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The results of recent and ongoing automobile Stirling engine development efforts are reviewed and technology status and requirements are identified. Key technology needs include those for low cost, high temperature (1300 - 1500 F) metal alloys for heater heads, and reliable long-life, low-leakage shaft seals. Various fuel economy projections for Stirling powered automobiles are reviewed and assessed.
A four working space, double acting piston, Stirling engine simulation is being developed for controls studies. The development method is to construct two simulations, one for detailed fluid behavior, and a second model with simple fluid behaviour but containing the four working space aspects and engine inertias, validate these models separately, then upgrade the four working space model by incorporating the detailed fluid behaviour model for all four working spaces. The single working space (SWS) model contains the detailed fluid dynamics. It has seven control volumes in which continuity, energy, and pressure loss effects are simulated. Comparison of the SWS model with experimental data shows reasonable agreement in net power versus speed characteristics for various mean pressure levels in the working space. The four working space (FWS) model was built to observe the behaviour of the whole engine. The drive dynamics and vehicle inertia effects are simulated. To reduce calculation time, only three volumes are used in each working space and the gas temperature are fixed (no energy equation). Comparison of the FWS model predicted power with experimental data shows reasonable agreement. Since all four working spaces are simulated, the unique capabilities of the model are exercised to look at working fluid supply transients, short circuit transients, and piston ring leakage effects.
The elastohydrodynamic behavior of sliding elastomeric seals for the Stirling engine, was analyzed using an experimental apparatus to determine the instantaneous oil film thickness throughout the cyclic reciprocating motion. Tests were conducted on two commercial elastomeric seals: a "T" seal (76 mm O.D. and 3.8 mm between backing rings) and an "O" ring (76 mm O.D. and 5.3 mm diameter). Testing conditions included seal durometers of 70 and 90, sliding velocities of 0.8, 2.0, and 3.6 m/s, and no pressure gradient across the seal. Both acrylic and aluminum cylinders were used. Measured oil film thickness profiles were compared to results of the elastohydrodynamic analysis. The comparison shows an overall qualitative agreement. Friction and oil leakage measurements were also made at these sliding speeds. The fluid used was a typical synthetic base automotive lubricant. It is concluded that this first time experimental analytical comparison for oil film thickness indicates the need for some improvements in the analytical model and in the experimental technique.
A four working space, double acting piston, Stirling engine simulation was developed for controls studies. Two simulations, one for detailed fluid behavior, and a second model with simple fluid behavior but containing the four working space aspects and engine inertias, validate these models separately, then upgrade the four working space model by incorporating the detailed fluid behavior model for all four working spaces. The single working space model contains the detailed fluid dynamics. The four working space (FWS) model was built to observe the behavior of the whole engine. The drive dynamics and vehicle inertia effects are simulated. The capabilities of the model are exercised to look at working fluid supply transients, short circuit transients, and piston ring leakage effects.
An overview of the DOE/NASA Automotive Stirling Engine Project is presented. The background and objectives of the project are reviewed. Project activities are described and technical progress and status are presented and assessed. Prospects for achieving the objective 30% fuel economy improvement are considered good. The key remaining technology issues are primarily related to life, reliability and cost, such as piston rod seals, and low cost heat exchanges.
Sixteen candidate iron base Stirling engine heater head tube alloys are evaluated in a diesel fuel fired simulator materials test rig to determine their oxidation and corrosion resistance. Sheet specimens are tested at 820 C for 3500 hr in 5 hr heating cycles. Specific weight change data and an attack parameter are used to categorize the alloys into four groups; 10 alloys show excellent for good oxidation and corrosion resistance and six alloys exhibit poor or catastrophic resistance. Metallographic, X-ray, and electron microprobe analyses aid in further characterizing the oxidation and corrosion behavior of the alloys. Alloy compositions, expecially the reactive elements aluminum, titanium, and chromium, play a major role in the excellent oxidation and corrosion behavior of the alloys. The best oxidation resistance is associated with the formation of an iron nickel aluminum outer oxide scale, an intermediate oxide scale rich in chromium and titanium, and an aluminum outer oxide scale adjacent to the metallic substrate, which exhibits a zone of internal oxidation of aluminum and to some extent titanium.
The design of reference Stirling engine system as well as the engine auxiliaries and controls is described. Manufacturing costs in production quantity are also presented. Engine system performance predictions are discussed and vehicle integration is developed, along with projected fuel economy levels.
The materials research program in support of the Automotive Stirling Engine Project focuses on the hot heater head of the engine including the heater head tubes, cylinders, and regenerator housings, which are considered to be the most critical components from a materials viewpoint. The specific areas of investigation in the program involve hydrogen permeability testing, doping of the hydrogen working fluid to reduce permeability rates, oxidation/corrosion studies, creep-rupture evaluation, and assessing effects of hydrogen environment on mechanical properties. Emphasis is placed on the materials challenges that result from the use of hydrogen as the working fluid. Previously announced in STAR as N81-26236
An overview of the DOE/NASA Automotive Stirling Engine Project is presented. The background and objectives of the project are reviewed. Project activities are described and technical progress and status are presented and assessed. Prospects for achieving the objective 30 percent fuel economy improvement are considered good. The key remaining technology issues are primarily related to life, reliability and cost, such as piston rod seals, and low cost heat exchanges. Previously announced in STAR as N83-27924
The Mod II engine is a second-generation automotive Stirling engine (ASE) optimized for part-power operation. It has been designed specifically to meet the fuel economy and exhaust emissions objectives of the ASE development program. The design, test experience, performance, and comparison of data to analytical performance estimates of the Mod II engine to date are reviewed. Estimates of Mod II performance in its final configuration are also given.
This video describes the Stirling engine, an external combustion engine which creates heat energy to power the motor, and can use many types of fuel. It can be used for both stationary and propulsion purposes and has advantages of better fuel economy and cleaner exhaust than internal combustion engines. The engine is shown being road tested at Langley Air Force Base.
The technology for a full-up hybrid dish-Stirling Solar Thermal Power system is discussed. Overall solar-to-electric efficiency for the dish-Stirling system demonstration is approximately 30%. Hybrid operation is provided by fossil fuel combustion augmentation, which enables the Stirling engine to operate continuously at constant speed and power, regardless of insolation level, thus providing the capability to operate on cloudy days and at night.
The modifications and testing of a standard Stirling engine, required for connection to a 25 kW induction alternator, for use with a solar thermal parabolic dish electric module is described. Power was absorbed by a GE induction alternator connected to the utility grid. Also included are the results from recent testing of another solar engine at the DOE-Georgia Tech solar site. It was done in parallel with the testing at Edwards for the purpose of comparing performance of two solar-only receivers, which were based on the standard 4-95 involute heat exchanger.
A hydraulic output system for the RE-1000 free piston stirling engine (FPSE) was designed. The hydraulic output system can be readily integrated with the existing hot section of RE-1000 FPSE. The system has two simply supported diaphragms which separate the engine gas from the hydraulic fluid, a dynamic balance mechanism, and a novel, null center band hydraulic pump. The diaphragms are designed to endure more than 10 billion cycles, and to withstand the differential pressure load as high as 14 MPa. The projected thermodynamic performance of the hydraulic output version of RE-1000 FPSE is 1.87 kW at 29/7 percent brake efficiency.
Computer program developed for analyzing thermodynamic characteristics of kinematic Stirling engine. Computes time-varying piston positions, pressures, and gas temperatures in each of gas-control volumes into which engine working space is divided. Engine performance characterized by calculations of power and efficiency (both indicated and brake). Inputs to code are engine geometrical parameter, engine-operating conditions, and indexes that specify various options available.
A Stirling engine was tested without auxiliaries at Nasa-Lewis. Three different regenerator configurations were tested with hydrogen. The test objectives were: (1) to obtain steady-state and dynamic engine data, including indicated power, for validation of an existing computer model for this engine; and (2) to evaluate structurally the use of silicon carbide regenerators. This paper presents comparisons of the measured brake performance, indicated mean effective pressure, and cyclic pressure variations from those predicted by the code. The silicon carbide foam generators appear to be structurally suitable, but the foam matrix showed severely reduced performance.
Replacing the mechanical check-valve in a Stirling engine with a micromachined, non-moving-part flow diode eliminates moving parts and reduces the risk of microparticle clogging. At very small scales, helium gas has sufficient mass momentum that it can act as a flow controller in a similar way as a transistor can redirect electrical signals with a smaller bias signal. The innovation here forces helium gas to flow in predominantly one direction by offering a clear, straight-path microchannel in one direction of flow, but then through a sophisticated geometry, the reversed flow is forced through a tortuous path. This redirection is achieved by using microfluid channel flow to force the much larger main flow into this tortuous path. While microdiodes have been developed in the past, this innovation cascades Tesla diodes to create a much higher pressure in the gas bearing supply plenum. In addition, the special shape of the leaves captures loose particles that would otherwise clog the microchannel of the gas bearing pads.
A 6 kW (8 hp), single-cylinder, rhombic-drive Stirling engine was restored to operating condition, and preliminary characterization tests run with hydrogen and helium as the working gases. Initial tests show the engine brake specific fuel consumption (BSFC) with hydrogen working gas to be within the range of BSFC observed by the Army at Fort Belvoir, Virginia, in 1966. The minimum system specific fuel consumption (SFC) observed during the initial tests with hydrogen was 669 g/kW hr (1.1 lb/hpx hr), compared with 620 g/kWx hr (1.02 lb/hpx hr) for the Army tests. However, the engine output power for a given mean compression-space pressure was lower than for the Army tests. The observed output power at a working-space pressure of 5 MPa (725 psig) was 3.27 kW (4.39 hp) for the initial tests and 3.80 kW (5.09 hp) for the Army tests. As expected, the engine power with helium was substantially lower than with hydrogen.