STIRLING ENGINE

HEAT AND MASS TRANSFER BMCT3143

STERLING ENGINE

Fakhrurazi Bin Aziz B040910051

Halimaton Basmatu Ali B040910081

Mohd Azarul Syazari Bin Che Aziz B040910167

Muhammad Hafiz Bin Abd Rahim B040910092

Nurul Nadia Binti Abdullah B040910227

DUE DATE 25 MEI 2012

LECTURE Pn. Mahanum Mohd Zamberi

Bachelor of Mechanical Engineering (Thermal-Fluid), Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka.

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Table of Contents

Abstract......3 Acknowledgement.4 Introduction....5-6 Chapter 1 : Theory6-8 Chapter 2 : Discussion9-21 2.1. Design Details..9-13 2.1.1. Flow chart.14 2.1.2. Block diagram..15 2.2. Design Verification and Testing...16 2.3. Discussion of Problem Encountered..16-17 2.3.1. Calculation..17-22 2.3.2. Application...22 Chapter 3 : Conclusion...22 References23 Appendix A : Simple Performance Prediction Method.24-25 Appendix B : GANTT CHART.26

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Abstract

Despite vast research on energy generating engines for a long time, human particularly the human society had not found the winning formula to create an engine that has 100% efficiency. One of the closest engine that has a very high efficiency is the Stirling engine, however it has several downfalls that deters any further application in our life. This report subsequently is intended to find out the manufacturing process of a Stirling Engine using recycled materials. The fabrication and assembly of all the parts requires knowledge about theoretical application on how this engine works. Based on several dimensions and data from the design, a Pressure-Volume(P-V) diagram had been obtained in order to know about the theoretical performance of this engine. The engine had also been adds up with an application in order to better understand its working principle. The application must not be overdone because our engine design complies with only a small amount of torque so it cannot run on heavy loads. The Stirling engine was used to remove the electrical load from the internal combustion engine and to increase the fuel efficiency of the engine. The efficiency of heat engine was limited by the law of thermodynamics. The powered of stirling engine was causing by the differences of temperature at the radiator ends. The engine with high efficiency helps to conserve fossil fuels and other natural resources, reducing global-warming emissions and pollutants.

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Acknowledgement

The special thank goes to our lecturer, Puan Mahanum bt Zamberi. The supervision and support was mostly helpful in progression and smoothness of this project. The cooperation is much indeed appreciated. Great deals appreciated to all team members that had give the support and struggle to ensure this project was success. A big contribution and hard worked from all of team member during eight week is very great indeed. This project would be nothing without the enthusiasm and imagination from all team members. Our grateful thank also go to all classmate members that give us support and briefly idea that helpful in ensure this project was successful. Besides, due to this project there are many new experiences in working environment which challenges us every minutes. We also realized the value of working together as a team.

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Introduction

Stirling Engine is one of the reversible thermodynamic cycle application, it is consisting of four phases that include heat addition (isovolumetric heating), expansion (isothermal expansion), heat rejection (isovolumetric cooling), and compression (isothermal compression) which is perform in one complete cycle. They are widely can found in industry application because of the high thermal efficiency, form a quiet and safe operation, ease of operation and able to working with form of thermal energy. Beta Stirling engine is one of the type of sterling engine, it is and improvment from the alpha type of stirling engine. The new design have eliminated the hot seal failure that can found in Alpha and the hot power piston is replaced by a displacer for the improvement. Other design is still the same with. The power piston and the displacer is sharing the same common cylinder and flywheel/crankshaft. Unlike the piston power, the displacer size need to be small from the the cylinder so that the friction between the cylinder and the displacer will be lower and easily to move up and downward.

Figure 1 Beta Sterling Engine

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In Beta Sterling Engine, it has four basic stages to complete one cycle of operation. First stage is heating process. The heat will be supplied from the bottom of cylinder. Then the displacer will going upward due to the heat energy being transferred to the atom in a form of kinetic energy. The collision between the atom with each other and with the wall will produce pressure that push the displacer. The piston power will also going upward because of the compression state at upper cylinder. Then the heat being remove, the expand part is contract because of the kinetic energy is converted into potential energy, the piston will followed the same motion with the displacer. And once the heat being supplied again, it will repeat the same process.

Chapter 1 : Theory

Based on SCHMIDT theory and the theory of stirling engine, there are four type of stirling engine where it is APLHA, BETA, GAMMA and Low Temperature Displacer (LTD). The theory that used an isothermal calculation for the stirling engine is a Schmidt Theory. Where it was the simplest method for the Stirling engine. This theory is based on the isothermal expansion and compression of an ideal gas. Due to assumption of Schmidt Theory, the performance of engine can be calculated by using P-V diagram. Where the volume in the engine can be calculated by internal geometry and the mass of working gass and the temperature are decided. The pressure can be calculate using an ideal gas method where shown on equation (1). PV = mRT (1) Where: P (Pa) = engine pressure V (m3) = total momental volume m (kg) = total mass of working gas R (J/kgK) = gas constant

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STIRLING ENGINE T (J) = space gas temperature For the BETA-TYPE stirling engine, there are calculation model. The equation that involve are; VE = VSE / 2 (1- cos x) + VDE (2) Vc = VSE / 2 (1- cos x) + VSC / 2 [ 1-cos(x-dx)] + VDC VB (3) Where; VE = expansion momental volume Vc = compression momental volume VSE = swept volume of displacer piston VSC = swept volume of power piston dx = phase angle between the diesplacer piston and power piston

In case of stirling engine, the displacer piston and the power piston was located in the same cylinder. An effective working space was created when the both piston was overlaps then there are a stroke. The overlap volume (VB) was calculated based on equation (4); VB = (VSE + VSC) /2 - cos dx (4)

So, the total momental volume (V) is V = VE + Vc + VR (5) To define the engine pressure; P = [ Pmean ] /[ 1-c.cos(x a)]

= [ Pmin (1+c)] / [ 1-c.cos(x a)] = [ Pmax (1-c)] / [ 1-c.cos(x a)] (6) 25/5/2012

STIRLING ENGINE Where; Pmean = mean pressure Pmin = minimum pressure Pmax = maximum pressure There are several ratios and coefficients are defined as; t = TC / TE (7) v = VSC / VSE (8) XB = VB / VSE (9) XDE = VDE / VSE (10) XDC = VDC / VSE (11) XR = VR / VSE (12) a = tan 1[ v sin dx /( t + cos dx + 1)] (13) S = t + 2txDE + 4t XR / (1 + t) + v + 2XDC + 1-2XB (14) B= c = B /S (16) where; TC = compression space gas temperature TE = expension space gas temperature VR = regenerator volume (15)

Then, the P V diagram of Beta-type Stirling engine can be made based on the equation above.

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Chapter 2 : Discussion

2.1. Design Details

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Figure 2 : Connecting Rod

Figure 3 : Crankshaft Holder

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Figure 4 : Flywheel

Figure 5 : Displacer

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Figure 6 : Displacer Block

Figure 7 : Rendering of Stirling Engine in Solidworks

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Figure 8 : Isometric View

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2.1.1. Flow chart

START

END

Brainstorming

YES

Selecting material NO

Is the engine running

Is it a recycle material

NO NO

YES

Is there any air leakage

YES

Fabrication of engine block by using aluminum tin

Engine testing

Fabrication of displacer

Assemble all part

Can it fit with the tin

NO

Fabrication of crank shaft, connecting rod, and flywheel by using compact disc.

YES

Fabrication of power piston by using balloon

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2.1.1. Block diagram STERLING ENGINE LIST OF COMPONENT AND FUNCTION

ENGINE BLOCK the bore of the cylinder will create pressure difference between upper and lower compartment

BLOCK LEG To create room for heater( candle) compartment

DISPLACER to move the working gas back and forth between the hot and cold heat exchangers.

POWER PISTON to amplify the displacer stroke (power stroke)

CONNECTING RODS It changes the reciprocating motion of piston into rotary motion at crankshaft. This way connecting rod transmits the power produced at piston to crankshaft. 25/5/2012

CRANKSHAFT Receives oscillating motion from connecting rod and gives a rotary motion to the flywheel

FLYWHEELS The flywheel smoothes out the pulse of the power stroke and its inertia allows the crank shaft to continue rotating.

ENGINE FRAME To hold crankshaft and flywheel together.

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2.1. Design Verification and Testing

The verification is intended to check that a product, service, or system meets a set of initial design requirements, specification and regulations. For the stirling engine project, the functionality of the design and also the application needs to be evaluated in order to ensure the project complies with regulations, specifications, or conditions imposed at the start of a development phase. On this project, there are several benchmarks to be met by the product in order to ensure it achieves a high standard. The design of this engine speed is about 100 revolutions per minutes. The speed of this engine does not necessarily be so high because the application for this system is light. For ensure the application of this stirling engine project was run smoothly, the light application was chosen that are shoes polisher. By using the minimal amount of heat, the engine was run at least with two candles. Due to this application and design, it was safe for domestic usage that are not be harmful towards costumer, however it was not suitable for children that was below age of 7 years.

2.2. Discussion of Problem Encountered

This project development was divided into several phase that are multiple types of problem that should be encounter in order to ensure the stirling engine was working. The first type of stirling engine that was chosen was Low Temperature Displacer ( LTD)There was several factor that make the design of LTD was failure and it is down, which is the heat required to run the engine was so high. Due to this requirement, the displacer bore is quite spacious that in this stirling engine, it cannot been able to create the sufficient amount of pressure to lift the displacer up. The factor that was affected this type of stirling engine was diameter of the bore. The big displacer must been fabricate due to this type of stirling engine where it was quite heavy. The crankshaft design had met a design complication that caused the piston and displacer movement to be not smooth.

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Got a failure from the first design of stirling engine, the type of Beta stirling engine. There are also several complication that was faced in terms of design and also application before it was successful. The dimensions of bore and piston diameter was been ensure suitable for the compression ratio of the engine. It was important because it has possibility to face with malfunction of stirling engine. The balloon was inserting in the system that act as power piston. The balloon has its nature elasticity that was used as advantage for air tight purpose. It was installing carefully to ensure that it was tight properly. The complexity of the crankshaft was design properly because it was important for the piston and displacer stroke smoothness. The fabrication of cooling compartment is quite complicated as to cut the compartment to suit the block diameter.

2.2.1. Calculation

Given that( from stirling engine): T = 650c R= 287.06 VSE = 0.000184 m3 ( volume of piston) VSC = 1m3 VR = 0.00010053 m3 dx = 900c Tc = 65 0c Te = 600c X = 0 ( ideal stirling engine) t = 0.8 sec (complete one cycle) VE = r2 h = (3x 10-2)2 (6.5x10-2) = 0.1838x10-3 m3 VC = r2 h = (3x 10-2)2 (4.5x10-2) = 0.127x10-3 m3 25/5/2012

STIRLING ENGINE V = VE + VC + VR = 0.000184 + 0.000127 +0.00010053 = 0.000412m3

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To find the pressure on the stirling engine, PV= m RT, = m / V,

To find mass expansions of gas, = mE / V From table 2; T1 =350c, = 1.1455 kg/m3 So, = mE / VE 1.1455 kg/m3 = mE / (0.1838x10-3 m3) mE = 0.0002105KG

To find mass compression of gas, = mc / Vc From table 2; T1 =350c, = 1.1455 kg/m3 So, = mc / Vc 1.1455 kg/m3 = mc / (0.127x10-3 m3) mc = 0.0001457KG so, the pressure are;

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STIRLING ENGINE Pmax (Pexpansion) : PVE = mE RT (Pmax)(0.1838 X10-3) = (2.105 X 10-4)(287.06)(65+ 273) Pmax = 111.13kPa Pmin (Pcompression) : PVC = mC RT (Pmin)(0.127x10-3) = (1.4574 X 10-4)(287.06)(65+ 273) Pmin = 111.35kPa Pmean = =111.24kPa

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After that, to find the overlap volume; VB = (VSE + VSC) /2 cos dx

VB = (0.000184+ 1) /2 VB = 9.2 x 10-5m3

cos (90)

Engine pressure; P = [ Pmax (1-c)] / [ 1-c.cos(x a)] C=B/S B= B= B = 0.2 S = t + 2txDE + 4t XR / (1 + t) + v + 2XDC + 1-2XB S = 0.8 + 2(0.8)(0) + 4(0.8)(0) / (1 + 0.8) + 0.000412 + 2(0) + 1-2(0) 25/5/2012

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S = 1.800412 C=B/S C = 0.2 / 1.800412 = 0.11109 t = TC / TE = (65/ 60) = 1.08 a = tan 1[ v sin dx /( t + cos dx + 1)] a = tan 1[ (0.000412) sin (900) /( 1.08 + cos (900) + 1)] = 0.01135 P = [111.13x103 (1-0.11109)] / [ 1-0.11109cos(0 0.01135)] = 111.12 kPa

After that, by using the simple performance prediction method for stirling engine (ver. 1.8J, koichi Hirata (31 March, 1998)). Step to used; 1) The mean pressure, a swept volume, gas temperature, and a type of working gas was added on the calculated condition. 2) Due to this stirling engine, it was operate by using the design and permitted value. 3) After complete the fill in the blank of the table, the button start was click. 4) The maximum output power and the engine speed was calculate when the engine was at maximum output power due to the experimental equations.

The result that was get from these experimental equations is; Viscosity coefficient, vlim = 1.74E-5 m2/s Gas constant, R = 287.3 J/kgK Engine speed, N = 11552.7 rpm

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Graph 1 : P V DIAGRAM

Based on the Graph 1 for the stirling engine that had been plotted due to the calculation that had done, the amount volume of compression are 0.127x 10-3m3. While volume of expansion on this stirling engine are 0.1838x10-3m3. This is due to the volume displacement that involve during the stirling engine cycle. The total volume of the can that was assumed as cylinder is 3.6757 x 10-4 m3. The heights of the cylinder are 13 cm and the diameters of the can are 6cm. The volumes of the displacer that are on the cylinder are half of the height of the cylinder where it was 6.5 cm. Amount of pressure that involve on this stirling 25/5/2012

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engine is due to the volume of expansions and compression. Pressure at expansion are 111.13 kPa while at compression, the pressure was at 111.35 kPa. The heating process was happen at pressure 1 until pressure 2. Where between 111.13kPa until 111.35kPa. The expansion process was happen during 111.35 kPa until 111.24 kPa. At this situation, the work done of expansion was out while the flow rate was in the system. On the cooling process, the pressure from 111.24 kPa was drop until 111.12 kPa. The compressions on the system were happen from pressure 4 to pressure 1.

2.1.1. Application

By manipulate the stirling engine system and translate it into shoes polisher as the application. How the shoes polisher is working? By manipulate the heat being transfer to the system, the air in the cylinder will expend due to the pressure increased. Once the pressure increased, it will push away the displacer upward and make a half cycle. At upper cylinder included power piston is placed and ice that will make a temperature difference. Because of the low temperature being supplied, the pressure at the power piston will contract due to the kinetic energy being transferred into potential energy. The power piston will push away the displacer to the downward movement and make another half cycle. The complete cycle will make a rotational movement and transfer to the crank shaft and then transfer to the span that will act as shoes polish.

Chapter 3 : Conclusion

From the project that have been build, many type of properties need to be considered to perform a good result in this project. From the fabrication process, each of the dimensions need to be precise or otherwise the project will not running at all. This is due to the friction factor between the displacer and the tin, temperature difference that not meet specification that have been stated and maybe will form a leakage place that will lowered the performance

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of the engine. Engine that had high efficiency is the one that can manipulated the lower temperature an in this project it can run by using at least with two candle. References

[1] LARRY KEEGAN'S EXPERIMENTS WITH STIRLING ENGINES. Retrieved from http://www.keegan.org/larry/stirling.html

[2] The Stirling engine. Retrieved from http://www.pha.jhu.edu/~broholm/l39/node5.html

[3] Simple Performance Prediction Method for Stirling Engine. Retrieved from http://www.bekkoame.ne.jp/~khirata/academic/simple/simplee.htm

[4] SCHMIDT THEORY FOR STIRLING ENGINES. Retrieved from http://www.bekkoame.ne.jp/~khirata/academic/schmidt/schmidt.htm

[5] STIRLING ENGINES. Retrieved from http://www.robertstirlingengine.com/theory.php

[6] Beta Type Stirling Engines. Retrieved from http://www.ohio.edu/mechanical/stirling/engines/beta.html

[7] Stirling engine http://en.wikipedia.org/wiki/Stirling_engine

[8] Beta And Gamma Engine Phase Angle Calculation. Retrieved from http://newenergydirection.com/blog/2008/11/beta-and-gamma-engine-phase-anglecalculation/

[9] Innovative Rotary Displacer Stirling Engine: Sustainable Power Generation for Private and Fleet Vehicle Applications. Retrieved from http://scholar.lib.vt.edu/ejournals/JOTS/v37/v37n2/foster.html

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Appendix A : Simple Performance Prediction Method [3]

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Appendix B : GANTT CHART ( TIME DURATION OF PLANNING STIRLING ENGINE PROJECT)

ACTIVITIES 22/3 29/3 DURATION IDENTIFYING THE PROBLEM BRAINSTORMING AND PLANNING THE PRODUCT OF STIRLING ENGINE PROCESS DESIGN AND DEVELOPMENT DETAILED TECHNICAL DESIGN DESIGN FUNCTIONALITY AND EFFECTIVENESS PRODUCT DESIGN ANALYSIS 29/3 5/4 5/4 12/4 12/4 19/4 19/4 26/4 3/5 10/5 17/5 24/5 24/5 25/5

PRESENTATION REPORT

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