1. Field of the Invention
The present invention relates to engines and, more specifically, to Stirling cycle engines.
2. Description of the Related Art
Stirling cycle engines have a high theoretical thermodynamic efficiency. However, Stirling cycle engines are not as widely used as internal combustion engines because Stirling cycle engines are typically associated with higher cost and lower proven reliability as compared to internal combustion engines.
For example, one type of Stirling cycle engine includes an enclosed chamber, a displacer piston, a power piston and a crankshaft. The displacer piston is positioned within the enclosed chamber and is connected to the crankshaft by a displacer rod, which extends through the walls of the chamber. The power piston is also connected to the crankshaft through a piston rod and has one end that is in communication with the interior of the chamber. With respect to the crankshaft, the displacer piston and the power piston are typically 90 degrees out of phase with each other.
In operation, the displacer piston moves working fluid from a cold side of the chamber to a hot side of the chamber. This causes the working fluid to expand. This expansion pushes the power piston and the piston rod, thereby rotating the crankshaft. As the crankshaft rotates, the displacer piston moves the working fluid to the cold side of the chamber. This causes the working fluid to contract, pulling the piston down. As the piston moves back down, the crankshaft rotates and the displacer piston moves the working fluid to the hot side of the chamber, thereby completing the cycle.
A rhombic drive is a solution to the problem of providing dynamic balance in a single-cylinder-type Stirling cycle engine. In such an engine, the power piston and the displacer piston are positioned within a common cylinder. The displacer rod passes through the piston. The piston rod terminates at a rigid yoke. In a similar manner, the displacer rod also terminates at a rigid yoke. A combination of connecting rods and crank pins are used to couple the yokes to a pair of crankshafts. Timing gears are attached to the crankshaft to insure the symmetrical geometry of the connecting rods and crank pins. In operation, the two crankshafts are counter rotating. The direction of rotation is such that the variation of the volume in the hot space (above the displacer) leads the variation in the volume in the cold space (between the two pistons) by about 120 degrees. This arrangement has made possible the design of single-cylinder-type Stirling engines of high power (e.g., 40 horsepower or more). Although various other aspects of Stirling cycle engines have been improved over the years, the fundamental design of the rhombic drive mechanism has remained the same.
While elegant in many respects, the conventional geared rhombic drive has certain disadvantages. For example, it is relatively large, heavy, and complicated because it utilizes two geared drive shafts, four connecting rods, and it requires that the displacer rod pass through the body of the power piston. A need therefore exists for an improved design of a rhombic drive that minimizes or eliminates at least some of the disadvantages described above.
Accordingly, a first embodiment of the present invention comprises a drive mechanism for a Stirling engine. The mechanism includes a piston rod, a displacer rod, a first crankshaft and a second crankshaft. The piston rod has a first end and a second end. The first end of the piston rod is configured to be coupled to a power piston of the Stirling engine. The displacer rod has a first end and a second end, the first end being configured to be coupled to a displacer piston of the Stirling engine. A rhombic drive mechanism comprises a plurality of pivotally connected connection members. The rhombic drive mechanism is configured to convert the linear movement of the piston rod to rotational movement of the first and second crankshaft and to convert linear movement of the piston rod to movement of the displacer rod. A linear constraint is configured to substantially prevent lateral motion while allowing axial movement of at least one of the displacer rod and the piston rod.
Another embodiment of the present invention comprises a Stirling cycle engine that includes a cylinder, a displacer piston, a power piston, a piston rod, a displacer rod, a first crankshaft and a second crankshaft. The displacer piston is configured for reciprocal movement along a first axis within the cylinder. The power piston is configured for reciprocal movement along the first axis in the cylinder. The piston rod has a first end and a second end. The first end is coupled to the power piston. The displacer rod also has a first end and a second end. The first end is coupled to the displacer piston. The displacer rod extends through the power piston and the piston rod. The first crankshaft has a rotational axis that is substantially perpendicular to the first axis. The second crankshaft has a rotational axis that is substantially perpendicular to the first axis and substantially parallel to the rotational axis of the first crankshaft. A first yoke is coupled to the second end of the piston rod. A second yoke is coupled to the second end of the displacer rod. A first pair of connection members are each pivotally coupled to a crank pin for the first crankshaft and one of the first or second yokes. A second pair of connection members are each pivotally coupled a crank pin for the second crankshaft and one of the first or second yokes. A linear constraint is positioned about at least one of the displacer rod or the piston rod.
Another embodiment of the present invention comprises a Stirling cycle engine that includes a cylinder, a displacer piston, and a power piston. The displacer piston is configured for reciprocal movement along a first axis within the cylinder. The power piston is configured for reciprocal movement along the first axis in the cylinder. A piston rod has a first end and a second end with the first end coupled to the power piston. A displacer rod extends at least partially through the power piston and the piston rod. The displacer rod has a first end and a second end. The first end is coupled to the displacer piston. A first crankshaft has a rotational axis that is substantially perpendicular to the first axis. A second crankshaft has a rotational axis that is substantially perpendicular to the first axis and substantially parallel to the rotational axis of the first crankshaft. A rhombic drive mechanism comprises a plurality of pivotally connected connection members. The rhombic drive mechanism is configured to convert the linear movement of the piston rod to the rotational movement of the first and second crankshaft and to convert linear movement of the piston rod to movement of the displacer rod. The engine includes means for constraining, without timing gears, straight-line motion of the displacer rod and the piston rod.
As shown in
With continued reference to
In general, the regenerator 15 can comprise a volume of space through which the working gas passes on its way from the heater 15 to the cooler 14. The regenerator 15 can be configured to absorb heat and, in one embodiment, can be filled with, for example, a porous medium, packed random wire, stacked, fine mesh screens, layers of stainless steel foil (e.g., 0.001″ thick) with narrow gas passages in between or other configurations configured to remove and/or transfer heat to a gas flow. Hot gas traveling from the heater 16 to the cooler 14 pass through the regenerator 15 where a large portion of the heat carried by the gas can be absorbed by the regenerator 15. The gas can thus leave the regenerator 15 several degrees cooler than when it entered the regenerator 15. The remaining heat can then extracted at the cooler 14. In the other direction, the gas picks up the heat energy it previously deposited in the regenerator 15 as it flows from the cooler 14 to the heater 16. Thus, the regenerator 15 can greatly increase the efficiency of the engine 100
In operation, the displacer piston 10 moves working fluid from the cold side C of the cylinder 18 to the hot side H of the cylinder 18. This causes the working fluid to expand. This expansion pushes the power piston 9 and the piston rod 8, thereby rotating the crankshafts 5, 21 through the drive 102. As the crankshafts 5, 21 rotate, the displacer rod 7 is moved through the rhombic drive mechanism 102 causing the displacer piston 10 to move the gaseous working fluid to the cold side C of the cylinder 18. This causes the working fluid to contract, pulling the power piston 9 up. As the power piston 9 moves back up, the crankshafts 6, 21 rotate and the displacer piston 10 moves the working fluid to the hot side H of the cylinder, thereby completing the cycle. The sum of the forces acting on the power piston 9 over one full cycle produces a net work output on the crankshafts 5, 21.
As mentioned above, in prior art rhombic drives, the timing gears are part of the kinematic constraints that insure that the motion of each piston and its' rigidly attached piston rod is perfectly linear. However, the timing gears are bulky and heavy. In addition, the gears are a source of noise and potential wear. The gears also require lubrication. Furthermore, the gears require a certain level of clearance, which can result in backlash and/or rocking of the pistons 9, 10 and the mechanism 102, which can cause binding of the pistons and piston rods.
With the timing gears optionally removed to provide a gearless rhombic drive, the linear guide 17 is used to ensure that both pistons 9, 10 are constrained to a substantially straight-line motion. As mentioned above, the guide 17 can be in the form of a bushing or bearing or flexure that is installed near the lower end of the displacer rod 7. In a modified embodiment, the constraint can comprise a “skirt” on either, or both, pistons 9, 10 that is sufficiently long that the cocking force introduced by unequal loading of the output crankshafts is tolerable. In the illustrated embodiment of
In this embodiment, it is possible to take power from the engine 200 via one of the crankshafts 5, 21 and guide 17. However, as will be explained with reference to
As mentioned above,
In the embodiment of
The series connection of the generators 31, 32 can provide certain advantages. If instead the generators 31, 32 are connected in parallel, so that they can “see” each other electrically, small differences in phasing between the generators 31, 32 can result in power being transferred back and forth between them, depending on the instantaneous voltage being generated by each. Nonetheless, optionally, the generators can be connected in parallel, preferably with the magnitude and phase of the generator outputs exactly or substantially matched. The generators 31, 32 are mechanically linked to each other by the rhombic drive 202, which has a certain compliance. This can be modeled as a spring-mass system, which has a resonant frequency. In addition to the high electrical losses suffered with a parallel connection (unless the magnitude and phase of the generator outputs are exactly or substantially matched), the system can go into a destructive resonant vibration.
By rectifying each generator output and connecting them in series, these potential problems are avoided or minimized. In this example, each generator 31, 32 is isolated electrically from the other. The phase angle between the corresponding sinusoidal outputs of the three phases on each generator is preferably still kept as close to zero as possible or as needed. That is, the relative angular positions of the stator assemblies are preferably carefully adjusted to bring the sinusoidal outputs of each generator exactly (or substantially) in phase with each other. This has the effect of making the loads absorbed by each generator exactly (or substantially) equal at a given instant in time. This advantageously keeps the side loads on the displacer rod bearing 11, the guide 17 and pistons 9, 10 as close to or equal to zero as possible. It is still advantageous, although not required, that the generators are otherwise as similar as possible. For example, it is desirable that the generators have the same number of turns, winding resistance, and/or magnet field strength, etc.
In light of the disclosure herein, those of skill in the art will recognize various other embodiments for electrically connecting the motors given the goal of providing a substantially equal load to the crankshafts 5, 21. For example,
In the embodiments described above, there are at least three general ways to deal with the high average gas pressures in the Stirling engine: (i) use rod seals on both piston rods to isolate the working gas from the crankcase, permitting the crankcase to be at atmospheric pressure; (ii) pressurize the crankcase as well, and use a shaft seal where the output shaft(s) extend through the crankcase to the driven load; and (iii) hermetically seal the entire mechanism, including the driven load. In the illustrated embodiments which utilize a pair of electric generators, it is generally desirable, although not required, to use methods (i) and (iii) to substantially reduce, minimize or eliminate different levels of torque that might be exerted on the separate shaft seals in the crankcase.
The above described embodiments are particularly advantageous in applications for engines of low power (e.g., 10 kW or less). Such engines might be served better with a single cylinder engine such as those illustrated herein. For example, the “hot end” components of a Stirling engine of any design are costly due to the use of expensive, difficult to work high temperature alloys. In a Stirling Engine that utilizes a four-cylinder swashplate drive, there are four cylinders instead of one, and thus a complex heater, due to the manifolds to and from four cylinders and regenerators. There are also four pressure bearing dynamic piston seals, which are a major source of friction losses. In contrast, a single cylinder rhombic engine has only one such piston seal or seal system (and a much smaller one on the displacer rod). The swashplate engine can also incorporate a unique method of changing power, by changing the swashplate angle. This results in an elaborate, expensive, and failure-prone system for changing engine pressure. However, the small, single cylinder engine using the modified rhombic drive as described above can be run at a constant power level for charging batteries, for example.
The above-described embodiments can also be applied to a Stirling cooler. In such an embodiment, the engine 200 can be run such that motor-generators 31, 32 are used to move the shafts 9,10 to create a temperature difference. In such an embodiment, the engine 200 acts as a heat pump, forcibly extracting heat from the heater 16 and rejecting it at the cooler 14.
With reference back to
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combine with or substituted for one another in order to form varying modes of the disclosed invention.
This application claims the priority benefit under 35 U.S.C. § 119(e) of Provisional Application 60/692,516 filed Jun. 21, 2005, the entirety of which is hereby incorporated by reference herein.
Number | Date | Country | |
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60692516 | Jun 2005 | US |