Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 1

INTRODUCTION

The Sterling engine is a heat engine of the external combustion piston engine
type. It was invented and developed by Reverend Dr. Robert Sterling in 1816. A well-
designed Sterling engine can achieve 50% to 80% of the ideal efficiency in the
conversion of heat into mechanical work, limited only by friction and material
properties. The engines can theoretically run on any heat source of sufficient
temperature, including solar energy, chemical and nuclear fuels.

While the Sterling engine is more expensive than an internal combustion engine
of the same power rating, its many unique advantages make it preferred for a variety,
can be made very energy efficient, quiet, reliable, long-lasting and row-maintenance.
In recent years, these advantages have become increasingly significant given the
general rise in energy costs and the environmental concerns of climate change. This
growing interest in Sterling technology has led to the ongoing development of
Sterling devices for many applications, including renewable power generation and
Astronautics.

Stirling engines have two pistons that create a 90-degree phase angle and two
different temperature spaces. The working gas in the engine is perfectly sealed and
doesn't go in and out to the atmosphere. The Stirling engine uses a Stirling cycle,
which is unlike the cycles used in normal internal combustion engines.

The gas used inside Stirling engine never leaves the engine. There are no exhaust
valves that vent high-pressure gases as in petrol or diesel engine, and there are no
explosions taking place.

The Stirling cycle uses external heat source, which could be anything from
gasoline to solar energy to heat produced by decaying plants. No combustion takes
place inside cylinder of the engine.

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 Design and Fabrication of Solar Powered Stirling Engine

Stirling engines also reduces noise pollution because they do not require intake
and exhaust valves which is the main source of engine noise. However, Stirling

engines that can be used for automobile use would be larger, heavier, and more
expensive than conventional internal combustion engines. Moreover, Stirling engines
require warm up time before they start, however the output of the engine cannot be
changed quickly for quick acceleration and retardation.

Although Stirling engines have not yet found use in the automotive industry.
Recently, there has been an interest in Stirling engines as more fuel efficient and clean
engines are demanded. The engine has been the source of interest over decades
because the theoretical efficiency is calculated to be nearly equal to its theoretical
maximum efficiency.

This report presents an external combustion engine. The engine is designed so

that the working gas (air) is generally compressed in the colder portion of the engine
and expanded in the hotter portion resulting in a net conversion of heat into work. So,
a Stirling engine system has at least one heat source, one heat sink and heat
exchangers and transmitted from a heat source to the working fluid by heat
exchangers and finally to a heat sink.

There are three types of Stirling engines that are distinguished by the way they
move the air between the hot and cold sides of the cylinder is alpha, beta and gamma
types, In a beta configuration similar to the engine used in this study, A beta Stirling
has a single power piston arranged within the same cylinder on the same shaft as a
displacer piston The displacer piston shuttle the working gas from the hot heat
exchanger to the cold heat exchanger. The displacer is a special-purpose piston; used
in Beta and Gamma type Stirling engines, to move the working gas back and forth
between the hot and cold heat exchangers. The working gas is pushed to the hot end
of the cylinder so; it expands and pushes the power piston. The displacer is large
enough to insulate the hot and cold sides of the cylinder thermally and to displace a
large quantity of gas.

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 Design and Fabrication of Solar Powered Stirling Engine

1.1 Theoretical Background

Function of Parts
Compression Cylinder
Compression cylinder is used to move piston inside it. It must compact and
leakage free. The material is of C.I. (Cast Iron).
Compression Piston(displacer)
The working gas is transferred from one end of the cylinder to the other, a
device called a displacer. This has a reciprocating motion and it moves inside the
cylinder. The material used for piston is of C.I. (Cast Iron).
Crank Shaft
Piston has a piston rod which is connected to crankshaft. The piston rod
engages in a crank pin, which is rigidly mounted on the crankshaft through a
crank web. This reciprocating motion of the piston is converted into rotary motion
of the crankshaft. Here the material used is BRASS.
Stand
Stand used for support entire assembly.

1.2 Motivation

Due to the continuous depletion of fossil fuels we must look for an alternating
energy sources for producing desired form of energy, so our project finds its basis on
checking for the solar energy as an alternate source to run the sterling engine.

The power obtained by sterling engine is quite less than other type of engines,
so to increase the power output of sterling engine we are using solar radiation.

As the solar energy is renewable or rather never-ending source of energy, we

can utilize it as a external heat source for Stirling engine. So, we could run the engine
on solar power in future on large scale fulfilling the need of energy for various day to
day work.

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 Design and Fabrication of Solar Powered Stirling Engine

1.3 Objective

To fabricate the model of solar powered Stirling engine.

To study the working mechanism of parabolic concentrated solar panel and

Stirling engine.

1.4 Scope of work

The future is all about how we utilize our remaining fossil fuels and how we
use the renewable energy sources for power generation. The course of the world will
be decided by use of renewable energy sources. So, our work focuses on how to
utilize solar energy to run the Stirling engine instead of any traditional external
heating source such as flame torch, etc.

1.5 Advantages
1. The heat is external, and the burning of a fuel-air mixture can be more
accurately controlled.
2. A continuous combustion process can be used to supply heat, so emission of
unburned fuel can be greatly reduced.
3. The engine is much less complex than other reciprocating engine types. No
valves are needed. Fuel and intake system are very simple.
4. They operate at relatively low pressure and thus are much safer than typical
stem engines.
5. Low operating pressure allows the usage of less robust cylinders and of less
weight.
6. They can be built to run very quietly and without air, for use in submarines or
in space.
7. They start easily and run more efficiently in cold weather, features lacking in
their internal combustion cousins.
8. A Sterling engine which is pumping water can be configured so that the
pumped water cools the cool side. This is, of course, most effective when
pumping cold water.

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 Design and Fabrication of Solar Powered Stirling Engine

1.6 Applications

Combined heat and power applications

The principle use of Stirling engines today is as an economical source of electrical

power often utilizing a heat source from an industrial process. WhisperGen, a New
Zealand firm with offices in Christchurch, has developed an “AC Micro combined
Heat and Power” Stirling cycle engine. These microchip units are gas fired central
heating boilers which sends power back in electricity grid. They announced in 2004
that they were producing 80,000 units for the residential market in UK. A 20-unit trial
started in Germany in 2006.

Solar power generation

Placed at the focus of a parabolic collector a Stirling engine can convert the solar
energy in electricity with an efficiency better than photovoltaic cell. On August 11,
2005, southern California Edison Council announced an agreement to purchase solar
powered Stirling engines from Stirling Energy systems over a twenty-year period and
in quantity 20,000 units enough to generate 500 MW of electricity. This system is on
a 4500 acre (19 sq.km.) solar farm, will use mirrors to direct and concentrate sunlight
onto the engines which in turn drives generators.

Stirling cryo-coolers

Any Stirling engine will also work as reverse as heat pump i.e. when a motion is
applied to a shaft, a temperature difference appears between reservoir. One of this
modern used in refrigeration and cryogenics.

The essential mechanical component of Stirling cryocooler is identical to Stirling

engine. The turning of the shaft will compress the working gas causing its temp to
rise. This heat will then be pushing the gas against heat exchanger. Heat would flow
from the gas into this heat exchanger which would probably be cooled by passing

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 Design and Fabrication of Solar Powered Stirling Engine

flow of air or other fluids over its exterior. The further turning of the shaft will then
expand the working gas since it had just been cooled the expansion will reduce its
temp even further. Now very cold gas will push against heat exchanger and heat
would flow from it into the gas. The external side of this heat exchanger would be
inside a thermally insulated compartment such as refrigerator. This cycle would be
repeated once for each turn of the shaft. Heat is in effect pumped out of this
compartment, through the working gas of cryocooler and dumped into environment.
The temp inside the compartment will drop because its insulation prevents ambient
heat from coming into replace that pumped out.

As with this Stirling engine efficiency is improved by passing the gas through
“Regenerator” which buffer the flow of heat between hot and cold end of gas
chamber.

The first Stirling cryocooler was developed at Philips in the 1950’s and
commercialized in such a place as a liquid nitrogen production plant. The PHILIPS
CRYOGENS BUSINESS evolved until it was split off in 1990 to form the Stirling
cryogenics and refrigeration.

Heat pump

Stirling heat pump is very similar to Stirling cryocooler. The main difference being
that it usually operates at room-temp and its principle application to date is to pump
heat from the outside of a building to the inside, thus cheaply heating it.

As with any other Stirling device, heat flows from the expansion space to the
compression space; however, in contrast to the Stirling engine, the expansion space is
at lower temp than the compression space. So, instance of producing work, an input of
mechanical work is required by the system. When the mechanical work for the heat
pump is provided by a second Stirling engine, then the overall system is called as heat
pump. The expansion side of heat pump is thermally coupled to the heat source,
which is often external environment. The compression side of the Stirling engine is
placed in environment to be heated, for example a building, and the heat is pumped in

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 Design and Fabrication of Solar Powered Stirling Engine

it. Typically, there will be thermal insulation between two side so there will be
temperature rise inside insulated space. Heat pumps are by far the most energy-
efficient types of heating systems. Stirling heat also have obtained higher coefficient
of performance than conventional heat pump.

Marine engine: -

Kockums, the Swedish Shipbuilder had built at least 10 commercially successful

Stirling powered submarines during 1980’s. As of 2005 they have started to carry
compressed oxygen with them.

Nuclear power: -

There is potential for nuclear powered Stirling engine in electric power generation
plant. Replacing the steam turbine of nuclear powerplant with Stirling engine might
simplify the plant, yield greater efficiency and reduce the radioactive by-product. A
number of Breeder reactor designed, used liquid sodium as a coolant if the heat is to
be employed in heat plant. Water sodium heat exchanger is required which rise some
concern as sodium reacts violently with water. A Stirling engine obviates the need of
water anywhere in cycle. It is designed to generate electricity for deep space probes
on mission lasting decades. The engine uses a single displacer to reduce moving part
and use high energy acoustics to transfer energy. The heat source is that solid nuclear
fuel slug and the cool source is space itself.

Aircraft engine: -

They hold theoretical promise as aircraft engine, they are less polluting gain
efficiency with altitude are more reliable due to fewer parts and absence of an ignition
system, produce much less vibration (airframes last longer) and safer, less explosive
fuels maybe used.

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 Design and Fabrication of Solar Powered Stirling Engine

Geothermal energy: -

Some believe that the ability of the Stirling engine to convert geothermal energy to
electricity and then to hydrogen may well hold the key to replacement of fossil fuels
in a future hydrogen economy.

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 Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 2

LITERATURE REVIEW

This article provides a literature review on solar-powered Stirling engines and

low temperature differential Stirling engines technology. A number of researches
works on the development of Stirling engines, solar-powered Stirling engines, and
low temperature differential Stirling engines is discussed. The aim of this review is to
find a feasible solution which may lead to a preliminary conceptual design of a
workable solar-powered low temperature differential Stirling engine. Results from the
study indicate that Stirling engines working with relatively low temperature air are
potentially attractive engines of the future, especially solar-powered low temperature
differential Stirling engines with vertical, double-acting, gamma-configuration.

In order to develop a compact and low cot Stirling engine with simple moving
tube type heat exchangers and a rhombic mechanism as developed. Its target shaft
power is 50W at engine speed of 4000 rpm and mean pressure of 0.79 MPa using
helium as working gas. This paper describes the outline of engine design and
performance test. The test was done without any load using air in atm condition. Also
a mechanical loss measurement was done in highly pressurized condition in which
engine was driven by motor compulsory. Then methods to get higher performance
were considered based on comparison of experimented and calculated results. This
result indicates that a higher performance heat exchanger and decreasing of
mechanical loss are needed for attainment of target performance.

Recent Stirling engine research at university of Canterbury has focused on

development of a compact 12 V 200 W electrical battery charger suitable for use in
yacht, mobile homes or remote dwellings and intended for scaling up to larger power
applications. The hermetically sealed engine with integral alternator uses a
pressurized air of 1MPa as working fluid. The paper has described wobble yoke
mechanism which is central to engine design it requires a pre lubricated single degree
of freedom bearing. It explains the design philosophy behind new engine. Features
examined include alternator, the cylinder mounted seals and heat exchangers.

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 Design and Fabrication of Solar Powered Stirling Engine

Worldwide attempts are being made to increase the use of our renewable
energy sources as well as to use our current fossil fuel energy sources more
efficiently. Waste heat recovery forms a substantial part of the latter and is the focus
of this project. Stirling technology finds application in both the renewable energy
sector and in waste heat recovery. Investigating the applicability of Stirling engines in
the above-mentioned fields is relevant to develop more efficient external combustion
units as well as to utilize our renewable energy sources. Developing a design analysis
and synthesis tool capable of optimizing Stirling powered units forms the main
objective of this project. The methodology followed to achieve this, involved the
application of three different methods of analysis, namely the method of Schmidt, the
adiabatic analysis and the simple analysis based on a five-volume approach. The
Schmidt analysis is used to obtain the internal engine pressure which is a required
input for the adiabatic analysis while the simple analysis introduces pumping losses
and regenerator inefficiencies. These methodologies are discussed briefly in this
paper. Experimental verification of the analytical data was carried out on a Henrici
Stirling engine and both the analytical data and the experimental data are presented
here. Shortcomings of these methods of analysis are highlighted and an alternative
approach to solve particular shortcoming is presented.

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 Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 3

DESIGN, MECHANISM AND FABRICATION

3.1 Operating Principle of Stirling Engine

Stirling engine consists of a cylinder that contains gas, a piston and a displacer. The
regenerator and a flywheel are other main parts of the engine. When heat part of
cylinder is heated up by an external heat source, the temperature rises and gas
expansion is proportional to the temperature of the heat side. Total volume is kept
constant and is maintained by a piston, thus the expanded gas keeps pushing the
piston down, so the volume of the pressured gas is increased and the gas loses its
temperature and pressure, then the piston moves back to the heat side and compresses
the gas by momentum force of the flywheel, when it reaches near its upper limit the
displacer pushes the cooled off gas to the heat side of the cylinder so that the gas is
compressed and it is prepared to do another cycle. Thus, expanded gas pushes the
piston down again so as to produce mechanical energy for doing work, this cycle
continues till an external heat source is available for work. The flywheel and the
regenerator have immense contribution towards the engine’s performance. The fly-
wheel converts the linear motion of a working piston to rotary motion; it gives the
required momentum for the cycle procedure. Regenerator derives heat from gas in the
expansion phase and releases heat to the gas in the compression phase, thereby
improving the engine’s efficiency considerably. A Stirling engine and its components
are shown in below.

Figure 1. Operating Principle of Stirling Engine

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 Design and Fabrication of Solar Powered Stirling Engine

Stirling engine’s working cycle has four phases; heating, expansion, cooling and
Compression.

1. Heating: Heat source provides thermal energy to the engine so that pressure and
temperature of gas is raised.

2. Expansion: In this phase the volume increases, but the pressure and temperature are
decreased, mechanical energy is produced from heat energy during this phase of
cycle.

3. Cooling: The gas is cooled followed by temperature and pressure decreases, so the
gas is prepared to be compressed during this cycle.

4. Compression: The pressure of gas increases whereas its volume decreases; part of
mechanical energy produced is used for processing of this phase, as it needs an
amount of work to be done.

The procedure of phase can be illustrated graphically in a PV diagram as it is shown

in.

Figure 2. PV and TS Diagram of Stirling Cycle

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 Design and Fabrication of Solar Powered Stirling Engine

Looking at the graph of Stirling cycle one can see that; the volume is constant in
heating phase (1-2) and cooling phase (3-4) while during Expansion (2-3) and
Compression (4-1) volume is varying but temperature is constant.

The Stirling engine approximates the idealized thermodynamic process shown in

Figure above, known as the Stirling cycle:

1. Process 1-2: Isothermal compression. One piston compresses the working fluid
within the compression volume, while the other is stationary. This increases the
pressure of the system at a constant temperature.

2. Process 2-3: Isochoric transfer I. Both pistons move in opposition (90° out of
phase) to transfer the working fluid from compression to expansion volume. The
regenerator, in an ideal situation, raises the fluid temperature to 30 using heat stored
from process 4-1.

External heat supplies the remainder.

3. Process 3-4: Isothermal expansion. The expansion piston is moved by the

expanding fluid, which is maintained at a constant temperature by the external heat
source. Work is done in this stage on the piston by the working fluid.

4. Process 4-1 Isochoric transfer II. The reverse process of 2-3, both pistons work to
transfer the fluid from the expansion to the compression space. The regenerator
absorbs heat from the fluid, reducing the fluid temperature to that at 1’.

3.2 Stirling Engine Configurations

Various machine components have been combined to provide the Stirling cycle.

The cycle provides a constant-volume process during the transfer of working fluid
between the hot and cold space of the engine and provides a constant-temperature
heating and cooling process during compression and expansion. The compression and
expansion processes of the cycle generally take place in a cylinder (called power
cylinder) with a piston (called power piston). A displacer piston (simply called

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 Design and Fabrication of Solar Powered Stirling Engine

displacer) shuttles the working fluid back and forth through the heater, regenerator,
and cooler at constant volume.

Three different configurations; each configuration has different mechanical design

characteristics.

1. Alpha-Configuration

Displacer is not used. Two pistons, called the hot and cold pistons, are used on either
side of the heater, regenerator, and cooler. These pistons move uniformly in the same
direction to provide constant-volume heating or cooling processes of the working
fluid. When all the working fluid has been transferred into one cylinder, one piston
will be fixed and the other piston moves to expand or compress the working fluid. The
expansion work is done by the hot piston while the compression work is done by the
cold piston.

1. Alpha Type 2. Beta Type 3. Gamma Type

Figure 3. Stirling Engine Configurations

2. Beta-Configuration

Displacer and a power piston are incorporated in the same cylinder. The displacer
moves working fluid between the hot space and the cold space of the cylinder through
the heater, regenerator, and cooler. The power piston, located at the cold space of the

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 Design and Fabrication of Solar Powered Stirling Engine

cylinder, compresses the working fluid when the working fluid is in the cold space
and expands the working fluid when the working fluid is moved into the hot space.

3. Gamma-Configuration

Separated cylinders for the displacer and the power pistons are used, with the power
cylinder connected to the displacer cylinder. The displacer moves working fluid
between the hot space and the cold space of the displacer cylinder through the heater,
regenerator, and cooler. In this configuration, the power piston both compresses and
expands the working fluid.

3.3 Design Calculations

To fist order, two properties of a drive mechanism influence the performance of

Sterling engines, the volume amplitude ratio and the phase lag between expansion and
compression space.

The volume amplitude ratio, VAR, is defined as the change of the volume of the
compression space divided by the change in volume of the expansion space during a
complete revolution VAR = 1 is suggested by many researchers for this quantity.

The volumetric phase lag, VPL, refers to the angular offset between the volume of the
compression space as function of crank angle and that of the expansion space. VPL =
90 Degree is an often-cited optimal value with the compression space lagging behind
the expansions space. For strictly sinusoidal function this definition of phase lag is
unique for others one might look at the phase lag of the maxima and the minima of
compression and expansion space.

The equations for the size of the expansion and compression space are:

1. Swept volume= (π/4*D²*L)

2. Clearance volume = 5% of swept volume
3. Volume of air admitted (V₁) = Swept + Clearance
4. %Efficiency = (work done/Heat supplied)

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 Design and Fabrication of Solar Powered Stirling Engine

Performance Calculations

1. Power = 2πNT/60 KW
2. Torque = Force * Radius
3. Force = Pressure * Area
4. Area = π*D*L

3.4 Parabolic dish calculations:

f = (D’ * D’ ) / ( 16 * c )

where, f= Focal length

c=Depth of dish

D’=Diameter

2.8 Calculation for direct radiation:

Tilt angle Σ =90 ̊

Disinclination, d = 23.5 ̊

Altitude angle β at solar noon βmax = 90-(l-d)

At solar noon solar azimuth angle γ =180 ̊

Wall azimuth angle α = 180 – (γ-ξ) = 0

Incident angle θ overall = Cos-1(Cosβ*Cosα)

Direct radiation IDN =A*exp(-B/Sinβ)

Diffuse radiation, Id

View factor Fws= (1+CosΣ)/2

Diffuse radiation, Id =C*IDN*Fws

Reflected radiation for .96 (ρg) Ir=(IDN+Id)*ρg*Fw

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 Design and Fabrication of Solar Powered Stirling Engine

3.5 Specification of Parts

1. Expansion Cylinder O. D. = ϕ 41 mm

I. D. = ϕ 39.9 mm

2. Working Stroke of Expansion Cylinder = 75 mm

3. Capacity of Expansion Cylinder = 93.72 cm 3

4. Compression Cylinder O. D. = ϕ 60 mm

I. D. = ϕ 40 mm

5. Working Stroke of Compression Cylinder = 30 mm

6. Capacity of Compression Cylinder = 28.26 cm3

7. Maximum Speed of Engine = 350 R. P. M

8. Temperature of Focal Point = 130 0C

9. Temperature at the Cool Zone = 85 0C

10. Weight of Flywheel = 0.85 kg

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 Design and Fabrication of Solar Powered Stirling Engine

3.6 Bill of Material

Sr. Name of Parts Qty. Material Cost

No. Nos. (Rs.)
Frame 1 M. S 1200
1.
Crank Shaft 1 BRASS 180
2.
Crank Pin Expansion Piston 1 H.C.A. S 80
3.
Crank Pin Compression Piston 1 H.C.A. S 80
4
Fan Blade 1 Aluminum 95
5.
Engine Base Plate 1 M.S 120
6.
Bush Expansion Piston Rod 1 BRASS 120
7.
Compression Piston 1 Al 250
8.
Compression Cylinder 1 C.I 350
9.
Expansion Cylinder 1 Cu 600
10.
Expansion Piston 1 Cu 160
11.
Compression Piston Connecting Rod 1 BRASS 95
12.
Expansion Piston Connecting Rod 1 BRASS 95
13.
Piston Pin 1 H.C. S 30
14.
Hardware – Nuts, Bolts, etc. 1 lot M.S 500
15.

Total = 4775

Table 1. Bill of Material

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 Design and Fabrication of Solar Powered Stirling Engine

Figure 4. Expansion Piston - Cylinder Assembly

Figure 5. Connecting Rod and Pins

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 Design and Fabrication of Solar Powered Stirling Engine

Figure 6. C.I. Cylinder and Accessories

Figure 7. Lock and Flat Connecting Rod

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 Design and Fabrication of Solar Powered Stirling Engine

3.7 Manufacturing Process Sheets

1. Name of the Part: Cylinder Support Plate Qty : 1 No.

Raw Material : M.S

Sr. Operation Machine Speed Feed Tool Time

No. (RPM) (Min)

1. Cut a plate from as per dwg Power 350 Auto Hack 15

width MS. Stock Hack Saw Saw
Blade
2. Fit a 4 jaw a dog chuck on Lathe 75 Manua Side Tool 45
the spindle of lathe. Grip l
plate in chuck & take light
cleans cuts on all the 6 faces
one by one at right angles.
Deburr the corners.
3. With the help of Vernier Work -- Manua Vernier 35
mark all center lines & locate Table l Scale
the machining positions as Scriber
per the dimensions of Center
drawing. Punch

4. Crip the place & center true Lathe 650 Manua Side Tool 240
the marked positions & 75 l Threadin
machine threading Bore Manua g
l Tool
5. Drill tapping holes as per Drill 850 Drill By 35
dimensions & thread 75 Tap Manual
deburring Set Handling
Total time …… 370

Table 2. Manufacturing Process Sheet - Cylinder Support Plate

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 Design and Fabrication of Solar Powered Stirling Engine

2. Name of the part: Compression Cylinder Qty: 1 No.

Raw Material: CI Overall size: Día 70 mm X 60 mm long

Sr. Operation Machine Speed Feed Tool Time

No. (RPM) (min)
1. Cut a raw stock high ci bar of Power 350 Auto Hack Saw 15
size Día 75 X 65 long Hack Blade
Saw
2. Grip bar pieces in true chuck Lathe 650 Manual Side Tool, 15
face & drill center Drill center
3. Pass pilot drill to through & Lathe 850 Manual Drill 15
then drill Día 38 reamer size
drill
4. Pass Día 40 reamer through Lathe 75 Manual Reamer 10
5. Hone & polish the bore to size Lathe 1000 Manual Honing 75
+0.00001 Tool
Día 40 -0.00000 Check the Energy
honed bore using plug gauge. Paste &
Super Fine
Polish
Paper
6. Reverse job & face to total Lathe 650 Manual Side Tool 10
length 60 mm.
7. Grip the job in taper mandrel Lathe 75 Manual Parting 30
& cut the grooves. Deburr. Tool
Mandrel
Total … 170
…

Table 3. Manufacturing Process Sheet - Compression Cylinder

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 Design and Fabrication of Solar Powered Stirling Engine

3. Name of the Part : Compression Piston Qty : 1 No.

Raw Material : Al Weight : 125 g kgs.

Overall size : Día 40 mm X 41 mm long

Sr. Operation Machine Speed Feed Tool Time

No. (RPM) (min)

1. Grip a road of size Día Lathe 650 Manual Side Tool Drill 15
42 in true chuck face & center
drill center.

2. Pass Día 3 drill through Lathe 850 Manual Drills 20

then pass pilot drill
Día 10 to depth 12 mm

3. Boring hole of size Lathe 75 Manual Boring tool 20

Día 14 X 15 depth

4. Turn O.D. to size Día 40 Lathe 1000 Manual Side Tool 55

& then tap the O.D. to Energy Paste
size +0.0000 Día 40 - & Polish Paper
0.00000

5. Cut oil grooves & part off Lathe 75 Manual V. Tool 15

piston to length 18 mm. Parting Tool

Total time …………..140

Table 4. Manufacturing Process Sheet - Compression Piston

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4. Name of the Part : Crank Shaft Qty : 1 No

Raw Material : brass.

Overall size O.D. Día 6.5 mm X 80 mm long

Sr. Operation Machine Speed Feed Tool Time

No. (RPM) (min)

1. Cut round bar of size O.D Work -- Manual Hack Saw 3

Dia 6.5 X 82 long Table Blade
2. Grip bar stock in true chuck Lathe 650 Manual Side Tool, 10
& center true. Take a face Drill center
cut & drill center.
3. Reverse job. Take a face Lathe 850 Manual Side tool 10
cuts & check length 80mm Drill center
drill counter
4. Fit a carrier in chuck & true Lathe -- Manual Carrier Dead 15
it. Grip dead center in chuck Centre
& in tailstock
5. Align the shaft in center & Lathe 850 Manual Side Tool 15
turn ball bearing steps
+0.00001 Día 6 -0.00000 as
per dimensions between
centers.

Total time………..53

Table 5. Manufacturing Process Sheet - Crank Shaft

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 Design and Fabrication of Solar Powered Stirling Engine

5. Name of the part : Expansion Cylinder Qty : 1 No

Raw Material : Cu.

Overall size : O.D Día 41 mm x 115 mm long

Sr. Operation Machine Speed Feed Tool Time

No (RPM) (min)
.

1. Cut a pipe pieces in true Work table --- Manual Hack Saw Blade 10
chuck & center face
2. Grip pipe pieces in true Lathe 650 Manual Side Tool 15
chucks &center face
3. Reverse pipe & face to Lathe 650 Manual Side tool 15
length 115
4. Fit a taper mandrel in Lathe 350 Manual Taper Mandrel 40
true chuck center. Press one side tool &
fit the pipe I.D. on polish paper
mandrel. Turn O.D of
size to 41 . also bore
counter bore of size Dia
39.9

Total time………..80

Table 6. Manufacturing Process Sheet - Expansion Cylinder

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 4

ASSEBLY, WORKING AND TESTING

Working

4.1 Actual Working of Stirling Engine

A fixed volume of air is heated. As it gets warmer, its pressure increases. By allowing
the air to act on underside of a piston, the engine can do work. Having pushed the
piston to the top of its stroke, the air is then cooled. Reducing its pressure and
allowing atmospheric pressure to push the piston back down. Repeat rapidly and you
have a hot air engine!

Turning the idea into reality has involved many engineers over a long period of time.
The Frenchman Cannot proposed the first theoretical work, which was developed into
a practical machine by the Englishman Thomas Mead and, in Scotland, Dr. Robert
Sterling. Such was Sterling’s contribution that “hot air engine” and “Sterling cycle
engine” now get used almost interchangeably.

There are several design considerations. Firstly, the air must be heated from an
external source (yes – this is an external combustion engine!). Having heated the air,
it must then be cooled effectively and some way found of preventing heat “leaking”
from one end of the engine to the other. Finally, some mechanical means must be
contrived to make the preceding things happen in an appropriate order. The engine
starts with the displacer at the hot end of its cylinder – conversely, the air is displaced
to the cold end. As the air cools, the pressure drops. This in turn acts on the piston.
The piston descends, moving the displacer piston back along its cylinder.

The cool air is forced to the hot end of the displacer cylinder by the displacer. The air
pressure increases rapidly, forcing the piston back up its bore. This is turn starts to
moves the displacer piston back to the hot end, the air is displaced to the cold end, its
pressure drops and – we start again!

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

4.2 Working Process

A cylinder is mounted horizontally & machined with highly honed bore in which a
precision lapped piston works to & fro with a definite stroke travel the cylinder has
fines. For effective release of heat to the atmosphere there by keeping its other end
cool the cylinder is side faced which is lapped & polished for free leak proof slide of
the value. A pan for inlet of hot air is cut from the solar energy by reflector & exhaust
of cool air is cut on the cross face on the lower dead center this side of the cylinder is
plugged.

The piston reciprocates in the cylinder from its upstroke to the down stroke. The
piston rod engages in a crank pin, which is rigidly mounted on the crankshaft through
a crank web. This reciprocating motion of the piston is converted into rotary motion
of the crankshaft.

The crankshaft is supported in journal bearing fitted. On the vertical

Support mount a flywheel is mounted at the output side of the crank shaft. The
spherical reflector is mounted on the fabricated foundation & the engine is so adjusted
that the focal point of reflector is concentrated on the expansion cylinder & this focal
is drop on the expansion cylinder & heat is generated by this heat the engine of
operated. The engine is rigidly mounted on a fabricated foundation base the solar
energy by the reflector provides the required heat to the cylinder. The speed of the
engine is in the range of 350 to 400rpm.

Figure 8. Beta Type Stirling Engine

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

This type of Sterling engine, known as the beta configuration features just one
cylinder with a hot end a cool end. The working gas is transferred from one end of the
cylinder to the other by a device called a displacer (here illustrated in blue). The
displacer resembles a large piston, except that it has a smaller diameter than the
cylinder, thus its motion does not change the volume of gas in the cylinder – it merely
transfers the gas around within the cylinder.

The same four phases of the Sterling cycle are at work here:

Figure 9. Expansion

Expansion - At this point, most of the gas in the system has just been driven to the
hot end of the cylinder. The gas heats and expands driving the piston outward.

Figure 10. Transfer

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

Transfer - At this point, the gas has expanded. Most of the gas is still located in the
hot end of the cylinder. Flywheel momentum carries the crankshaft the next quarter
turn. The bulk of the gas is transferred around the displacer to the cool end of the
cylinder.

Figure 11. Contraction

Contraction - Now the majority of the expanded gas has been shifted to the cool end.
It contracts, drawing the piston inward.

Figure 12. Transfer

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

Transfer - The contracted gas is still located near the cool end of the cylinder.
Flywheel momentum carries the crank another quarter turn, moving the displacer and
transferring the bulk of the gas back to the hot end of the cylinder.

4.3 Problems Encountered During Fabrication

After the completion of fabrication, next step was to test the engine. While doing
so, we encountered both technical and manufacturing problems as given below:
a. Hard to find the cylinder of required dimension and material.
b. Difficult to give proper shape to the crank shaft manually.
c. Problem encounter with the air leakage in power piston.
d. Light weight displacer was hard to fabricate with proper dimension.
e. Problem in calculating output of the system.

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 5

RESULTS AND DISCUSSION

5.1 Power Output

Power = 10 W on Solar Radiation
Power = 200W at the maximum temperature of 400 0C.
5.2 Efficiency
Theoretically

Stirling engine efficiency = Carnot efficiency

Unfortunately working fluid or gas is not ideal this causes the efficiency to be lower
than Carnot efficiency. in fact, Stirling engine efficiency depends on

 Temperature ratio (proportionally)

 Pressure ratio (inversely proportional)
 Specific heat ratio (inversely proportional
It is considered that the gas used (air, hydrogen, helium, nitrogen...) is a“perfect”gas

PV=CONSTANT

where" P" represents the pressure of gas and" V "its volume.

If the temperature of gas is introduced, this law becomes:

PV = nRT

 Qexp +Qheat – Qcool - Qcomp = Wexp – Wcomp

 Efficiency = ( Wexp - Wcomp ) / (Qexp+ Qheat )

Efficiency = 1 - Tm / TM

= 1- (85/130) = 35%

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

CHAPTER 6

CONCLUSIONS

6.1 Conclusions

Solar powered Stirling engine has wide scope for the future. It will help for the
development of renewable energy in near future. As, it operates in reversible cycle so,
not only heat can be converted into mechanical energy but also can be used as cooler.
Though all the three configurations have different features but their working principle
(temperature difference) and components are almost similar.

Finally, we were able to develop the demonstrative model of solar powered stirling
engine that gives total output power of 20 watts. With the 40 mm diameter of
displacer cylinder and length of 138 mm. Also given parabolic dish when covered
with aluminum foil reflects total radiation of 7 kW per day. This system as a whole
converts solar energy to thermal to mechanical energy. But, it requires a lot of
precision and accuracy for the smooth operation.

6.2 Recommendations

Following suggestions are recommended if anyone wants to perform this project:

• Displacer cylinder and displacer should be tightly fitted. Otherwise the system will
not operate. Also, displacer of light weight is suggested.

• Leakage of air from power piston should be handle with care.

• Precise connection of connecting rod and crankshaft with displacer and power piston
should be done. This will help to reduce the friction.

• Setup of dish requires technical knowledge of antenna.

• Special care should be taken while using the material regarding its dimension while
fabricating.

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

6.3 Future scope

1. Water-cooling jacket.

2. Variation of the speed of the engine.

3. Compactness of the layout

4. Increases in boost of power for driving a water pump & on electric generator

5. Use of prime mover for agro based machinery.

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

REFERENCES

1. D. A. Reay, E & F. N. Span, “Heat Recovery Systems”, London, 1979.

2. Walker G. “Stirling engines”, Oxford: Clarendon Press, 1980.
3. Senft JR. Ringbom, “Stirling engines”, New York: Oxford University Press, 1993.
4. Walpita SH., “Development of the Solar Receiver for a Small Stirling Engine”,
Special study project report no. ET-83-1. Bangkok: Asian Institute of Technology;
1983.
5. Shah Alam, “A proposed Model for Utilizing Exhaust Heat to run Automobile Air
conditioner”, International Conference on “Sustainable Energy and Environment
(SEE 2006)”.
6. G. Walker, “Stirling Engines", Clarendon Press, (1980).
7. T. Finkelstein; A.J. Organ (2001), Chapters 2&3
8. V. Ganesan, “A Textbook of Internal Combustion Engine”.
9. Mathur, Sharma, “Internal Combustion Engine”, Dhanpat Rai Publication.
10. Sarath Raj, Ranjith Krishnan, Sujith G, Gokul Gopan, Arun G.S, “Analysis and
Fabrication of Solar Stirling Engines”, International Journal of Mechanical and
Industrial Technology ISSN 2348-7593.
11. Alok Kumar, Dinesh Kumar, Ritesh Kumar, “Design and Testing of Solar
Powered Stirling Engine”, International Journal of Engineering Research and General
Science, ISSN 2091-2730.
12. Design Engineering Technical Section, “A Review of Operation And Calculations
For A Solar Powered Beta Type Stirling Engine”.

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Department of Technology, Shivaji University, Kolhapur.
 Design and Fabrication of Solar Powered Stirling Engine

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Department of Technology, Shivaji University, Kolhapur.