Engine Design.
Summary - This work presents the design and analysis of parameters provide by an engine driven to electromagnetic piston using solenoid coils as a source of driving force. The study was done with the objective of presenting the construction of a functional prototype that was build with a support of an 3D printer.
In the end of building were made analysis of the parameters providede by the engine built and it was found that the engine presented a low performance compared to other electric motors. Despite the low performance, the engine can be used as a good didactic example that exemplifies the operation of an electromagnetic piston engine operating principle.
This is a topic with great economic importance on the world market. The use of electric motors to drive machines and equipment mechanical, both in domestic and industrial use. It is estimated that the
world electric motor market moves millions of dollars each year. In most industries, it is estimated that 70 to 80% of energy consumed, are transformed into mechanical energy by electric motors(FRANCHI, 2008). Innovations in the field of electric motors are always welcome, as these are widely used, and quite efficient, engines that use clean energy, justifying a more detailed study in this field. The objective of the work is to present the development and construction a prototype engine that will be powered by electromagnetic piston and analysis its parameters such as: torque, rotation and energy consumption. Finally, it will be analyzed as advantages and disadvantages of this specific type of engine.
For the construction of the engine I chose the the "PDCA design tool" which is based on Plan, Do, Check and Act. This step of the work follows the flowchart exposed in the below Flowchart picture for a better understanding of the processes used on my project.
Flowchart.
- Engine planning
The engine prototype was planned, following the project created from the SOLIDWORKS ™ modeling software. The engine design followed a model simplified version containing two pistons and two solenoids. The detailed design can be observed following the link referring to the Engine.
- Engine construction
The engine was designed following a cylinder arrangement similar to a car engine, containing 2 cylinders. The parts of the base and main structure of the motor were printed on a 3D printer using PLA filament as printing material. After making the parts, the engine was assembled following the project specifications contained in link upside. The model of the printer used for the Cliever CL2 Pro 1 E. It was decided to print the parts on a 3D printer, because the final material has high mechanical strength and printing has an error of approximately 0.2%, minimizing the construction errors. Model TAU-0630T 24VDC solenoid coils were used CNMAWAY, which can be used in various applications, such as locking electronic doors. Each coil has a load capacity of 980N, for Nominal voltage of 24V and nominal power of 25W. Technical information coil are shown in link below. Both motor coils can be mechanically actived, through limit switches or electronically via a control circuit Arduino.
Coil U:24VDC.
- Checking for proper operation.
- Engine parameters
After the construction and final adjustments of the engine, values of input power, rotation and Torque, with the calculation of the average of each from them. All values contained in the tables were calculated using of the equations contained in the "trabalho completo no final do artigo". Images of experiments and all calculation memory can be observed following the "Trabalho completo". The input power was calculated using Equation 4, the Rotation was measured using a model DT-2234C + tachometer. To obtain the torque, it was a dynamometer coupled to the flywheel was used, and the Equation 2 for the calculation of torque on the shaft. Were calculated with the values obtained, the output power of the motor. For this calculation, the following equations 5 and 6 to transform the rotation from rpm to rad / s and so it was used equation 7 for calculating the output power. With the obtained values it was Table 1 was constructed.
Table 1 - Engine measured and calculated parameters.
Legend: "Tensão (V) = Voltage"; "Corrente média (A) = Electric current"; "Potência de Entrada (W) = Input power"; "Rotação média (rpm) = average rotation"; "Torque no Eixo (Nm) = Shaft Torque"; "Potência de Saída (W) = Output power".
After all the Table 2 was built, which shows each input power, output power and engine efficiency.
Table 2 - Input and output power and Engine performance.
legend: "Potência de Entrada (W) = Input power"; "Potência de Saída (W) = Output power"; "Eficiência (η) = Engine Performace".
Engine speed (rpm) was controlled using the lab's power supply MOL-1303M. The value of the voltage supplied to the motor was adjusted by the power supply. To improve the visualization of the obtained parameters, Graph 1 was constructed, which relates the rotation in relation to the voltage supplied by the power supply.
Graph 1 - Average rotation x Average tension supplied.
legend: "Rotação média(rpm) = Average rotation"; "Tensão Média(V) = Average tension supplied".
The graph presents an exponential trend line showing that the more energy is supplied to the engine, the higher its speed increases engine efficiency. A graph was also constructed that relates to efficiency in relation to the power supplied Graph 2.
Graph 2 - Efficiency x Input power(W)
Legend: Eficiência (η) = Engine Performace"; "Potência de Entrada (W) = Input power".
Analyzing the graph, it was possible to notice that the engine presents better efficiency of an input power of 13.16 W because its efficiency in from that value, it stabilizes at approximately 40%. Engine efficiency has direct connection with torque and rotation. There are several factors that influenced by low performance, such as: losses by joule effect, vibrations, friction, noise, magnetic flux dispersion.
- Conclusions
From a functional point of view, the engine showed very good results. Because it is an engine model
which there is almost no technical information about the project. The whole project was elaborated by the Author's creativity. The engine surprised with high (rpm), however, it presented a low torque.
The analysis showed the positive and negative points of an engine powered
with electromagnetic piston. Are they:
Strengths:
- The engine is modular and its parts can be easily replaced and has with good maintenance;
- The main parts of the engine structure can be made using 3D printer;
- The engine has a simplified construction.
Negative points:
- The engine has high vibrations;
- The engine does not have a high torque;
- As it is an electric motor, the performance presented was below expected.
The work presented the functioning and the parameters of a motor powered with electromagnetic piston, with relevant information about the engine and also with a functional design that can be easily reproduced according to the information contained in the Project. In principle, the engine can be applied in situations where an easy-to-maintain engine is needed and which deliver high revs(rpm). The engine can also be used as a didactic prototype showing an engine powered by an electromagnetic piston in Operation. With improvements and more studies, it will be possible to increase the reach applications for this type of engine. As a proposal for the continuity of studies, it was found that there are still possibility to reuse the piston movement to generate energy and thus increase its performance, one of the parameters that most impacted negatively on the engine.
I'm working in the translate of the original document.
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