An experimental study on the development of a β-type Stirling engine for low and moderate temperature heat sources

In this study, a β-type Stirling engine was designed and manufactured which works at relatively lower temperatures. To increase the heat transfer area, the inner surface of the displacer cylinder was augmented by means of growing spanwise slots. To perform a better approach to the theoretical Stirling cycle, the motion of displacer was governed by a lever. The engine block was used as pressurized working fluid reservoir. The escape of working fluid, through the end-pin bearing of crankshaft, was prevented by means of adapting an oil pool around the end-pin. Experimental results presented in this paper were obtained by testing the engine with air as working fluid. The hot end of the displacer cylinder was heated with a LPG flame and kept about 200 °C constant temperature throughout the testing period. The other end of the displacer cylinder was cooled with a water circulation having 27 °C temperature. Starting from ambient pressure, the engine was tested at several charge pressures up to 4.6 bars. Maximum power output was obtained at 2.8 bars charge pressure as 51.93 W at 453 rpm engine speed. The maximum torque was obtained as 1.17 Nm at 2.8 bars charge pressure. By comparing experimental work with theoretical work calculated by nodal analysis, the convective heat transfer coefficient at working fluid side of the displacer cylinder was predicted as 447 W/m² K for air. At maximum shaft power, the internal thermal efficiency of the engine was predicted as 15%.     

Improved Stirling engine performance through displacer surface treatment

This study intended to improve the performance of the beta‐type Stirling engine, being developed by the authors for solar energy and low‐grade heat sources, by means of displacer surface treatments. Three different displacers were manufactured and tested where one of them was without any surface treatment, other was zirconium coated with 0.15 mm thickness, and the other was helically knurled with 0.30 mm track depth. Because of good thermo‐physical properties, helium was used as the working fluid. The heat was supplied by an LPG burner. Tests were conducted at 360±10°C hot end temperature. The highest engine power was obtained with knurled displacer as 250 W at 545 rpm speed and corresponding to this power 4.38 Nm torque was obtained. This was followed by coated and smooth displacers. Power increments provided by the knurled displacer are 40 and 60% compared with the zirconium‐coated and untreated displacers. Increments of knurled displacer's torque compared with that of coated and untreated displacers are 13 and 30%, respectively. Copyright © 2009 John Wiley & Sons, Ltd.     

The effect of displacer material on the performance of a low temperature differential Stirling engine

In this study, a gamma‐type low temperature differential Stirling engine was designed and manufactured. The displacer and piston of the engine were concentrically situated to each other. The engine was tested by using a liquefied petroleum gas burner at laboratory conditions. The working fluid was ambient air at atmospheric pressure. Test procedure intended to investigate the speed‐torque and speed‐power characteristics of the engine depending on the hot‐end temperature. Two different displacers made of aluminum alloy and medium density fiberboard were used. The maximum torque and power obtained were 0.166 Nm at 125 rpm speed and 3.06 W at 215 rpm speed, respectively, at 160 °C hot‐end temperature with medium density fiberboard displacer. Copyright © 2011 John Wiley & Sons, Ltd.     

Torque and power characteristics of a helium charged Stirling engine with a lever controlled displacer driving mechanism

This study presents test results of a Stirling engine with a lever controlled displacer driving mechanism. Tests were conducted with helium and the working fluid was charged into the engine block. The engine was loaded by means of a prony type micro dynamometer. The heat was supplied by a liquefied petroleum gas (LPG) burner. The engine started to run at 118 °C hot end temperature and the systematic tests of the engine were conducted at 180 °C, 220 °C and 260 °C hot end external surface temperatures. During the test, cold end temperature was kept at 27 °C by means of water circulation. Variation of the shaft torque and power with respect to the charge pressure and hot end temperature were examined. The maximum torque and power were measured as 3.99 Nm and 183 W at 4 bars charge pressure and 260 °C hot end temperature. Maximum power corresponded to 600 rpm speed.     

Experimental investigations of a gamma Stirling engine

The present work deals with the measurement and performance of a gamma Stirling engine of 500 W of mechanical shaft power and 600 rpm of maximal revolutions per minute. Series of measurements concerning the pressure distribution, temperature evolution, and brake power were performed. The study of the different functioning parameters such as initial charge pressure, engine velocity, cooling water flowrate, and temperature gradient (between the sources of heat) has been analyzed. The engine brake power increases with the initial charge pressure, with the cooling water flow, and with the engine revolutions per minute. The working fluid temperature measurements have been recorded in different locations symmetrically along both regenerator sides. The recorded temperature in regenerator side one is about 252 °C and about 174 °C in the opposite side (side two). It shows an asymmetric temperature distribution in the Stirling engine regenerator; consequently, heat transfer inside this porous medium is deteriorated. Copyright © 2011 John Wiley & Sons, Ltd.     

Thermodynamic analysis of rhombic-driven and crank-driven beta-type Stirling engines

This work aims to compare beta-type Stirling engine performance (GPU-3 [ground power unit]) driven by rhombic and crank mechanisms. A modified non-ideal adiabatic model accounting for different frictional and thermal losses was adopted in this study. After validating the current model with engine experimental data, different scenarios of operating conditions including heater temperature, cooler temperature, charge pressure and engine speed were investigated. The results revealed that rhombic drive mechanism generates 32% more power and provides 20% more efficiency than crank mechanism at normal operating conditions. However, at low hot end temperature (300°C) and high charge pressure (50 bar) crank drive mechanism tends to slightly generate power more than rhombic drive mechanism at lower engine speeds. At low hot end temperature (300°C) and charge pressure (10 bar) both mechanisms cannot deliver any positive power. Higher power loss is recognized in crank drive mechanism at higher speeds due to increased pumping and gas spring hysteresis losses. This study highlights a wide analysis opportunity for designers and researchers of GPU-3 Stirling engine for further optimization.     

Similarity design and experimental investigation of a beta‐type Stirling engine with a rhombic drive mechanism

Stirling engines are power machines that operate over a closed, regenerative thermodynamic cycle with the ability to use any heat source from the outside, including hydrogen, solar energy, and biomass fuels. In this work, the development of a beta‐type Stirling engine is presented. The improved similarity design and optimization methods are described in detail, as are the key parameters of the constructed prototype and the arrangement of the entire test rig. A new structure for the expansion exchangers is developed to reduce the flow loss. The performance test of the prototype engine is conducted under laboratory conditions using an electrical heating system. In this test, the temperature and the pressure of the working fluid are monitored by thermocouples and pressure sensors, respectively. The speed and the torque of the output shaft are obtained by the dynamometer. Finally, the preliminary test results with the prototype engine are shown. The maximum output shaft power can reach 288 W at 600°C and 15‐bar charge pressure. Copyright © 2014 John Wiley & Sons, Ltd.     

Performance of a twin power piston low temperature differential Stirling engine powered by a solar simulator

This paper provides an experimental investigation on the performance of a low-temperature differential Stirling engine. In this study, a twin power piston, gamma-configuration, low-temperature differential Stirling engine is tested with non-pressurized air by using a solar simulator as a heat source. The engine testing is performed with four different simulated solar intensities. Variations of engine torque, shaft power and brake thermal efficiency with engine speed and engine performance at various heat inputs are presented. The Beale number, obtained from the testing of the engine, is also investigated. The results indicate that at the maximum simulated solar intensity of 7145 W/m², or heat input of 261.9 J/s, with a heater temperature of 436 K, the engine produces a maximum torque of 0.352 N m at 23.8 rpm, a maximum shaft power of 1.69 W at 52.1 rpm, and a maximum brake thermal efficiency of 0.645% at 52.1 rpm, approximately.     

Simulation, construction and testing of a two-cylinder solar Stirling engine powered by a flat-plate solar collector without regenerator

In this research, a gamma-type, low-temperature differential (LTD) solar Stirling engine with two cylinders was modeled, constructed and primarily tested. A flat-plate solar collector was employed as an in-built heat source, thus the system design was based on a temperature difference of 80 °C. The principles of thermodynamics as well as Schmidt theory were adapted to use for modeling the engine. To simulate the system some computer programs were written to analyze the models and the optimized parameters of the engine design were determined. The optimized compression ratio was computed to be 12.5 for solar application according to the mean collector temperature of 100 °C and sink temperature of 20 °C. The corresponding theoretical efficiency of the engine for the mentioned designed parameters was calculated to be 0.012 for zero regenerator efficiency. Proposed engine dimensions are as follows: power piston stroke 0.044 m, power piston diameter 0.13 m, displacer stroke 0.055 m and the displacer diameter 0.41 m. Finally, the engine was tested. The results indicated that at mean collector temperature of 110 °C and sink temperature of 25 °C, the engine produced a maximum brake power of 0.27 W at 14 rpm. The mean engine speed was about 30 rpm at solar radiation intensity of 900 W/m² and without load. The indicated power was computed to be 1.2 W at 30 rpm.     

Development of a compact simple unpressurized Watt-level low-temperature-differential Stirling engine

Despite the fast advance of modern technology, poverty is still a serious problem in many developing countries; and more than 1 billion people are having no access to electricity. For these people, even a few Watts of electricity supply for lighting can make a big difference. In this study, a simple, compact, unpressurized, Watt-level low-temperature-differential Stirling engine has been developed aiming to solve the lighting problem in developing countries. The engine in this study is compact. Yet, it is capable of delivering useful electrical power. It is a γ-type Stirling engine with twin power pistons. The diameter of the displacer cylinder is 220 mm, comparable to the size of a cooking pot, and the weight of the engine is under 5 kg. Two energy-conservation/heat-transfer enhancement measures have been incorporated into the engine's design: one is adopting a displacer/regenerator unit, and the other is machining engine-turn slotted grooves on its hot- and cold-end plates. CFD analysis showed that the combination of both measures could effectively improve the performance of the engine. Experiments were conducted to examine the engine's performance. In one experiment, the engine produced 3.7 W of electric power as temperature difference was 100°C, and its power was found to be almost linearly proportional to temperature difference. With a higher temperature difference of 140°C, the electric power reached 5.3 W. Another experiment that operated the engine for a prolonged period has proven the reliability of the engine's performance for long-time use. In practice, the engine can be operated by putting it on a stove table, and the residual heat from cooking is good enough to power the engine to produce usable electricity. Or it can be directly put on a wood fire to generate even higher electrical power.     

A four power-piston low-temperature differential Stirling engine using simulated solar energy as a heat source

In this paper, the performances of a four power-piston, gamma-configuration, low-temperature differential Stirling engine are presented. The engine is tested with air at atmospheric pressure by using a solar simulator with four different solar intensities as a heat source. Variations in engine torque, shaft power and brake thermal efficiency with engine speed and engine performance at various heat inputs are presented. The Beale number obtained from the testing of the engine is also investigated. The results indicate that at the maximum actual energy input of 1378 W and a heater temperature of 439 K, the engine approximately produces a maximum torque of 2.91 N m, a maximum shaft power of 6.1 W, and a maximum brake thermal efficiency of 0.44% at 20 rpm.     

斯特林发动机瞬态模型及特性分析

为获得斯特林发动机的动态特性和优化方案,将损失机制和压力梯度耦合进控制方程中,提出一维瞬态斯特林循环分析模型及分析方法,并针对GPU-3斯特林发动机进行模型验证和特性分析.模型的指示功率相对误差平均值约为4.8％,热效率的相对误差小于1％.当氦气工质在热源温度为977 K、平均压强为2.76 MPa时,输出功率随转速的...     

Design and performance of a moderate temperature difference Stirling engine

The present work developed a prototype Stirling engine working at the moderate temperature range. This study attempts to demonstrate the potential of the moderate temperature Stirling engine as an option for the prime movers for Concentrating Solar Power (CSP) technology. The heat source temperature is set to 350–500 °C to resemble the temperature available from the parabolic trough solar collector. This moderate temperature difference allows the use of low cost materials and simplified mechanical designs. With the consideration of local technological know how and manufacturing infrastructure, this development works with a low charged pressure of 7 bar and uses air as a working fluid. The Beta-type Stirling engine is designed and manufactured for the swept volume of 165 cc and the power output of 100 W. The performance of engine is evaluated at different values of charge pressures and wall temperatures at the heater section. At 500 °C and 7 bar, the engine produces the maximum power of 95.4 W at 360 rpm. The thermal efficiency is 9.35% at this maximum power condition. Results show that the moderate temperature operation offers a clear advantage in terms of the specific power over the low temperature operation. In terms of the West number, the present work demonstrated that the moderate temperature difference operations could offer the performance on par with the high temperature operations with more simple and less costly development.     

Beta-type Stirling engine operating at atmospheric pressure

In this study, a beta-type Stirling engine, with a 192 cc total swept-volume, was manufactured and its performance tested at atmospheric pressure. The hot-source temperature is chosen as a fundamental parameter of the experimental study. Experiments were performed with an electrical heater at 800, 900 and 1000 °C temperatures. Torque and output-power variations were obtained for different engine speeds. The test engine reached a maximum of 5.98 W at 208 rpm, at the hot-source temperature of 1000 °C.     

Manufacturing and testing of a gamma type Stirling engine

In this study, a gamma type Stirling engine with 276 cc swept volume was designed and manufactured. The engine was tested with air and helium by using an electrical furnace as heat source. Working characteristics of the engine were obtained within the range of heat source temperature 700–1000 °C and range of charge pressure 1–4.5 bar. Maximum power output was obtained with helium at 1000 °C heat source temperature and 4 bar charge pressure as 128.3 W. The maximum torque was obtained as 2 N m at 1000 °C heat source temperature and 4 bar helium charge pressure. Results were found to be encouraging to initiate a Stirling engine project for 1 kW power output.     

1.2 kW beta type Stirling engine with rhombic drive mechanism

Because of some advantages such as higher theoretical thermal efficiency, lower pollutant release, working with lower noisy, working with any kind of thermal energy, and having longer life time, Stirling engines receive attentions of academic workers. The development studies related to the drive mechanism as well as the other components of Stirling engine are progressing. In the present study, a beta type Stirling engine with a rhombic‐drive mechanism was manufactured and tested. Tests were performed at hot end temperatures of 600 and 800°C for five different stages of charge pressure ranging from 1 to 5 bar with 1 bar increments. Torque and power characteristics of the engine were deduced. The maximum engine torque and power were obtained as 18 Nm and 1215 W at engine speeds of 612 and 722 rpm, respectively, at 4 bar charging pressure. The cyclic work generations of the engine, which is an important parameter indicating the engine performance, were determined as 19, 27, and 25 J corresponding to 1, 3, and 5 bar charging pressures, respectively. In the experiments, the cylinder pressure variation was also measured at various charging pressures. While the charge pressure increases from 1 to 5 bar, the location of the maximum cylinder pressure ranged from 86° to 74° of crankshaft angle, which may have a bit influence on the engine performance. Copyright © 2017 John Wiley & Sons, Ltd.     

Optimization of Stirling engine performance based on an experimental design approach

The Stirling engine performances depend on several physicals characteristics and functioning parameters. The influence of each parameter and of their interactions is difficult to achieve with classical univariate studies. The experimental design is an alternative to identify the parameters sets allowing optimal Stirling engine performances. Hence, a four factor Central Composite Rotatable Design was used to observe the effect of cooling water flowrate, initial charge pressure, heating temperature, and operation time on a Stirling engine brake power. The influence of each parameter and the effect of the interaction between two or three parameters on the engine performances are presented and discussed. Using the surface response method, it appears that initial charge pressure and heating temperature are the more influencing parameters on the Stirling engine performances. With modeling, optimal conditions for the Stirling engine functioning are the following: charge pressure of 8 bar, heating temperature of 500 °C, and cooling water flow rates of 7.34 l/min, independent of the engine operation time. Copyright © 2012 John Wiley & Sons, Ltd.     

Dynamic analysis of a free piston Stirling engine working with closed and open thermodynamic cycles

In free piston Stirling engines the power generated by the engine is related to the length of the piston and displacer strokes. Length of strokes vary with respect to the hot end temperature, external load, charge pressure, rod diameter, stiffness of springs, masses of piston and displacer and static positions of the piston and displacer. When the length of displacer and piston strokes exceeds the estimated limits, some mechanical collisions occur between piston and displacer or displacer and cylinder. In this work, the dynamic model of a free piston Stirling engine working with closed and open thermodynamic cycles was derived and numerically solved for an optional pair of the piston and displacer masses. Safe ranges were investigated for the hot end temperature, charge pressure, damping coefficient of the piston motion, stiffness of the piston spring and area of the displacer rod. The stiffness of the displacer spring and static positions of the piston and displacer were optimized. Analysis indicated that, a free piston Stirling engine working with a closed thermodynamic cycle performs a stable operation within a small range of the hot end temperature and damping coefficient of the piston motion. By means of inverting the engine into an open-cycle engine, the limited range of the hot end temperature and the damping coefficient of the piston motion were partially enlarged.     

Performance of a beta-configuration heat engine having a regenerative displacer

This paper investigates the performance of a beta-configuration heat engine having a regenerative displacer. In the conventional beta-engine; the displacer and the power piston are incorporated in one cylinder. The displacer transfers the working fluid between expansion and compression spaces via the heater, the regenerator, and the cooler. In the present work, successive homogeneous layers of square wire meshes occupy the displacer space of a beta-engine that make the displacer to be a displacer and a regenerator simultaneously. The theoretical analysis of the engine is based mainly on Schmidt theory. The optimum dimensions of the heater, cooler, regenerator, piston stroke and displacer stroke as dimensionless ratios of the bore were found. The optimum phase angle between the piston and the displacer and the optimum ranges of the speed for each working gas were also found. In a comparison between the proposed engine which has a regenerative displacer and the GPU-3 engine which has a stationary regenerator and a solid displacer; it was found that; the proposed one delivers 20% more power with 10% more efficiency than the GPU-3 engine.     

Performance investigation of a novel Franchot engine design

The double‐acting Franchot engine is inferior to the double‐acting Siemens engine under configurations limited by the Siemens engine. In this contribution, the performance of a novel Franchot engine design without the Siemens engine limitations is investigated with a new mathematical definition of the regenerator end temperatures, and the initial statement is challenged. The main advantages of the Franchot engine compared with the Siemens engine are the free control of the phase angle and the thermal separation of the cylinders. Here, the performance of a cylinder‐heated/cooled air‐filled Franchot engine is investigated at medium temperature under variations of engine speed, phase angle, geometry, dead volume, and gas density. A second‐order thermodynamic model with nonconstant, polytropic heat transfer is developed and implemented in Matlab/Simulink for this investigation. The nonconstant heat transfer is crucial to accurately model the behaviour of the direct cylinder heating and cooling. The results show that the phase angle and air charge density have the largest effect on the engine performance. An increase of the phase angle from 90^o to 150^o at a speed of 1000 RPM led to an increased output power of 58 W compared with a maximum power less than 20 W for a phase angle of 90^o. The efficiency at a phase angle of 150^o is approximately 25% which is slightly lower than the ideal Curzon and Ahlborn efficiency of 29.3%. This discrepancy can be explained by the nonconstant, polytropic heat transfer. In addition to the increase in engine power, the operation at higher phase angles reduces the pressure difference across the power piston by a factor larger than 4 which leads to a significant reduction in gas leakage across the power pistons. This shows that at higher phase angles, the 2 main disadvantages compared with the Siemens engine are at least reduced and arguably completely removed. Thus, the Franchot engine has the potential to be superior to the Siemens engine if freed from the operational restrictions of the Siemens engine.