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This idea builds on my earlier idea from a few years ago
[link], but improves it in a few subtle ways... enough, I
think, to warrant this being a separate idea.
Similar features:
* All of the valves of the engine are fully computer
controlled, so we can instantly switch from a four stroke
cycle to a two stroke cycle, and back, as needed.
* The engine block has no water jacket.
* The areas where hot combustion gasses are produced
and exhausted are lined with high tech insulating
ceramic, similar to Toyota's failed adiabatic engine.
This idea will take advantage of the high rate of heat
transfer that caused their engine to be no more
efficient than a normal one, and put that heat to good
use.
* There is a steam condenser is probably cooled by a
water/antifreeze mix, which in turn is cooled by a
radiator. This way, in very cold weather, we can
control the rate of coolant circulation so the condenser
is very-cold-but-not-freezing.
There will also be a (small) vacuum pump, to remove air
from the condenser. The air that comes out of the
pump will inevitably be very humid, so it would
probably be a good idea to route it to the exhaust gas
water recovery device.
Naturally, there's a pump to move water from the
condenser, to the boiler.
* There is high pressure exhaust powered steam
boiler/hot water heater. This component will be
producing hot liquid, and hot steam, both of which will
be used in the engine.
* Downstream of the boiler, some or all of the exhaust
passes through an exhaust gas water recovery system.
We only need to recover a small amount of water from
the exhaust, and we don't need it to be very pure. The
water needs to not have minerals or particulates, and
not chemically break down when heated in the boiler.
* A computer selects from three different modes of
operation, depending on the inputs of various
temperature and pressure sensors.
The default mode of operation is a perfectly normal
four stroke internal combustion cycle. Not only does
this produce a certain quantity of mechanical power
(our main product), but it also heats up the engine
block, and produces hot exhaust gas. For the latter two
reasons, I'll call this the heating cycle.
Note: There are many different variations of a four
stroke cycle, and for the sake of discussion, I do not
care which one is used. It could be an Otto cycle, a
Diesel Cycle, an Atkinson Cycle, a Miller Cycle, etc.. It
doesn't matter very much. I'd prefer that it take
advantage of the computer controlled valves to
eliminate the need for a throttle, but that's a minor
detail.
It *is* important that the exhaust not damage the water
boiler, but that can be avoided by using appropriate
pollution controls.
When the in-cylinder temperature exceeds some
threshold, the computer switches from the heating
cycle, to the primary cooling cycle.
We start with the piston at top dead center, with the
valves closed, and spray in a small amount of water.
This water is pumped from the exhaust heated boiler,
using a floating intake which ensures that it is liquid
water that comes out of the injector, not steam.
The quantity of water injected is carefully chosen by
the computer, to be as much as possible, but within the
following additional limitations: (A) The max steam
pressure won't exceed the engine's tolerances. (B) The
steam pressure at the end of the first (expansion) stroke
doesn't exceed the pressure in the steam condenser. (C)
The average torque over the two stroke cycle must not
be significantly more than the average torque of the
most recent four stroke cycle.
The water strikes the piston face and cylinder walls, and
is heated by them, changing from liquid to steam.
Since this phase chance happens in a confined space, it
produces high pressure. As the piston descends, the
expanding steam pushes on it, producing torque.
On the second stroke of the cycle, the low pressure
steam valve opens to allow steam out of the cylinder,
into the steam exhaust manifold, which leads to the
condenser.
The computer keeps the engine in the primary cooling
cycle until the engine's insides are cool enough to
switch back to the heating cycle.
When the steam pressure in the boiler exceeds some
threshold, the computer switches to the secondary
cooling cycle. This is a simple two stroke steam
expansion cycle. It cools the engine a bit, but not as
much as the primary cooling cycle.
In the first stroke, the high pressure steam valve opens,
steam comes in, then shortly afterward the valve
closes. The piston continues to descend, and the steam
expands against it, producing mechanical energy.
The quantity of steam admitted is selected by the
computer to have the same criteria as was used for
quantity of water to inject, in the primary cooling
cycle.
The second stroke of the cycle is the same as the
second stroke of the primary cooling cycle.
The computer keeps the engine in this cycle until the
steam pressure in the boiler drops below some
threshold, after which it switches back to the heating
cycle.
The reason why the idea is named as it is, is because
the the engine will switch between the three modes of
operation in a pattern that a human probably wouldn't
predict. Also, I fully expect that the exhaust noise
would be... well, odd.
Variable Stroke Count Engine
Variable_20Stroke_20Count_20Engine Like this idea, but only two modes of operation. [goldbb, Feb 03 2013]
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What is the block made from? There aren't a lot of
materials that can withstand the extreme thermal cycle
this system would produce. |
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The engine block would probably use some type of
zirconia ceramic, since it's been highly studied in the
context of engines, and unlike silicon nitride, it's unlikely
to degrade due to the hot, humid, environment inside the
engine. |
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Even if you have a constant power load, a water pump for example, would be hard to keep steady RPMs or torque between cycles. [+] |
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bigsleep,
A Stirling engine takes time to warm up. The more
powerful, the longer it takes. This engine idea start
with a four stroke cycle when cold, and can start just as
quickly as a conventional engine. |
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Also, it's very difficult to quickly adjust the specific
power of a Stirling engine. Sure, done using a
continuously variable transmission, but not exactly
easily. |
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piluso, for each of the three modes, controlling torque
is not that hard. |
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In the heating cycle, the computer controls the amount
of air and fuel admitted into the cylinder, exactly as in a
normal engine. In the primary cooling cycle, the
quantity of water injected is controlled by the
computer, and this directly controls the torque. In the
secondary cooling cycle, the quantity of steam admitted
is controlled by the computer, and this controls the
torque. |
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Controlling torque obviously controls RPM. |
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I'm giving this a bun despite what I'm saying
sounding like I'm shooting it down, I'm not. I've
considered schemes such as this. In the big
picture of things, the ideal vehicle would use
electric only for moving the wheels, and the
engine would be purely used as a generator. I
won't go into all the details of using pure electric
torque for the wheels but I am convinced it's
superior in every measure. This frees the engine
from performance requirements related to large
RPM range, broad torque curve, throttle response,
etc. Of course, this also makes variable valve
timing and all of those features to improve the
toque/rpm range irrelevant. To bail on the
electronic valves and use single traditional cam
would be simpler and probably less valvetrain
losses. Permanent 6-cycle and just wait until it's
hot to start the water injection. I think you may
also be underestimating how much cooler it will
run with steam sucking the heat out of the block.
Advanced ceramics may not be necessary. |
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I'm also torn on the issue of water recovery, more
specifically the issue of water freezing. It seems
like a lot of complication, I really don't mind filling
up a water tank if it's going to double how long
the gas lasts. |
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You could avoid the problem with the water freezing by injecting antifreeze or chlorofluorocarbons or ammonia. |
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// The engine block would probably use some type of
zirconia ceramic, since it's been highly studied in the
context of engines, and unlike silicon nitride, it's unlikely
to degrade due to the hot, humid, environment inside the
engine. // |
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Okay, I don't know anything at all about zirconia ceramic or
silicon nitride. I was sort of assuming that the block would
be made of some unobtanium metal alloy. I'll do some
reading to try and catch up with you, but first let me get
right to the crux of my point: how stretchy is zirconia
ceramic? The mechanical process you're describing here is
likely to produce a thermal cycle more extreme than any
found in conventional combustion engines. The water
injection is only part of this issue; the regular build-up and
release of pressure not only within the cylinders but also in
the boiler and the exhaust gas recovery system will also
cause significant thermodynamic exchange (somebody
correct me if that's not the proper term). |
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Basically, this thing is going to be rapidly expanding and
contracting at irregular rates in a staggering array of
locations and directions. A cast iron block asked to
perform like this would crack within a few minutes. Even a
highly ductile mega-ultra-high tech alloy like
cryo-forged tempered tichrome would probably develop
hot spots and
microfissures after less than a thousand hours. Would your
ceramic compounds be any better at taking this kind of
punishment? |
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^^That's why there would need to be some Aluminum in the mix to allow for flexing. all very possible. |
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I like this. What's more, in my job I've been currently researching moisture removing processes; the water recovery in the exhaust is as simple as either passing it through a series of fairly unrestrictive dessicant sillica filters with a sump collector, or a cyclonic separator. |
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AutoMcDonough, the advanced ceramics aren't *just* to
retain more heat (although that's an important part of
it), but rather to withstand the thermal shock that's
involved. |
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I agree the using electricity to torque the wheels
(instead of the motor directly), is the way to go. |
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And you're probably right, using a fixed six stroke cycle
would probably be simpler and lighter, which in a
moving vehicle is a very important thing. |
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This produces a potential problem: if we don't use
steam from the boiler, and if liquid water from the
boiler isn't taken out at a high enough rate, the boiler
could overheat and explode. |
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There are a handful of solutions. |
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First, we use steam from the boiler in a small, separate
steam engine. Since phase change from water to steam
absorbs lots of heat, this keeps the boiler cool enough,
and at a low enough pressure, to not go kaboom. We
can give this steam engine it's own alternator, to
simplify the mechanical portions of the system. |
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Second, we could use an exhaust gas diversion valve,
which stops heating the boiler if it gets too hot. This
throws away perfectly good heat though, which could be
used to make mechanical power. OTOH, we might want
this anyway, as a safety feature. |
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Third, if we can build the boiler strong enough, then we
can use simple high pressure to prevent the water from
boiling, no matter how hot it gets. A car's exhaust
manifold is very very hot, though. Very high pressures
might be needed. Would the water get hot enough to
become a supercritical fluid? It probably depends on the
mass flow rates of the water and the engine exhaust,
but it worries me. |
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And as for freezing of the water recovery system...
whether or not it's an issue would depend on what kind
of system was used. For example, suppose we used a
spray of concentrated liquid desiccant to remove water
from the engine exhaust, used exhaust manifold heat to
regenerate the dilute desiccant back into concentrated
desiccant, and used the already existing condenser to
turn the steam back into water. Common liquid
desiccants are very freeze resistant. The only liquid
water is in parts of the system (the condenser, etc)
where it would be even without the exhaust water
recovery system. |
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Alterother, although I'm not sure how stretchy zirconia
ceramic is, I do know that it's highly resistant to
thermal shock... which is probably a "good enough"
characteristic for it to work. |
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And I'm not sure what you mean by "thermodynamic
exchange." Metal fatigue? Thermal shock? |
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acurafan, unless the boiler is extraordinarily efficient,
the water in the exhaust will be in the form of steam
mixed with air (aka humidity), not liquid water droplets
suspended in air. So a cyclone would be useless. |
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Silica gel desiccant is an amazing substance wrt
adsorbing water, but... the adsorbed water will stay in
place on it's surface, not drip off. Once all of the silica
is covered with a thin film of water, the silica will stop
adsorbing. |
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To get the silica to adsorb more water, you need to add
heat to cook off the water that's on it's surface, then
cool the silica back down. |
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