous measurement of deposit thickness across the entire surface including lands and ring grooves as well as quantification of the volume of the deposits.

42 ENGINEERING↗

DOE OSTI2022

Effects of Port Angle on Scavenging of an Opposed Piston Two-Stroke Engine

Opposed-piston 2-stroke (OP-2S) engines have the potential to achieve higher thermal efficiency than a typical diesel engine. However, the uniflow scavenging process is difficult to control over a wide range of speeds and loads. Scavenging performance is highly sensitive to pressure dynamics, port timings, and port design. This study proposes an analysis of the effects of port vane angle on the scavenging performance of an opposed-piston 2-stroke engine via simulation. A CFD model of a three-cylinder opposed-piston 2-stroke was developed and validated against experimental data collected by Achates Power Inc. One of the three cylinders was then isolated in a new model and simulated using cycle-averaged and cylinder-averaged initial/ boundary conditions. This isolated cylinder model was used to efficiently sweep port angles from 12 degrees to 29 degrees at different pressure ratios. Results indicate that scavenging performance is correlated with the bulk swirl ratio generated by these port angles. Scavenging performance is also sensitive to the pressure ratio across the engine. It was concluded that, for a given pressure ratio, the smallest port angle produces the best scavenging; however, previous work indicates lower bulk swirl ratio during combustion can have an impact on emissions formation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Performance Enhancement of the Transcritical CO2 Cycle with a Near-Isothermal Liquid Piston Compression by an Ejector

This study investigates the use of an ejector in a transcritical CO2 cycle employing a near-isothermal liquid piston compressor, with the objective of mitigating refrigerant degassing in mineral oil. While the liquid piston compressor demonstrated high isothermal efficiency (˜90%), overall cycle performance was limited by CO2 degassing during chamber pressure fluctuations. A thermodynamic model was developed to compare baseline and ejector-assisted cycles, incorporating solubility correlations, entrainment ratio characteristics, and a degassing correction factor. Results indicate that the ejector increased suction pressure and reduced CO2–oil solubility variation, which improved refrigerant intake and reduced degassing losses. Despite these benefits, the ejector-assisted cycle showed a lower coefficient of performance (COP) than the baseline. Possible contributing factors include the limited marginal benefit of pressure reduction in a highly efficient isothermal compressor, reduced effectiveness of the separator due to the use of a suction-line heat exchanger in both cycles, and uncertainties in the solubility data under transient conditions. These findings suggest that degassing mitigation is essential for realizing the potential of liquid piston compression, but ejector integration alone is unlikely to enhance COP. Future work should focus on ejector optimization, improved oil–refrigerant management, introducing less-soluble working liquids, and experimental validation under realistic operating conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Optimized piston temperature control in gaseous fuel hydrogen engine system

Operating a gaseous fuel engine system includes combusting a mixture containing a gaseous hydrogen fuel and air in a cylinder of an engine, varying an operating parameter of the engine to which a crown surface temperature of a piston within the cylinder is responsive, and populating a temperature model based on a value of the varied operating parameter. Operating a gaseous fuel engine system further includes operating an oil spray apparatus to spray oil onto the piston based on the populated temperature model, and maintaining the crown surface temperature of the piston between a high temperature limit and a pre-ignition mitigation temperature limit based on the operating of the oil spray apparatus. Related apparatus and control logic is also disclosed.

Bochart, Michael R.↗

DOE OSTI2024

System and method for enclosing piston cooling gallery

A system includes a piston assembly. The piston assembly includes a crown portion having a crown, an outer wall coupled to the crown, a first inner wall disposed inside of the outer wall, a first fluid chamber disposed radially between the outer wall and the first inner wall, and an angled wall insert. An opening extends into the first fluid chamber in an axially inward direction. The outer wall, the first inner wall, the first fluid chamber, the opening, and the angled wall insert extend circumferentially about a central axis of the piston assembly. The angled wall insert is disposed in the opening, and the first fluid chamber is disposed axially between the crown and the angled wall insert.

Zimmerman, Daniel David↗

DOE OSTI2024

Enabling CO 2 Isothermal Compression Using Liquid Piston and Integrated Gas Cooler

This report outlines the development of a near-isothermal liquid piston compressor. Initially, a proof-of-concept experiment was conducted to validate the feasibility and potential of near-isothermal compression. A first-of-its-kind near-isothermal liquid piston compressor was then successfully built and tested. Additionally, a Matlab-based transient model was developed to capture performance trends accurately. These efforts laid the groundwork for developing a second-generation prototype with enhanced efficiency and design. Subsequent field tests at the Helix Innovation Center in Ohio demonstrated a cooling capacity of 2 kW with a COP of 1.64 at an ambient temperature of 25°C. An improved model was also created to suggest different heat exchanger geometries for better compression efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗