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Evaluating the feasibility of a '''large displacement 750 RPM powerplant engine'''. Naturally aspirated, CR=16.5 for producer-gas (appr 50..55 Nm / liter of displacement equivalent to 4300 Watt on shaft, 4kWe on generator). Gensets with similar engines usually achieve 50-80 kWe / ton of weight (the more common configuration is 1500 RPM engines with traditional crankshaft and connection-rods). ---- '''Cylinder liners''' - displacement * bore = max 220 mm for now. [http://www.hastingsmfg.com/RingFinderDiametricalDetails.aspx?AppMACD=8%201/2 Hastings] offers '''8.5 inch (=215.9mm) piston ring-sets''' ** the centrifugal- metalcasting shop specified max 270 mm outer dia for the cyl liner, preferrably max 260 mm if possible. 215.9mm should not be a problem ** for 750 RPM engines 340 mm bore is also reasonable (Caterpillar, Wartsila) but 215.9 mm sounds better for now * stroke=300..'''350 mm''' ** the centrifugal-metalcasting shop specified max 540 mm cylinder liner length ** ~ 12.8 liter / cylinder 2 * 6 cylinders (154 liter total, appr 640 kWe). 2*4 (103 liter) would be another option. '''Wet cyl liners or dry liners ?''' * originally wet liners were considered ** after discussions with motor repair shops, they recommended dry liner because wet liners have much more sealing issues. * note: optimally, the cylinders would be cooled by 100-120C termo-oil instead of antifreeze+water: many pellet-plants use 140C termo-oil for drying. ** the cooled oil would be heated by the cylinders (and head) first, than heated by the exhaust (and by the producer-gas) after that ideas ? ---- '''Double roller''' * connecting rods have 2 bearings, very hard to lubricate (and conrods stress the piston rings). * horizontal twin-piston (align their pair) with double roller "swashplate" design (not wobble-plate!) is Rollers are 110..160 kN radial force depending on bore. (bearing for this is appr 150 mm OD, and 3kg) A side roller sounds nice to counteract the force that pushes the crank during powerstroke. Perhaps a second, smaller side roller opposite (this is for the compression stroke). These relief the piston rods from the extreme stresses. '''See''' * http://www.eleg.hu/tiki/tiki-index.php?page=Axi%C3%A1lDugatty%C3%BAsMotor * See 40 sec in [http://www.youtube.com/user/EICADXB#p/u/1/sVEOTNjAtCU video] in this kinder engine ** note the rollers, and the oil-grooves in the twin-piston ---- '''Valves, valve-seat''' * traditional Preferrably compatible with an engine family (Caterpillar, Cummins, whatever...). '''intake valves''' * 61.6mm intake valve: http://www.summitracing.com/parts/MAN-11220-1/ * [http://www.summitracing.com/parts/TFS-53400213-1/ 57.1 mm] only 30 USD Exhaust valve: * [http://www.summitracing.com/parts/BRO-BR6170DI/ 51.3mm] 17 USD * [http://www.summitracing.com/parts/DCC-5249878/ 51.3mm] 22 USD * [http://www.summitracing.com/parts/MAN-11221-8/ 51.8mm] * [http://www.summitracing.com/parts/MAN-11219-1/ 52.3mm] 33 USD * [http://www.summitracing.com/parts/SLP-V-1802/ 50.8mm] 17 USD '''Caterpillar valves''' * [http://www.albertmuhely.hu/hengerfej_termekek.html D9 serial n.18A1] ** Caterpillar 015 intake vave 63.5mm (12.5, 238.5mm) ** Caterpillar 016 exhaust valve 60mm (12.5, 238.5mm) ** why is it so long ? * Mercedes ** Mercedes 015 59mm intake valve (12, 142.5mm) ** Mercedes 016N 51mm exhaust valve (12, 142.5mm) The availability of valve guides and seals must be considered also. (and possibly whole individual cyl heads if available). ---- '''Camplate''' 1 camplate at each end of the engine * with 4 fingers (different radius, of course) on each camplate ** odd cylinders: 1 finger for 2 intake valves + 1 finger for 2 exhaust valves ** even cylinders: 1 finger for 2 intake valves + 1 finger for 2 exhaust valves. Even cylinder fires 360+60 degrees after the neighbor odd cylinder. (for more even running) * Using rockers (of different length) to actuate the lifters. '''Lifters''' Mechanical or hydraulic ? * any suggestions for hydraulic lifters ? Which is the biggest ? * [http://transautopart.en.made-in-china.com/product/zMpmlYsVgXhf/China-Hydraulic-Lifter-for-Nissan-TSVL-040-.html Nissan] lifters are quite big, around 40mm diameter ** Peugeot are very small ** VAG diameter is somewhere between But see [http://www.twinturbo.net/nissan/300zx/forums/technical/view/917346/Lifter-Rebuild-101.html Nissan lifter guts]. The internal diameter that counts (where the oil pressure acts during valve lifting) is much smaller even for the nissan, around 12mm. ---- '''Rockers''' Rockers are probably the best choice for a camplate (instead of camshaft) engine. Nice rocker arrangements: * I like this (US patent 4561391 from 1985): [http://cgi.ebay.com/ebaymotors/MITSUBISHI-GALANT-ECLISPE-2-4-SOHC-16V-CYLINDER-HEAD-_W0QQcmdZViewItemQQhashZitem255d9141d5QQitemZ160483590613QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessoriesQQxZ38QQyZ10 Mitsubishi-Galant-Eclipse SOHC 4 valve cyl head ] * Honda introduced the 4-valve XL250 SOHC single cylinder engine in 1972 (13 years before the 1985 patent). ** In 1977 Honda introduced the 3-valve SOHC CB400 twin cylinder models. ** any pictures about these ? ---- '''Head''' * traditional. * 4 valves per cylinder + preferrably 2 sparkplugs per cyl ** min 3 valves per cyl in any case. * Separate head for each cylinder ---- '''Oil pump''' * electrical oil pump can be switched on before cranking. ** provision for chain-driven mechanical oil pump. One-way valves allow the 2 pumps to be connected in parallel ---- '''Coolant pump''' * electrical coolant pump ** provision for chain-driven mechanical coolant pump. One-way valves allow the 2 pumps to be connected in parallel ---- '''Starter motor''' * torque ? * max RPM ? ** is 50 RPM (more than) enough to start this 12 cyl 750 RPM engine ? The 3.4MW V20 GE Jenbacher engine (turbo-natural gas 1500 RPM is 21656 Nm, assuming 180 Nm /liter the total displacement can be around 120 liter) is started by 2 x 9 kW electric motor (24V each, ~400A current). It can be started by just 1 of the starters operating. A similar starter would seem suitable for the slightly bigger displacement barrell engine. A [http://www.dbelectrical.com/p-2242-new-starter-caterpillar-marine-3208-3304-3306-4-6-8-cyl-sdr0049.aspx 24V 7.8 kW caterpillar marine starter] 27.6 kg, $195 It is theoretically possible to use the syncronous generator as a starter * at least with the brush type generator. ** Maybe excitation would be lacking with the brushless type or AC excitation would be needed. However, this (with the high current relays and added complexity) might be more costly (even with 400V but most likely with a 6-10kV generator) than a dedicated starter motor.
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