Patent Application
20080072751
The present invention relates to a piston apparatus, a stirling engine, and an external combustion engine.
In recent years, stirling engines which have an excellent theoretical thermal efficiency attract attention as means for recovering exhaust heat of factories or exhaust heat of internal combustion engines mounted on vehicles such as passenger cars, buses, and trucks.
One known technique is described in Japanese Patent Application Laid-Open No. 2000-46431 (Patent Document 1) which discloses a piston apparatus which is applicable to an external combustion engine such as a stirling engine. A piston of an external combustion engine disclosed in Patent Document 1 is such a type that is applicable to a stirling engine provided with a displacer driven by the function of a working medium which repeats compression and expansion within a working space according to reciprocating movements of a piston in a cylinder. The piston apparatus includes a compression chamber which is formed inside the piston to temporarily store the working medium compressed in the working space, an orifice through which the working medium in the compression chamber is ejected to a clearance between the piston and the cylinder, and a check valve which is arranged at an end of the orifice at the side of the compression chamber. The check valve is arranged so as to prevent a back-flowback-flow of the working medium from the compression chamber to the working space at a time the pressure of the working medium in the working space is decreased due to the movements of the piston.
Patent Document 1: Japanese Patent Application Laid-Open No. 2000-46431
However, when a working medium is compressed in a working space of an external combustion engine such as a stirling engine, introduced into a piston, and ejected to a clearance between the piston and a cylinder through plural holes formed in a circumferential portion (outer circumferential portion) of the piston, it is difficult to secure reliability and longevity of a thus-formed air bearing. Because a one-way valve (check valve) conventionally used in such a configuration has a mechanical, movable part and opens/closes according to the vertical movements of the piston. Sometimes the movements of the movable part of the check valve relative to the acceleration of the vertical movement of the piston are not stable, and the movable part does not stay at a predetermined position. Then, the check valve cannot exert an accurate function thereof. Thus, the check valve poses constraints on the design and structure.
An object of the present invention is to provide a piston apparatus, a stirling engine, and an external combustion engine that form an air bearing by introducing a working medium compressed inside a working space of the external combustion engine into an inside of a piston, and ejecting the compressed working medium to a clearance between the piston and a cylinder through plural holes provided in a circumferential portion of the piston, wherein a function of suppressing a back-flow of the working medium inside the piston into the working space is securely provided, and reliability and longevity are secured.
Another object of the present invention is to provide a piston engine which introduces a working medium from a working space into a pressure-accumulating chamber arranged inside the piston via a compressed-state maintaining unit, and which ejects the working medium from a circumferential portion of the piston, wherein an operation failure of the compressed-state maintaining unit can be suppressed even when rapid acceleration works on the compressed-state maintaining unit.
According to one aspect of the present invention, a piston apparatus applied to an external combustion engine, includes a piston main body, a pressure-accumulating chamber that is formed inside the piston main body, an introduction portion that serves to introduce a working medium compressed in a working space of the external combustion engine into the pressure-accumulating chamber, and a hole that is formed on a circumferential portion of the piston main body and that runs from the pressure-accumulating chamber through the piston main body to a cylinder of the external combustion engine, wherein the introduction portion is arranged so that the working medium can flow in an introduction direction toward the pressure-accumulating chamber and an opposite direction of the introduction direction, and the introduction portion has a channel resistance which is larger for the opposite direction than for the introduction direction.
According to another aspect of the present invention, in the piston apparatus, difference between the channel resistance for the introduction direction and the channel resistance for the opposite direction in the introduction portion may not be based on an channel opening/closing operation of a channel of the introduction portion which is caused by an operation of a movable part such as a valving element, but based on a shape of the introduction portion.
According to still another aspect of the present invention, the piston apparatus may further include a channel that serves to introduce the working fluid compressed in the working space to the pressure-accumulating chamber, and a channel opening/closing unit that is provided in the pressure-accumulating chamber and that opens/closes the channel according to an operation of a movable part such as a valving element, wherein the movable part is configured to operate at a time the piston apparatus is activated, and to stop operation in a normal operation range of the piston apparatus so as to close the channel.
According to still another aspect of the present invention, in the piston apparatus, pressure Pc necessary for making the movable part perform an opening operation is set so as to satisfy expressions:
Pc<P+Pand
Pc>(P+P−PF),
where P+P represents pressure amplitude at a side of a higher pressure relative to an average pressure of the working space, and PF represents a saturation value of accumulated pressure of the pressure-accumulating chamber caused by the introduction portion.
According to still another aspect of the present invention, in the piston apparatus, the channel opening/closing unit may be arranged so that a direction of movements of the movable part in operation substantially coincides with an axial direction of the piston main body, and a pressure Pc′ necessary for making the movable part perform the opening operation is set so as to satisfy expressions:
(Pc′+PA)<P+Pand
(Pc′+PA)>(P+P−PF),
where PA represents an amount of rise of pressure necessary for making the movable part perform the opening operation with an application of an upward maximum acceleration on the movable part at a set number of rotations lower than a number of rotations in a normal operation range of the piston apparatus.
According to still another aspect of the present invention, in the piston apparatus, a chamber may be arranged on the channel between the channel opening/closing unit and the working space, the chamber communicate with the working space via an orifice, and the working medium passes through the chamber.
According to still another aspect of the present invention, in the piston apparatus, the piston main body may be arranged so as to reciprocate in the cylinder, the introduction portion may be an introduction channel, and the piston apparatus may further include a pressurized-state maintaining unit which operates in a direction perpendicular to the direction of movements of the piston main body so as to introduce the working medium from an introduction-portion opening of the introduction channel which opens toward the pressure-accumulating chamber to the pressure-accumulating chamber, and to prevent a back-flow of the working medium in the pressure-accumulating chamber to the cylinder.
According to still another aspect of the present invention, in the piston apparatus, the pressurized-state maintaining unit may be a reed valve configured with a plate-like elastic body and provided with an operating portion and a fixed portion, and the introduction-portion opening may be formed in a valve-forming portion which has a valve attachment portion which is a plane parallel to the direction of movements of the piston main body, the fixed portion of the reed valve is attached to the valve attachment portion, and the introduction-portion opening is opened/closed by the operating portion.
According to still another aspect of the present invention, in the piston apparatus, the fixed portion and the operating portion of the reed valve may be arranged on a straight line parallel to the direction of movements of the piston main body.
According to still another aspect of the present invention, in the piston apparatus, the fixed portion of the reed valve may be arranged at each of a top surface side and a hem side of the piston main body, and the reed valve may be fixed to the valve attachment portion at the top surface side and the hem side of the piston main body.
According to still another aspect of the present invention, in the piston apparatus, the fixed portion of the reed valve may be arranged at a hem side of the piston main body, and the reed valve may be fixed to the valve attachment portion at the hem side of the piston main body.
According to still another aspect of the present invention, in the piston apparatus, the fixed portion of the reed valve may be arranged at a top surface side and a hem side of the piston main body on a straight line crossing with the direction of movements of the piston main body, and the reed valve may be fixed to the valve attachment portion at the top surface side and the hem side of the piston main body.
According to still another aspect of the present invention, in the piston apparatus, the fixed portion of the reed valve may be arranged in a direction perpendicular to the direction of movements of the piston main body, and the reed valve may be fixed to the valve attachment portion in the direction perpendicular to the direction of movements of the piston main body.
According to still another aspect of the present invention, in the piston apparatus, the introduction channel, the introduction-portion opening, and the pressurized-state maintaining unit may be arranged at a central portion of the top surface portion of the piston main body.
According to still another aspect of the present invention, a stirling engine includes the piston apparatus according to one of the aspects of the present invention as described above, and the cylinder.
According to still another aspect of the present invention, an external combustion engine includes a piston apparatus, and a cylinder. The piston apparatus includes a piston main body, a pressure-accumulating chamber formed inside the piston main body, an introduction portion that is arranged in a first portion corresponding to a predetermined height position in a circumferential portion of the piston main body, and that serves to introduce a working medium compressed in a working space of the external combustion engine into the pressure-accumulating chamber, and a hole that is arranged in a second portion corresponding to a position lower than the predetermined height position in the circumferential portion of the piston main body, and that runs from the pressure-accumulating chamber to a clearance between the piston main body and the cylinder, and a size of the clearance between the first portion in the circumferential portion of the piston main body and the cylinder is configured to be larger when the piston apparatus is at a top dead center than when the piston apparatus is at a bottom dead center.
According to still another aspect of the present invention, in the external combustion engine, a size of a clearance between the second portion in the circumferential portion of the piston main body and the cylinder may be configured to be substantially the same when the piston apparatus is at the top dead center and when the piston apparatus is at the bottom dead center, and a size of the clearance between the first portion and the cylinder and a size of the clearance between the second portion and the cylinder in the circumferential portion of the piston main body may be configured to be substantially the same when the piston apparatus is at the bottom dead center.
According to still another aspect of the present invention, in the external combustion engine, a diameter of an inner circumferential wall portion of the cylinder to which the first portion of the circumferential portion of the piston main body faces when the piston apparatus is at the bottom dead center may be configured to be smaller than a diameter of the inner circumferential wall portion of the cylinder to which the first portion of the circumferential portion of the piston main body faces when the piston apparatus is at the top dead center.
According to still another aspect of the present invention, in the external combustion engine, the external combustion engine may be an α-type stirling engine, and the size of the clearance between the first portion in the circumferential portion of the piston main body and the cylinder may be configured to be larger when the piston apparatus is within a range of ±45° of the top dead center than when the piston apparatus is outside the range.
According to still another aspect of the present invention, in the external combustion engine, a top surface of the introduction portion may be formed in a flat shape so that the entire top surface is of approximately the same height.
According to still another aspect of the present invention, a piston engine includes a piston that performs reciprocating movements in a cylinder, a hollow portion formed inside the piston, an introduction channel that communicates a working space in the cylinder with the hollow portion, and introduces a working fluid in the working space into the hollow portion, a pressurized-state maintaining unit that operates in a direction perpendicular to a direction of movements of the piston, that introduces the working fluid from an introduction-portion opening of the introduction channel which opens toward an inside of the hollow portion, and that prevents a back-flow of the working fluid from the hollow portion to the cylinder, and plural air-feed holes that are arranged on a circumferential portion of the piston, and that eject the working fluid in the hollow portion to a space between the circumferential portion of the piston and the cylinder.
In the piston engine which introduces the working fluid from the working space in the cylinder to the hollow portion in the piston, and ejects the introduced working fluid to a space between the circumferential portion of the piston and the cylinder, the pressurized-state maintaining unit is provided so as to operate in a direction perpendicular to the direction of movements of the piston. Therefore, even when the acceleration attributable to the reciprocating movements of the piston is applied to the pressurized-state maintaining unit, the operation of the pressurized-state maintaining unit is not affected significantly. As a result, even when the acceleration applied on the pressurized-state maintaining unit is large, the pressurized-state maintaining unit is prevented from malfunctioning.
According to the present invention, when the working medium compressed in the working space of the external combustion engine is introduced inside the piston, the introduced working medium is ejected through plural holes arranged on the circumferential portion of the piston to the clearance between the piston and the cylinder, so as to form an air bearing, the present invention can securely provide a function of suppressing the back-flow of the working medium from the inside of the piston to the working space. Further, the reliability and the longevity can be readily secured.
An exhaust heat recovery system to which a piston apparatus according to one embodiment of the present invention is applied will be described in detail below as a first embodiment with reference to the accompanying drawings. It should be noted that the present invention is not limited to the embodiments. Further, components of the embodiments described below may include those which can be readily achieved by those skilled in the art or those equivalent to those which can be readily achieved by those skilled in the art.
An object of the first embodiment is to provide an exhaust heat recovery apparatus which includes a stirling engine having a piston apparatus. The piston apparatus configures an air bearing by introducing a working fluid compressed inside a working space of an α-type stirling engine into an inside of a piston, and ejecting the compressed working fluid to a clearance between the piston and a cylinder through plural holes provided in a circumferential portion of the piston, wherein a function of suppressing a back-flow of the working medium in the piston toward the working space can be securely obtained, and reliability and longevity are readily guaranteed.
When the stirling engine uses the exhaust heat of, for example, exhaust gas of an internal combustion engine of a vehicle as a heat source, there is a limitation in an obtainable heat amount. Therefore, it is necessary to operate the stirling engine as effectively as possible within the range of obtainable heat amount. Against such a background, the first embodiment aims at weight saving of the piston. Further, the first embodiment aims at downsizing of an apparatus dimension (overall configuration) of the stirling engine. This is because, when the stirling engine uses an exhaust heat of, for example, an exhaust gas of the internal combustion engine of a vehicle, as a heat source, the stirling engine sometimes needs to be installed in a limited space, such as a space adjacent to an exhaust pipe of an internal combustion engine arranged below a floor of the vehicle. A stirling engine described below realizes a reduced weight of a piston, and downsizing of an overall apparatus dimension.
A working fluid heated by a heater 47 flows into an upper space (expansion space) of a cylinder 22 of the high-temperature side power piston 20 (cylinder 22 will be referred to as high-temperature side cylinder, hereinbelow). A working fluid cooled by a radiator 45 flows into an upper space (compression space) of a cylinder 32 of the low-temperature side power piston 30 (cylinder 32 will be referred to as low-temperature side cylinder, hereinbelow).
A regenerator (regenerative heat exchanger) 46 accumulates heat when the working fluid moves back and forth between the expansion space and the compression space. Specifically, the regenerator 46 receives heat from the working fluid when the working fluid flows from the expansion space to the compression space, and delivers an accumulated heat to the working fluid when the working fluid flows from the compression space to the expansion space.
Along with the reciprocating movements of two pistons 21 and 31, reciprocating flows of the working gas occur, which changes the ratio of the working fluid in the expansion space of the high-temperature side cylinder 22 to the working fluid in the compression space of the low-temperature side cylinder 32, and at the same time the total volume of the working fluid changes, whereby the pressure variations occur. When two pistons 21 and 31 are at the same position, pressure varies as follows. Pressure is higher when the expansion piston 21 is at a lower position than at a higher position. On the other hand, pressure is lower when the compression piston 31 is at a lower position than at a higher position. Therefore, the expansion piston 21 performs a large positive work (expansion work) to the outside, and the compression piston 31 needs to receive work (compression work) from the outside. The expansion work is partially expended for the compression work and the rest is output through a drive shaft 40.
The drive shaft 40 is connected to a crank shaft 43 housed in a case 41. The crank shaft 43 is connected to two pistons 21 and 31 through a piston-side rod 61, a coupling pin 60, and a rod 109. The crank shaft 43 converts the reciprocating movements of two pistons 21 and 31 into rotating movements, and transmits the rotating movements to the drive shaft 40. A space inside the case 41 is pressurized by a pressurizing unit. This is for pressurizing the working fluid (i.e., air in the first embodiment) and extracting as much output as possible from the stirling engine 10.
The stirling engine 10 of the first embodiment is employed together with a gasoline engine (i.e., internal combustion engine) in a vehicle, thereby forming a hybrid system. The stirling engine 10 uses exhaust gas of the gasoline engine as a heat source. The heater 47 of the stirling engine 10 is arranged inside an exhaust pipe 100 of the gasoline engine of the vehicle. Heat energy recovered from the exhaust gas heats up the working fluid so as to run the stirling engine 10.
The stirling engine 10 of the first embodiment is installed in a limited space in the vehicle, specifically, the heater 47 thereof is housed inside the exhaust pipe 100. A degree of freedom in design can be increased when the apparatus as a whole is made compact. Therefore, in the stirling engine 10, two cylinders 22 and 32 are not arranged in a V-like shape. Two cylinders 22 and 32 are arranged in parallel and connected in series.
When the heater 47 is arranged inside the exhaust pipe 100, a high-temperature side cylinder 22 side of the heater 47 is arranged at an upstream side (i.e., a side close to the gasoline engine) 100a where a relatively high-temperature exhaust gas flows in the exhaust pipe 100, and a low-temperature side cylinder 32 side of the heater 47 is arranged at a downstream side (i.e., a side farther from the gasoline engine) 100b where a relatively low-temperature exhaust gas flows. This is for heating the high-temperature side cylinder 22 side of the heater 47 more than the other side.
Each of the high-temperature side cylinder 22 and the low-temperature side cylinder 32 is formed in a cylindrical shape and supported by a basal plate 42 which serves as a baseline. In the first embodiment, the basal plate 42 is placed at a reference position for each component of the stirling engine 10. Such a configuration guarantees a relative positional accuracy of each component of the stirling engine 10. Further, the basal plate 42 may serve as a reference when the stirling engine 10 is attached to the exhaust pipe (exhaust channel) 100 from which the exhaust heat is to be recovered.
The basal plate 42 is fixed to a flange 100f of the exhaust pipe 100 via a heat insulator (i.e., spacer not shown). Since the relative positional accuracy of the exhaust pipe 100 and the basal plate 42 is secured when they are fixed with each other, the basal plate 42 can be considered as a fixed structural object provided in the exhaust pipe 100 as an attachment surface. Further to the basal plate 42, a flange 22f is fixed. The flange 22f is arranged on a side surface (outer circumferential surface) of the high-temperature side cylinder 22. Still further to the basal plate 42, a flange 46f is fixed via a heat insulator (i.e., spacer not shown). The flange 46f is arranged on a side surface 46c (outer circumferential surface) of the regenerator 46. Still further, a dividing wall 70 mentioned later is fixed to the basal plate 42.
The basal plate 42 support all components of the stirling engine 10. Therefore, when the basal plate 42 is deformed due to the heat of the exhaust gas in the exhaust pipe 100, effect of the deformation extends over all the components of the stirling engine 10. Therefore, the heat insulator is arranged between the flange 100f of the exhaust pipe 100 and the basal plate 42, and additionally, a shroud 90 is arranged to minimize the transfer of the heat from the exhaust gas inside the exhaust pipe 100 to the basal plate 42.
The exhaust pipe 100 is attached to the stirling engine 10 via the basal plate 42. When the stirling engine 10 is attached to the basal plate 42, the basal plate 42 is made substantially parallel to an end surface, to which the heater 47 is connected, of the high-temperature side cylinder 22 (upper surface of the top portion 22b) and an end surface, to which the radiator 45 is connected, of the low-temperature side cylinder 32 (top surface 32a). Put differently, the stirling engine 10 is attached to the basal plate 42 so that the basal plate 42 is parallel to the rotation axis of the crank shaft 43 (or the drive shaft 40), or so that the central axis of the exhaust pipe 100 is parallel to the rotation axis of the crank shaft 43. Thus, the stirling engine 10 can be readily attached to the exhaust pipe 100 without major change in design of the existing exhaust pipe 100. Hence, the stirling engine 10 can be mounted on the exhaust pipe 100 without deterioration in performance, mountability, and noise-related functions of the internal combustion engine itself of the vehicle, from which the exhaust heat is recovered. Further, since the stirling engine 10 of the same specification can be mounted to different types of exhaust pipe only with the changes in the specification of the heater 47, the versatility of the stirling engine 10 can be increased.
The stirling engine 10 is arranged in a space adjacent to the exhaust pipe 100 arranged below the floor of the vehicle so that the stirling engine 10 lies horizontal, in other words, so that the axial direction of each of the high-temperature side cylinder 22 and the low-temperature side cylinder 32 is approximately parallel to the floor surface (not shown) of the vehicle, and two pistons 21 and 31 reciprocate in a horizontal direction. In the first embodiment, however, a top-dead-center side of two pistons 21 and 31 is described as an upper direction, and a bottom-dead-center side as a lower direction.
The working fluid with a higher average pressure can provide a higher output since the higher average pressure means a higher pressure difference at the same temperature difference caused by the radiator 45 and the heater 47. Hence, the working fluid in the high-temperature side cylinder 22 and the low-temperature side cylinder 32 is maintained in a high pressure.
The pistons (piston apparatuses) 21 and 31 are formed in a columnar shape. Between the outer circumferential surface of each of the pistons 21 and 31, and the inner circumferential surface of the corresponding cylinder 22 or 32, a minute clearance of a few tens micrometers (μm) is provided. The working fluid (which is a gaseous matter, and is air in the first embodiment) exists in the clearance thereby forming an air bearing 48. The air bearing 48 keeps the pistons 21 and 31 in a floating state relative to the cylinders 22 and 32 utilizing an air pressure (air distribution) generated in the minute clearance between the pistons 21 and 31 and the cylinders 22 and 32. The pistons 21 and 31 are supported by the air bearing 48 in a non-contact state with the cylinders 22 and 32. Therefore, no piston ring is arranged around the pistons 21 and 31, and lubricant oil, which is generally used together with the piston ring, is not employed. However, it is preferable that a solid lubricant member is arranged on the inner circumferential surface of each of the cylinder 22 and 32. This is because the solid lubricant member contributes to reduce the sliding resistance between the piston and the cylinder, for example, when the air bearing 48 does not work sufficiently at the time of start-up. As described above, the air bearing 48 maintains the air-tightness of the expansion space and the compression space with the use of the working fluid (gaseous matter), thereby providing a clearance seal in a ring-less, oil-less manner.
As shown in
In the first embodiment, since the heat source of the stirling engine 10 is exhaust gas of the internal combustion engine of the vehicle, the obtainable heat amount is limited. Hence, it is necessary to operate the stirling engine 10 as effectively as possible within the limit of obtainable heat amount. Therefore, the top portion (upper portion) 22b of the high-temperature side cylinder 22 and the upper portion of the side surface 22c of the high-temperature side cylinder 22 are arranged inside the exhaust pipe 100 so that the working fluid flowing through the expansion space is as high in temperature as possible. Thus, the upper portion of the expansion piston 21 near the top dead center is placed inside the exhaust pipe 100, whereby the upper portion of the expansion piston 21 is heated effectively. In the stirling engine 10 of the first embodiment, the basal plate 42 is arranged to the high-temperature side cylinder 22 and the low-temperature side cylinder 32 at the side from which the working fluid is introduced, and the two cylinders 22 and 32 are fixed to the basal plate 42. In such a configuration, the high-temperature side cylinder 22 and the low-temperature side cylinder 32 are put under restraint, so that the increase in the distance between the high-temperature side cylinder 22 and the low-temperature side cylinder 32 is suppressed. As a result, even when the heater 47 is heated up during the operation of the stirling engine 10, the clearance between the cylinder and the piston is maintained and the air bearing 48 can be made to function properly.
Configurations of the pistons 21 and 31 will be described in detail below with reference to
As shown in
The piston main body 211 has a circumferential portion (sliding portion) 211a which slides against the high-temperature side cylinder 22 (
The communication channel 214 is configured with a fluid device 215 which has a significantly higher channel resistance to an adverse current than to a following current, and which does not have a movable part such as a valving element. Specifically, the fluid device 215 is shaped so as to have a relatively low channel resistance when the working fluid passing through the communication channel 214 is directed downward (direction from the working space to the hollow portion 212) (i.e., at the time the working fluid forms a following current). On the contrary, the fluid device 215 is shaped so as to have a significantly higher channel resistance when the working fluid is directed upward (direction from the hollow portion 212 to the working space) (i.e., at the time the working fluid forms an adverse current) in comparison with the time of the following current.
When the movements of the piston 21 causes the pressure of the working fluid in the working space of the high-temperature side cylinder 22 to decrease, the fluid device 215 suppresses the back-flow of the working fluid in the hollow portion 212 toward the working space in the high-temperature side cylinder 22. Since the fluid device 215 does not have a movable part like a valving element of the check valve (i.e., one-way valve), it is easy to secure the reliability and longevity, and further it does not pose much constraint on the design and the structure.
In the fluid device 215, while there is no protruding portion that protrudes from a top surface portion 811b towards the side of the working space on the side of the following-current inlet portion 215a (as indicated by reference character D1), there is a protruding portion D2 that protrudes towards the side of the hollow portion 212 at the side of the adverse-current inlet portion 215b, and an adverse current inlet portion 215b is formed at a tip end of the protruding portion D2.
In the fluid device 215, an angle θ formed by an end surface S at the side of the adverse-current inlet portion 215b and the communication channel 214 is a sharp angle (i.e., smaller than 90°). However, when the protruding portion D2 of the adverse-current inlet portion 215b is thin and the end surface itself is extremely small, it is not necessary to define the angle (described later with reference to
When the fluid device 215 is to be formed as one integral unit with the piston 21 as shown in
As shown in
The communication channel 214 is formed at a central portion of the top surface portion 211b. Therefore, the distances between the communication channel 214 and the plural air-feed holes 216 are made equal. Therefore, ejected state (amount of ejection, ejection pressure, etc.) of the working fluid ejected from each of the plural air-feed holes 216 after the introduction of the working fluid in the working space into the hollow portion 212 through the communication channel 214 tends to be the same, and there is less possibility of a circumferential deviation in the working fluid ejected to the clearance. Thus, the air bearing 48 can function more stably.
It is desirable that the pressure of the working fluid sealed in the hollow portion 212 be slightly lower than the maximum compression pressure of the working fluid.
In
When the working fluid whose pressure is slightly lower than the maximum compression pressure Pmax of the working fluid is sealed in the hollow portion 212, the piston operates as follows. While the piston 21 is at the position near the top dead center during the compression process, at one point, the pressure of the working space of the high-temperature side cylinder 22 comes to exceed the pressure of the hollow portion 212. Then, a portion of the working fluid in the working space is introduced through the communication channel 214, and a portion of the working fluid in the hollow portion 212 is ejected outside the piston 21 through the air-feed holes 216. When the piston 21 is placed at a position other than the position mentioned above, the pressure of the hollow portion 212 is higher than the pressure of the working space of the high-temperature side cylinder 22. However, since the fluid device 215 is configured in such a manner that the channel resistance is significantly higher at the time of adverse current in comparison with the time of following current, the back-flow of the working fluid in the hollow portion 212 into the working space in the high-temperature side cylinder 22 from the adverse-current inlet portion 215b through the communication channel 214 is suppressed.
At least one air-feed hole 216 is arranged in each of an upper portion and a lower portion of the piston 21 at an approximately equidistance from an approximately central portion of the piston 21 (for example, two for each of the upper and lower portions, and four in total are shown in
The heater 47 has plural heat transfer tubes (tube group) 47t which are arranged in an approximately U-like shape. A first end 47a of each heat transfer tube 47t is connected to an upper portion (end surface at the side of the top surface 22a) of the high-temperature side cylinder 22. First ends 47a of plural heat transfer tubes 47t are arranged approximately on the same plane (flat plane). First ends 47a of the plural heat transfer tubes 47t on approximately the same plane are each connected to the upper portion 22b, which is formed as an approximately flat surface, of the high-temperature side cylinder 22. Such shapes of the elements simplify the working and the connecting works of the first ends 47a sides of the plural heat transfer tubes 47t. On the other hand, a second end 47b of each heat transfer tube 47t is connected to an upper portion 46a (end surface at the side of the heater 47) of the regenerator 46.
The regenerator 46 is provided with a heat storage material (matrix not shown) and a regenerator housing 46h in which the heat storage material is stored. The regenerator housing 46h houses the heat storage material which is approximately columnar and whose section is approximately the same shape as that of the upper portion of the low-temperature side cylinder 32. The regenerator housing 46h is formed in a columnar shape (i.e., hollow columnar shape) whose bottom surface and upper surface are approximately the same shape as the section of the upper portion of the low-temperature side cylinder 32.
On a circumferential surface (outer circumferential surface) 46c of the regenerator 46, a flange 46f is arranged. The flange 46f is fixed to the basal plate 42 via the heat insulator. The regenerator 46 employs laminated wire sheets (laminated material) as the heat storage material. The wire sheets are laminated along a flow direction of the working fluid, and arranged in such a state that heat transfer seldom occurs between the plural metal sheets.
When the heat storage material receives heat from the working fluid flowing from the expansion space to the compression space, the uppermost wire sheet of the laminated plural wire sheets closest to the heater 47 first receives the heat of the working fluid and thereby lowers the temperature of the working fluid. Then the wire sheet second closest to the heater 47 receives the heat to further lower the temperature of the working fluid, and then, the wire sheet third closest to the heater 47 receives the heat to still further decrease the temperature, and thus, the temperature of the working fluid gradually decreases every time the working fluid passes through the wire sheet from the top to the bottom in the regenerator 46.
Due to the function mentioned earlier, the regenerator 46 is required to satisfy the following conditions. Firstly, the regenerator 46 has to have a high heat transfer capacity, a high heat storage capacity, a small flow resistance (flow loss, pressure loss), and a small heat conductivity in a direction of flow of the working fluid, so that a large temperature gradient can be set. Therefore, it is required that the heat transfer between the wire sheets is as low as possible. The wire sheet may be of stainless steel.
When the regenerator 46 is designed to be arranged inside the exhaust pipe 100, it is highly necessary to suppress the negative influence of the heat transfer of the regenerator housing 46h in the direction of flow of the working fluid. Hence, in the first embodiment, the regenerator housing 46h is provided with a shroud 90. The shroud 90 is intended to prevent the transfer of the heat inside the exhaust pipe 100 (approximately 600 to 800° C., for example) to the regenerator housing 46h. In particular, the shroud 90 is intended to prevent the transfer of heat to surfaces of the regenerator housing 46h other than the upper surface 46a (i.e., the side surfaces 46c and the flange 46f).
Here, the length of the expansion piston 21 in an axial direction is longer than that of the compression piston 31, and the length of the high-temperature side cylinder 22 in an axial direction is longer than that of the low-temperature side cylinder 32 due to the following reasons.
It is necessary to keep the space other than the expansion space in the high-temperature side power piston 20 and the space other than the compression space in the low-temperature side power piston 30, i.e., the space around the crank shaft 43 in each of the high-temperature side power piston 20 and the low-temperature side power piston 30 at a room temperature in order to suppress the efficiency degradation of the stirling engine 10. Hence, the high-temperature side cylinder 22 and the expansion piston 21, and the low-temperature side cylinder 32 and the compression piston 31 must be securely sealed (specifically, the air bearing 48 is used as the sealer as mentioned later) so that the high-temperature working fluid in the expansion space does not flow into the space around the crank shaft 43 at the side of the high-temperature side power piston 20, or the low-temperature working fluid in the compression space does not flow into the space around the crank shaft 43 at the side of the low-temperature side power piston 30.
On the other hand, since the top portion 22b and the upper portion of the side surface 22c of the high-temperature side cylinder 22 are housed inside the exhaust pipe 100 so that the expansion space attains a high temperature, the upper portion of the high-temperature side cylinder 22 and the upper portion of the expansion piston 21 undergo heat expansion. In a thermally-expanding portion of the upper portions of the high-temperature side cylinder 22 and the expansion piston 21, the sealing might not be securely performed. Hence, in the first embodiment, the length of the expansion piston 21 and the high-temperature side cylinder 22 in the axial direction are set long. Therefore, the temperature gradient of the expansion piston 21 is set larger in the axial direction, and the sealing is securely provided in a portion not influenced by the heat expansion (i.e., lower portion of the expansion piston 21). Further, since a space between the high-temperature side cylinder 22 and the expansion piston 21 is sealed at the lower portion of the expansion piston 21, the length of the high-temperature side cylinder 22 in the axial direction is set long so that sufficient length is secured as the travel distance of the sealed portion and the expansion space is sufficiently compressed.
The configuration of the radiator 45 will be described.
In
The dividing wall (member) 70 is arranged between the regenerator 46 and the low-temperature side cylinder 32. The dividing wall 70 is formed of a material with low heat conductivity. The dividing wall 70 is designed so that the dimension thereof along an axial direction of the low-temperature side cylinder 32 is as short as possible while the size thereof is sufficiently large so as to lead the heat transfer tubes 45t around. This is to contribute to the downsizing of the stirling engine 10.
As mentioned above, the dividing wall 70 is fixed to the basal plate 42. The upper surface 70a of the dividing wall 70 is arranged so as to directly contact with the lower surface 46b (i.e., end surface opposite to the end surface 46a at the side of the heater 47) of the regenerator 46. The lower surface 70b of the dividing wall 70 serves as the top surface 32a of the low-temperature side cylinder 32. On the side surface 70c (i.e., outer circumferential surface) of the dividing wall 70, a radiator case 45c of the radiator 45 is fixed.
The radiator 45 is configured with a water-cooled shell-and-tube exchanger or a tubular exchanger. The radiator 45 includes plural heat transfer tubes (tube group) 45t and the radiator case 45c. Most part of the plural heat transfer tubes 45t of the radiator 45 is housed in the radiator case 45c. The part of the plural heat transfer tubes 45t housed in the radiator case 45c is brought into contact with cooling water (refrigerant) supplied to the radiator case 45c, whereby the working fluid flowing through the heat transfer tube 45t is cooled.
As described above, the radiator case 45c is fixed to the outer circumferential surface 70c of the dividing wall 70. The radiator case 45c is arranged like a ring over the circumferential direction of the outer circumferential surface 70c. The radiator case 45c is formed in a ring-like shape so as to surround the upper portion (portion corresponding to the compression space) of an outer circumferential portion 32k of the low-temperature side cylinder 32 from the circumferential direction. Alternatively, the radiator case 45c may be arranged so as to surround a part of the outer circumferential portion 32k of the low-temperature side cylinder 32 in the circumferential direction.
A sealing mechanism of the piston and the cylinder and a mechanism of the piston/crank unit will be described.
Since the heat source of the stirling engine 10 is the exhaust gas of the internal combustion engine of the vehicle as described above, there is a limit in the obtainable heat amount, whereby the stirling engine 10 must be operated within the range of the obtainable heat amount. Therefore, in the first embodiment, an internal friction of the stirling engine 10 is reduced as much as possible. In the first embodiment, the piston ring is not employed so as to eliminate the frictional loss caused by the piston ring whose frictional loss occupies the largest part of the internal friction in the stirling engine. Instead, the air bearing 48 is provided between the cylinders 22 and 32 and the pistons 21 and 31, respectively.
Since the sliding resistance of the air bearing 48 is extremely small, the internal friction of the stirling engine 10 can be significantly reduced. Even when the air bearing 48 is employed, the air-tightness between the cylinders 22 and 32 and the pistons 21 and 31 is secured, whereby there is no inconvenience caused by the leakage of the high-pressure working fluid during the expansion/compression.
The air bearing 48 is a bearing which supports the pistons 21 and 31 in a floating state utilizing the air pressure (air distribution) generated in a minute clearance between each of the cylinder 22 and the piston 21 and the cylinder 32 and the piston 31. In the air bearing 48 of the first embodiment, the diametrical clearance between the cylinder 22 or 32 and the piston 21 or 31 is several tens micrometers (μm). A hydrostatic air bearing is employed to realize an air bearing that supports an object in a floating state. The hydrostatic air bearing is realized by ejecting a pressurized fluid to generate static pressure, and keeping an object (i.e., pistons 21 and 31 in the first embodiment) in a floating state by the static pressure.
Further, the use of the air bearing 48 eliminates the need of lubricating oil which is employed with the piston ring. Therefore, there is no inconvenience caused by the lubricating oil, such as the deterioration of the heat exchanger (i.e., regenerator 46, heater 47) of the stirling engine 10.
When the pistons 21 and 31 are made to reciprocate inside the cylinders 22 and 32, respectively, with the use of the air bearing 48, the accuracy of the linear motion must be below the size of the diametrical clearance of the air bearing 48. Further, since the loading capacity of the air bearing 48 is low, side force of the pistons 21 and 31 must be substantially zero. In other words, since the air bearing 48 has a low capacity to bear the force in a diameter direction (i.e., lateral direction, or thrust direction) of the cylinders 22 and 32, the accuracy of the linear motions of the pistons 21 and 31 relative to the axial direction of the cylinders 22 and 32 must be particularly high. In particular, the air bearing 48, which supports the object in a floating state with the use of air pressure in the minute clearance, as applied in the first embodiment, has a lower capacity to bear the force in the thrust direction even in comparison with an air bearing which shoots high-pressure air. Therefore, a higher accuracy of the linear motions of the pistons is required.
Due to the reasons described above, the first embodiment employs a grasshopper mechanism (linear approximation link) 50 in the piston/crank unit. The size of a required mechanism is smaller in the grasshopper mechanism 50 in comparison with that in the other linear approximation mechanism (such as Watt mechanism) for achieving the same accuracy of linear motions. Therefore, the use of the grasshopper mechanism 50 makes the overall size of the apparatus more compact. In particular, since the stirling engine 10 of the first embodiment is installed in a limited space, for example, since the heater 47 thereof is housed inside the exhaust pipe of the passenger car, the compactness of the apparatus increases the degree of freedom in design. Further, since the grasshopper mechanism 50 can achieve the same accuracy of linear motions as other mechanism with a mechanism whose weight is lighter than that required in other mechanism, whereby the grasshopper mechanism 50 is advantageous in terms of energy efficiency. Still further, the grasshopper mechanism 50 is relatively simple in terms of its mechanical configuration, and therefore is easy to configure (manufacture, or assemble).
As shown in
In the first embodiment described above, the stirling engine 10 is configured to be attached to the exhaust pipe 100 so as to use the exhaust gas of the internal combustion engine of the vehicle as a heat source. However, the stirling engine of the present invention is not limited to the type attached to the exhaust pipe of the internal combustion engine of the vehicle.
In the above, the example of the piston apparatus applied to the piston of the stirling engine is described with respect to the configuration, operation, and effect thereof. However, the piston apparatus can be readily applied to an external combustion engine other than the piston of the stirling engine, and similarly useful in other application.
A first modification of the first embodiment will be described with reference to FIGS. 9 to 11.
As shown in
As shown in
A second modification of the first embodiment will be described with reference to
In the second modification, the hydrostatic floating mechanism may be arranged at the side of the high-temperature side cylinder 22. In
The communication channel 202 is arranged at a higher point than the top dead center of the piston 21 and communicates the working space of the high-temperature side cylinder 22 with the pressure-accumulating chamber 201. The communication channel 202 is configured with a fluid device 204 which has a significantly higher channel resistance for an adverse current than for a following current and which has no movable part. Specifically, the fluid device 204 is configured in such a shape that the channel resistance is relatively small when the direction of flow of the working fluid passing through the communication channel 202 is that of the following current (i.e., directed from the side of the working space to the pressure-accumulating chamber 201), whereas the channel resistance is significantly large when the direction of flow of the working fluid is that of the adverse current (i.e., directed from the pressure-accumulating chamber 201 to the side of the working space) in comparison with the time of the following current.
Plural air-feed holes 203 are provided at regular intervals in a circumferential direction in the high-temperature side cylinder 22. Along with the rise of the piston 21, the working fluid in the working space of the high-temperature side cylinder 22 is compressed and the pressure of the working fluid exceeds the pressure of the pressure-accumulating chamber 201. Then, a part of the working fluid in the working space is introduced into the pressure-accumulating chamber 201 from a following-current inlet portion of the fluid device 204 through the communication channel 202. As the working fluid is introduced into the pressure-accumulating chamber 201 through the communication channel 202, a part of the working fluid in the pressure-accumulating chamber 201 is ejected to the clearance between the piston 21 and the cylinder 22 through the air-feed hole 203. Further, the fluid device 204 suppresses the back-flow of the working fluid in the pressure-accumulating chamber 201 into the working space in the high-temperature side cylinder 22 when the pressure of the working fluid in the working space of the high-temperature side cylinder 22 decreases due to the movements of the piston 21.
A second embodiment will be described with reference to FIGS. 13 to 18.
In the following description of the second embodiment, the description of those components common to those of the first embodiment will not be repeated.
In
Similarly to the first embodiment, plural air-feed holes 216 are arranged at regular intervals in a circumferential direction in the circumferential portion (sliding portion) 211a, which slides against the high-temperature side cylinder 22, of the piston main body 211 of the piston 21. On the circumferential portion 211a, the communication channel 314 which communicates the working space 301 in the high-temperature side cylinder 22 with the hollow portion 212 is formed at a higher position than the position of the air-feed hole 216.
The communication channel 314 is arranged at such a position that the communication channel 314 communicates the hollow portion 212 with the working space 301 only when the piston 21 is near the top dead center (
A diameter-expanded portion 22g is arranged at an upper portion of the inner circumferential wall portion of the high-temperature side cylinder 22 (i.e., a portion forming the working space 301). The diameter-expanded portion 22g is a portion where the diameter is expanded in comparison with the other portion. The communication channel 314 is positioned at the height of the diameter-expanded portion 22g only when the piston 21 is near the top dead center, and communicates the hollow portion 212 with the working space 301 (
Specifically, in the state shown in
As shown in
As described above, the communication channel 314 is arranged at a first portion corresponding to a predetermined height position in the circumferential portion 211a of the piston main body 211, and is used to introduce the working fluid compressed in the working space 301 into the pressure-accumulating chamber 212. The air-feed hole 216 is arranged at a second portion corresponding to a position lower than the predetermined height position in the circumferential portion 211a of the piston main body 211, and runs from the pressure-accumulating chamber 212 to the clearance between the piston main body 211 and the high-temperature side cylinder 22.
If the state of the apparatus when the piston 21 is at the top dead center and the state when the piston 21 is at the bottom dead center are compared, the clearance between the first portion of the circumferential portion 211a of the piston main body 211 and the high-temperature side cylinder 22 is configured to be larger when the piston 21 is at the top dead center than when the piston 21 is at the bottom dead center.
If the state of the apparatus when the piston 21 is at the top dead center and the state when the piston 21 is at the bottom dead center are compared, the clearance between the second portion of the circumferential portion 211a of the piston main body 211 and the high-temperature side cylinder 22 is configured to be approximately the same size in both states. When the first portion and the second portion of the circumferential portion 211a of the piston main body 211 are compared, the clearance with the high-temperature side cylinder 22 is configured to be approximately the same size when the piston 21 is at the bottom dead center.
The diameter of the inner circumferential wall portion 22g of the high-temperature side cylinder 22, to which the first portion of the circumferential portion 211a of the piston main body 211 faces when the piston 21 is at the top dead center, is configured to be larger than the diameter of the inner circumferential wall portion of the high-temperature side cylinder 22 to which the first portion of the circumferential portion 211a of the piston main body 211 faces when the piston 21 is at the bottom dead center.
As shown in
As described above, the clearance between the first portion of the circumferential portion 211a of the piston main body 211 and the high-temperature side cylinder 22 is configured so as to be larger when the piston 21 is within the range of ±45° from the top dead center than when the piston 21 is outside this range.
Since the communication hole 314 in the second embodiment does not have the movable part such as a valving element as in the check valve (one-way valve), it is easy to secure the reliability and the longevity, and the element does not pose constraint on the design and configuration.
With reference to
As shown in
According to the first modification, the effect of preventing the inflow/outflow of the working fluid between the hollow portion 212 and the working space 310 from deteriorating the efficiency is further enhanced.
A second modification of the second embodiment will be described with reference to
As shown in
A third embodiment will be described with reference to FIGS. 19 to 23.
In the following description of the third embodiment, the description of those components common to those of the above embodiments will not be repeated.
When the fluid device without an operating mechanism (i.e., movable part) is employed as in the first embodiment, though it is easy to secure reliability and longevity, the accumulated pressure value in the hollow portion increases only slowly at the time of activation and the air bearing cannot provide a sufficient force to float the piston 21 (
As described earlier, when the fluid device whose channel resistance significantly varies depending on the direction of flow (i.e., depending on whether it is a following current or an adverse current) is employed, the apparatus must be designed so that the amount of introduced flow per unit time is small. The purpose of such a design is to decrease the movements (amount of inflow/outflow) between the working space and the pressure-accumulating space while keeping a high current speed. Therefore, a few ten cycles is required until the accumulated pressure value rises at the time of activation.
Hence, in the third embodiment, the fluid device 215 is employed together with a check valve 401 as a device to introduce pressure into the hollow portion (pressure-accumulating chamber) 212 of the piston 21 as shown in
The check valve 401 has a valving element (movable part) 402, a valve seat 403, and a spring 404 which pushes the valving element 402 into the valve seat 403. The check valve 401 operates (opens) only at the time of activation. Once the normal operation starts (once the apparatus enters a normal operation range), the valving element 402 stops (closes) to stop the functioning of the check valve and to keep the second communication channel 414 closed.
In
Pc<P+P,and
Pc>(P+P+PF),or(Pc+PF)>P+P.
When the PF is small, e.g., at the time of activation, P+P exceeds the set valve-opening pressure value Pc of the check valve 401, and the check valve 401 is open. Then, the pressure is introduced into the hollow portion 212 through the second communication channel 414. As the PF increases (as the accumulated pressure value of the hollow portion 212 increases after the activation), the check valve 401 is closed. Then, the valving element 402 of the check valve 401 is fixed to the valve seat 403 and stops the movements.
As shown in
According to the third embodiment, the accumulated pressure value of the hollow portion 212 can be increased via the check valves 401 and 430 relatively early at the time of activation (including immediately after the activation). After the accumulated pressure value of the hollow portion 212 is increased to a predetermined value at the time of activation, the movable part 402 of the check valve 401 and the movable part 431 of the check valve 430 remain in a stopped state (closed state). Therefore, the uncertain behavior, reliability, and durability would not pose significant problems, similarly to the first embodiment.
A first modification of the third embodiment will be described with reference to FIGS. 22 to 24.
When the check valves 401 and 430 are arranged as shown in
In
On the other hand, reference character 504 denotes the amount of rise in the valve-closing pressure caused by the downward (direction to open the valve) maximum acceleration (applied when the piston 21 is at the bottom dead center) working on the movable parts 402 and 431 of the check valves 401 and 430. As shown in
As shown in
Pc′≦(P+P−PA),and
Pc′+PA<(P+P−PF),orPc′>(P+P−PF−PA).
According to the first modification, the valve-opening pressure Pc′ of the movable parts 402 and 431 of the check valves 401 and 430 can be designed to be smaller than the set valve-opening pressure value Pc of the third embodiment by the amount of PA (for example, the force of the spring 404 of the check valve 401 can be designed to be weaker), so that the check valves 401 and 430 are made to be easily open at the early phase of the activation, whereby the accumulated pressure value of the hollow portion 212 can be increased during cycles of a smaller number at the early phase of the activation.
In the first modification, as the amount of rise in the valve-opening pressure 503 caused by the upward maximum acceleration working on the movable parts 402 and 431 rises according to the rise in the number of rotations of the stirling engine 10, the check valves 401 and 430 become difficult to open. Utilizing this characteristic, the check valves 401 and 430 can be designed so as to make the valve-opening pressure Pc′ of the movable parts 402 and 431 of the check valves 401 and 430 lower. Thus, when the number of rotations of the stirling engine 10 is small (at the early phase of the activation), the check valves 401 and 430 can be made to open easily, whereby the accumulated pressure value of the hollow portion 212 can be increased within cycles of a smaller number.
When the piston 21 is at the bottom dead center, the raised amount of the valve-closing pressure caused by the downward maximum acceleration works on the movable parts 402 and 431. At this time, since the working space of the high-temperature side cylinder 22 is at a lower pressure than the pressure within the pressure-accumulating chamber of the hollow portion 212, the check valves 401 and 430 are difficult to open even if the valve-opening pressure Pc′ of the movable parts 402 and 431 of the check valves 401 and 430 is designed to be low. Even when the number of rotations of the stirling engine 10 increases and the amount of rise of the valve-closing pressure caused by the downward maximum acceleration working on the movable parts 402 and 431 increases, the check valves 401 and 430 do not open unless the amount of rise of the valve-closing pressure 504 exceeds (Pc′+PF−P−P). In the example shown in
In view of the above, in the first modification, the amount of rise of the valve-closing pressure 504 is designed so as not to exceed (Pc′+PF−P−P) 505 while the number of rotations is a predetermined number within an actual operation range. Alternatively, the mass of the movable parts 402 and 431 of the check valves 401 and 430 may be decreased so that the amount of rise of the valve-closing pressure 504, which increases corresponding to the number of rotations, draws a gentler slope, so that the amount of rise of the valve-closing pressure 504 does not exceed (Pc′+PF−P−P) 505 within the actual operation range where the number of rotations is the predetermined number of rotations.
If it is desirable to securely suppress the opening of the check valves 401 and 430 when the piston 21 is at the bottom dead center by preventing the influence of the amount of rise of the valve-closing pressure 504 caused by the downward maximum acceleration on the movable parts 402 and 431 even when the mass of the movable parts 402 and 431 of the check valves 401 and 431 is large and the number of rotations increases, the moving direction of the movable parts of the check valves may be set so as not to coincide with the vertical (acceleration) direction of the piston 21, as shown in
A second modification of the third embodiment will be described with reference to FIGS. 25 to 28.
Small chambers (buffers) 610 and 620 are arranged between the check valves 440 and 450 and the working space of the high-temperature side cylinder 22 shown in
As shown in
In the second modification, small chambers 610 and 620 communicating with the working space through the orifices 611 and 621, respectively, are provided between the check valves 440 and 450 and the working space. Therefore, the check valves 440 and 450 become difficult to open along with the rise of the number of rotations of the stirling engine 10 (i.e., as the fluctuation cycle of the pressure within the working space becomes shorter). Thus, the check valves 440 and 450 can be designed to have a low valve-opening pressure Pc. Therefore, when the number of rotations of the stirling engine 10 is small (at the early phase of the activation), the check valves 440 and 450 can be made to easily open, whereby the accumulated pressure value of the hollow portion 212 can be raised in cycles of a smaller number.
In the second modification, it is possible to make the check valve operate only at the time of activation and close in the normal operation range even when the condition concerning the set value of valve-opening pressure Pc described in relation to the third embodiment is not satisfied, with the use of the small chambers 610 and 620 communicating with the working space through the orifices 611 and 621 provided between the check valves 440 and 450 and the working space. The second modification can be combined with the third embodiment, or with the first modification of the third embodiment.
A fourth embodiment will be described.
A stirling engine will be described as an example of a piston engine, hereinbelow. In the following example, exhaust heat of an internal combustion engine mounted on a vehicle, for example, is recovered with the use of the stirling engine. An object from which the exhaust heat is recovered is not limited to the internal combustion engine. The present invention is applicable, for example, to the recovery of exhaust heat from factories, plants, or power generation plants.
A piston engine according to the fourth embodiment introduces a working fluid from a working space in a cylinder to a hollow portion in a piston, and ejects the introduced working fluid to a space between a circumferential portion of the piston and the cylinder. The piston engine includes a pressurized-state maintaining unit which operates in a direction perpendicular to the operational direction of the piston, and introduces the working fluid into the hollow portion from an inlet opening, which opens towards the hollow portion, of an introduction channel, and which also prevents the back-flow of the working fluid from the hollow portion to the cylinder.
A piston 721 of a high-pressure side piston/cylinder unit 720 is housed in a cylinder (high-temperature side cylinder) 722, and reciprocates inside the cylinder. A piston 731 of a low-temperature side piston/cylinder unit 730 is housed inside a low-temperature side cylinder 732, and reciprocates inside the cylinder. A working fluid heated by the heater 47 flows into a space (hereinbelow, referred to as expansion space ES for the convenience of description) in the high-temperature side cylinder 722 at the side of the heater 47. A working fluid cooled by the radiator 45 flows into a space (hereinbelow, referred to as compression space PS, for the convenience of description) in the cylinder (low-temperature side cylinder 732) at the side of the regenerative heat exchanger (hereinbelow, referred to simply as regenerator) 46. The expansion space ES and the compression space PS will collectively be referred to as a working space MS.
Configurations of the pistons 721 and 731 will be described in detail below with reference to FIGS. 30 to 33. As shown in
The piston 721 includes a piston main body 811, a hollow portion (hereinbelow, referred to as pressure-accumulating chamber) 812 formed in the piston main body 811 (i.e., inside the piston 721), and a dividing member 813. In the fourth embodiment, the dividing member 813 is attached to an inner wall 811w of the piston 721 at a hem portion 811s of the piston main body 811. The dividing member 813 is configured so as to avoid the piston pin 62 which serves to attach the piston 721 to the piston-side rod 61 as shown in
The piston main body 811 includes a circumferential portion (sliding portion) 811a which slides against the high-temperature side cylinder 722 (
The reed valve 815 is fixed to the valve-forming portion 818 together with a reed-valve guide 819 via a screw 818s which serves as a fixing unit (see
The reed valve 815 is fixed to the valve-forming portion 818 at a fixed portion 8151 (
The reed valve 815 limits the flow of the working fluid passing through the introduction channel 814 to the direction from the working space MS to the pressure-accumulating chamber 812. The reed valve 815 opens when the pressure Pc of the working fluid in the working space MS (in-working-space pressure) in the high-temperature side cylinder 722 increases due to the movements of the piston 721 and exceeds the pressure Pp inside the pressure-accumulating chamber 812 (in-pressure-accumulating-chamber pressure), so as to introduce the working fluid in the working space MS of the high-temperature side cylinder 722 to the pressure-accumulating chamber 812. Further, when the in-working-space pressure Pc of the working space MS in the high-temperature side cylinder 722 decreases due to the movements of the piston 721 and becomes lower than the in-pressure-accumulating-chamber pressure Pp, the reed valve 815 is pushed towards the valve-forming portion 818, so as to prevent the back-flow of the working fluid from the hollow portion 812 to the working space MS in the high-temperature side cylinder 722. Thus, the reed valve 815 has a function of maintaining a pressurized-state and a function of introducing the working fluid.
Plural air-feed holes 816 are arranged on a circumferential portion 811a of the piston main body 811 at regular intervals in the circumferential direction. As shown in
As the piston 721 rises, the working fluid in the working space MS of the high-temperature side cylinder 722 is compressed, and the in-working-space pressure Pc becomes higher than the in-pressure-accumulating-chamber pressure Pp. Then, the reed valve 815 opens. A part of the working fluid in the working space MS is introduced into the pressure-accumulating chamber 812 through the introduction channel 814. When the working fluid is introduced into the pressure-accumulating chamber 812 via the introduction channel 814, a part of the working fluid of the pressure-accumulating chamber 812 is ejected to the clearance between the piston 721 and the high-temperature side cylinder 722 through the air-feed hold 816, thereby forming the air bearing 48. The clearance is approximately 15 micrometers to 30 micrometers in size ts. The reed valve 815 which serves as the pressurized-state maintaining unit and the valve-forming portion 818 to which the reed valve 815 is attached will be described in more detail.
Since the reed valve 815 is a plate-like elastic member as described above, when the reed valve 815 is fixed to the valve-forming portion 818 via the screw 818s, the reed valve 815 is brought into contact with the valve attachment portion 818p and closes the working-fluid outlet 814o of the introduction channel 814 (
When the in-working-space pressure Pc exceeds the in-pressure-accumulating-chamber pressure Pp, and the force acting on the reed valve due to the pressure difference between Pc and Pp exceeds the force pushing the reed valve 815 to the valve attachment portion 818p, the reed valve 815 behaves so as to move away from the valve attachment portion 818p. Then, the working fluid passes through the introduction channel 814 and flows from the working-fluid outlet 814o to the pressure-accumulating chamber 812 (see
When the in-working-space pressure Pc becomes lower than the in-pressure-accumulating-chamber pressure Pp, and the force acting on the reed valve due to the pressure difference between Pc and Pp becomes lower than the force of the reed valve 815 pushing itself to the valve attachment portion 818p, the reed valve 815 behaves so as to move toward the valve attachment portion 818p. Then, the working-fluid outlet 814o is closed and the flow of the working fluid toward the pressure-accumulating chamber 812 (see
When the piston 721 comes to the position of a TDC (Top Dead Center) or a BDC (Bottom Dead Center) while the stirling engine 10 is running, the absolute value of the acceleration applied to the reed valve 815 reaches its maximum value. The acceleration applied to the reed valve 815 while the piston 721 is at the TDC is represented as αTDC, and the acceleration applied to the reed valve 815 while the piston 721 is at the BDC is represented as αBDC. As shown in
As shown in
When the technique described in Patent Document 1 is applied, since the direction of movement of the check valve is parallel to the acceleration attributable to the reciprocating movements of the piston 721, if the check valve is set so as not to malfunction at the BDC where the maximum force is applied in the direction to open the check valve, the check valve may not be open at the TDC. Particularly when the engine is running at a high rotational speed, such failure becomes prominent.
Therefore, it is difficult to set the check valve using the technique described in Patent Document 1 so as to introduce the gaseous matter into the space inside the piston at the TDC and maintain the introduced gaseous matter until the next introduction. Particularly when the engine is running at a high rotational speed, such setting is substantially impossible. Thus, the technique described in Patent Document 1 can be applied practically only when the engine is running at a low rotational speed.
As already described, in the stirling engine 10 according to the fourth embodiment, the plate surface of the reed valve 815 is parallel to the direction of movements MD of the piston 721 (i.e., parallel to the piston-center axis Z). Therefore, the direction of movements of the reed valve 815 is perpendicular to the direction of movements MD of the piston 721 (i.e., direction parallel to the piston-center axis Z), or perpendicular to the direction of acceleration generated due to the reciprocating movements of the piston 721 at the TDC or the BDC.
As a result, even when the acceleration attributable to the reciprocating movements of the piston 721 is applied to the reed valve 815, the operation of the reed valve 815 is not affected much. In other words, the valve-opening pressure of the reed valve 815 determined according to the elasticity modulus, the thickness, and the like of the reed valve 815 is not practically affected by the acceleration. Hence, the reed valve 815 can be opened/closed irrespective of the acceleration. Even when the stirling engine 10 is running at a high rotational speed, in other words, even under the high acceleration, the reed valve 815 operates securely to introduce the gaseous matter into the space inside the piston at the TDC and maintain the gaseous matter until the next introduction.
The check valve disclosed in Patent Document 1 has a mechanical operating portion which applies pressure to the valving element with the spring. In such a check valve, the valving element and the spring slide with each other at the operation. Therefore, the vibrations caused by the repeating reciprocating movements of the piston causes fretting wear, for example, in the valving element and the spring, and the durability of the check valve might be degraded. In the fourth embodiment, however, the reed valve which operates only according to the elastic deformation is used as the pressurized-state maintaining unit, and hence, the elements do not slide while the reed valve operates. Thus, the fretting wear and the like caused by the vibrations attributable to the reciprocating movements of the piston is significantly reduced. As a result, the durability of the pressurized-state maintaining unit can be significantly enhanced.
Further, in the fourth embodiment, the pressurized-state maintaining unit (i.e., reed valve 815) is used in a gaseous matter which has a low attenuation rate of the vibrations. Therefore, if the movements of operation of the pressurized-state maintaining unit is set parallel to the direction of acceleration attributable to the reciprocating movements of the piston as in the technique disclosed in Patent Document 1, the pressurized-state maintaining unit vibrates sympathetically due to the influence of the vibrations attributable to the change in the acceleration. Then, if the pressurized-state maintaining unit is employed in a gaseous matter having a low attenuation rate of vibrations, the pressurized-state maintaining unit easily vibrates sympathetically, because the vibrations thereof hardly attenuate. On the other hand, since in the fourth embodiment, the direction of operation of the pressurized-state maintaining unit (i.e., reed valve 815) and the direction of movements of the piston 21 are perpendicular with each other, the pressurized-state maintaining unit does not receive the influence of the vibrations caused by change in the acceleration substantially. Thus, the sympathetic vibrations of the pressurized-state maintaining unit (i.e., reed valve 815) are suppressed, and the stable operation can be realized.
In the neighborhood of the TDC, an upward acceleration, i.e., acceleration acting toward the top surface portion 811b of the piston 721 is applied to the reed valve 815, and reaches its maximum value at the TDC. As described earlier, the reed valve 815 is fixed to the valve-forming portion 818 at the bottom side of the piston 721, i.e., at the side of the hem portion 811s (
On the other hand, downward acceleration, i.e., acceleration acting towards a direction of the hem portion 811s of the piston 721 is applied to the reed valve 815 in the neighborhood of the BDC, and reaches its maximum value at the BDC. As shown in
When the structural body SI is arranged as described above, the distance between the introduction channel 814 formed in the valve-forming portion 818 shown in
Further, it is preferable to arrange the structural object SI at the central portion of the piston 721 in terms of its relation with the gravity G of the piston 721. Particularly in the fourth embodiment, the linear approximation of the trajectory of the reciprocating movements of the piston 721 is important since the air bearing 48 is employed. Therefore, it is preferable to match the position of the center of gravity g of the structural object SI with the center of gravity G of the piston 721 as much as possible on a plane perpendicular to the direction of movements of the piston 721 as shown in
A modification of the pressurized-state maintaining unit provided in the piston engine according to the fourth embodiment will be described.
The operating portion 815a2 covers the working-fluid outlet 814o of the introduction channel 814, and moves away from the valve-forming portion 818 when the pressure difference between the in-working-space pressure Pc and the in-pressure-accumulating-chamber pressure Pp exceeds the valve-opening pressure of the reed valve 815a. The reed valve 815a is fixed on the straight line Zc which is parallel to the central axis of the piston 721a, and fixed to the valve-forming portion 818 at two positions, i.e., at the side of the top surface portion 811b and at the side of the hem portion 811s of the piston 721a. Therefore, even when the piston engine provided with the piston 721 operates at an extremely high rotational speed and a large acceleration is applied to the reed valve 815a, the deformation of the reed valve 815a is suppressed and the reed valve 815a operates securely. Further, since the amount of operation of the operating portion 815a2 is smaller than that of the reed valve 815 (
A reed valve 815b which is the pressurized-state maintaining unit shown in
The operating portion 815b2 covers the working-fluid outlet 814o of the introduction channel 814, and moves away from the valve-forming portion 818 when the pressure difference between the in-working-space pressure Pc and the in-pressure-accumulating-chamber pressure Pp exceeds the valve-opening pressure of the reed valve 815b. The reed valve 815b is fixed to the valve-forming portion 818 at two positions. Therefore, even when the piston engine provided with the piston 721b operates at a high rotational speed and a large acceleration is applied to the reed valve 815b, the deformation of the reed valve 815b is suppressed and the reed valve 815b operates securely. The fixing portions 815b1 and 815b1 of the reed valve 815b are arranged in a direction perpendicular to the straight line Zc parallel to the central axis of the piston 721b. Therefore the dimension of the reed valve 815b in the direction of movements of the piston 721b can be made small, whereby the dimension of the piston 721b in the direction of movements can be made small, accordingly.
A reed valve 815c which serves as the pressurized-state maintaining unit and is shown in
The operating portion 815c2 covers the working-fluid outlet 814o of the introduction channel 814, and moves away from the valve-forming portion 818 when the pressure difference between the in-working-space pressure Pc and the in-pressure-accumulating-chamber pressure Pp exceeds the valve-opening pressure of the reed valve 815c. The reed valve 815c is fixed to the valve-forming portion 818 in the direction perpendicular to the straight line Zc which is parallel to the central axis of the piston 721c. Therefore, the dimension of the reed valve 815b in the direction of movements of the piston 721c can be made small, and the dimension of the piston 721c in the direction of movements can be made small, accordingly. The configuration of the reed valve 815c is effective when the piston engine provided with the piston 721c runs at a relatively low rotational speed.
In the piston engine according to the fourth embodiment and the modifications thereof described above, the working fluid is introduced from the working space in the cylinder to the hollow portion in the piston, and the working fluid is ejected to the space between the circumferential portion of the piston and the cylinder, and the piston engine is provided with the pressurized-state maintaining unit which operates in a direction perpendicular to the direction of movements of the piston. Therefore, even when the acceleration attributable to the reciprocating movements of the piston acts on the pressurized-state maintaining unit, the operation of the pressurized-state maintaining unit is not affected substantially. As a result, the pressurized-state maintaining unit can operate irrespective of the acceleration. Thus, even when the piston engine runs at a high rotational speed, i.e., even when the acceleration working on the pressurized-state maintaining unit is large, the pressurized-state maintaining unit operates securely so as to introduce the gaseous matter into the space inside the piston at the TDC and maintain the introduced gaseous matter until the next introduction of the gaseous matter.
In the above example, the stirling engine is configured to be attached to the exhaust pipe so as to use the exhaust gas of the internal combustion engine of the vehicle as a heat source. However, the stirling engine of the present invention is not limited to the type attached to the exhaust pipe of the internal combustion engine of the vehicle. In the above, the configuration, the operation, and the effect of the piston engine, as the stirling engine, are described. The piston engine according to the embodiment, however, is easily applicable to the piston engines other than the stirling engine, and performs the same operation, exerts the same effect, and has the same usefulness.
The piston apparatus according to the present invention is useful for a piston apparatus which does not include a piston ring. The piston apparatus according to the present invention is particularly suitable for a piston apparatus which includes a pressure-accumulating portion inside a piston main body and which ejects a fluid from the pressure-accumulating portion toward an inside of the cylinder.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-378172 | Dec 2004 | JP | national |
| 2004-378176 | Dec 2004 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP05/23966 | 12/27/2005 | WO | 6/25/2007 |
