Thesis (PhD)-- Stellenbosch University, 2013. / ENGLISH ABSTRACT: Control of beta-type free-piston Stirling engines has been the topic of research and development for many years. In this dissertation, an alternative approach to free-piston Stirling engine control, namely direct piston displacement control, is proposed. Direct piston displacement control entails the instantaneous and direct control of the piston displacement to control the engine according to preferred criteria, e.g. maximum power conversion or efficiency. To control free-piston engines in this manner, it is necessary to independently control both the displacement of the displacer and the power piston in real time. The primary arrangement by which to achieve this is through external control of the instantaneous forces exerted by the linear electrical machines fixed to the pistons. The challenge of displacement control is whether suitable linear machine technology exists or whether technology could be established that would adhere to the requirements of real time direct control. To answer the question whether direct piston displacement control is at all possible, a process was followed to set specifications that linear machines should adhere to and to set design guidelines for linear machines and free-piston Stirling engines. The first step was to establish the ability to simulate free-piston Stirling engine dynamics accurately. This was done by adapting a second order formulation and to verify and improve the accuracy thereof by comparing simulated results with experimental results of one of the best documented Stirling engines, namely the GPU-3 engine. It was found that this second order formulation could simulate the GPU-3 engine to a fair degree of accuracy. Key indicators were defined and later refined with the view of setting specifications. A case study of the influence of a range of variations, including operational, dimensional and other variations, on the dynamics of the GPU-3 was then undertaken. From the findings of this case study, specifications of the key indicators and design guidelines were established. A design optimisation approach was proposed to evaluate linear machine topologies. This approach makes specific provision for the specifications that linear machines need to adhere to, as well as for representative dynamic responses of the forces exerted on the linear machine by the displacer or the power piston. These representative responses and the associated piston displacement were determined for the displacer, the power piston and the combination of the two from the study conducted to set specifications. An air-core, longitudinal flux linear machine with surface mounted permanent magnets (LFPM) was then evaluated to determine its suitability for direct piston displacement control. This linear machine topology was optimised for the traditional approach to establish a benchmark with which to compare subsequent optimisations. The LFPM linear machine not only compared well with other topologies for the traditional application in resonant free-piston Stirling engines, but it was found also to be able to perform displacement control for both the displacer and the power piston. For both pistons, displacement should however be limited to sinusoidal displacement, and in the case of the displacer, an important qualification is that the linear machine should be assisted by spring forces to reach practical design optimisations. Direct piston displacement control is shown to be possible. Future work should concentrate on the practical implementation thereof in free-piston Stirling engines. / AFRIKAANSE OPSOMMING: Die beheer van beta-tipe vrysuier Stirling enjins is al vir baie jare die onderwerp van navorsing en ontwikkeling. In hierdie proefskrif word ’n alternatiewe benadering tot vrysuier Stirlingenjins voorgestel, naamlik direkte suierverplasingsbeheer. Direkte suierverplasingsbeheer behels die oombliklike en direkte beheer van die suierverplasing om die enjin volgens voorkeur kriteria, soos maksimum drywingsomsetting of benuttingsgraad, te beheer. Om vrysuier enjins op hierdie wyse te beheer, is dit noodsaaklik om intyds die verplasing van beide die verplaser en die werksuier onafhanklik te beheer. Die primêre wyse om dit te bereik is deur eksterne beheer van die oomblikskragte wat uitgevoer word deur die lineêre masjiene wat vas is aan die suiers. Die uitdaging van verplasingsbeheer is of toepaslike lineêre masjien tegnologie bestaan en of tegnologie gevestig kan word wat sal voldoen aan die vereistes van intydse direkte beheer. Om die vraag te beantwoord of direkte suierverplasingsbeheer hoegenaamd moontlik is, is ’n proses gevolg om spesifikasies daar te stel waaraan lineêre masjiene moet voldoen en om ontwerpsriglyne vir lineêre masjiene en vrysuier Stirling enjins te stel. Die eerste stap was om die vermoë daar te stel om vrysuier Stirling enjin dinamika akkuraat te simuleer. Dit is gedoen deur ’n tweede orde formulering aan te pas en om die akkuraatheid daarvan te kontroleer en te verbeter deur gesimuleerde resultate met eksperimentele resultate van een van die bes gedokumenteerde Stirling enjins, naamlik die GPU-3 enjin, te vergelyk. Daar is bevind dat die tweede orde formulering die GPU-3 tot ’n redelike mate akkuraat kon simuleer. Sleutel aanwysers is gedefinieer en later verfyn met die oog op die daarstelling van spesifikasies. ’n Gevallestudie van die invloed van ’n reeks variasies, insluitende operasionele, dimensionele en ander variasies, op die dinamika van die GPU-3 is onderneem. Gegrond op die bevindinge van hierdie gevallestudie kon spesifikasies en ontwerpsriglyne vasgestel word. ’n Ontwerpsoptimeringsbenadering is voorgestel om lineêre masjiene te evalueer. Hierdie benadering maak spesifiek voorsiening vir die spesifikasies waaraan lineêre masjiene moet voldoen, sowel as verteenwoordigende dinamiese response van die kragte wat op die lineêre masjien van die verplaser en die werksuier uitgeoefen word. Vanaf die bevindinge van die studie wat uitgevoer is om spesifikasies daar te stel, is verteenwoordigende response en gepaardgaande suierverplasing bepaal vir die verplaser, die werksuier en die kombinasie van die twee. ’n Lugkern, longitudinale vloed lineêre masjien met oppervlak-gemonteerde permanente magnete (LVPM) is toe geëvalueer om die geskiktheid daarvan te bepaal vir direkte suierverplasingsbeheer. Hierdie lineêre masjien topologie is geoptimeer vir die tradisionele benadering om ’n maatstaf te vestig waarteen daaropvolgende optimerings vergelyk kan word. Die LVPM lineêre masjien vergelyk nie net goed met ander topologieë vir die tradisionele toepassing in resonante vrysuier Stirling enjins nie, maar daar is ook bevind dat dit in staat is om verplasingsbeheer te doen vir beide die verplaser en die werksuier. Vir beide suiers moet die verplasing egter tot sinusvormige verplasing beperk word en in die geval van die verplaser, is ’n belangrike kwalifikasie dat die lineêre masjien ondersteun moet word deur veerkragte om praktiese ontwerpsoptimerings te bereik. Daar is aangetoon dat direkte suierverplasingsbeheer moontlik is. Toekomstige werk moet konsentreer op die praktiese implementering daarvan in vrysuier Stirling enjins.

Cette thèse porte sur le développement d’un cogénérateur résidentiel constitué d’un générateur linéaire asynchrone entraîné par deux moteurs Stirling fonctionnant en mode ‘piston libre double effet’. Les critères caractérisant un tel cogénérateur sont décrits ainsi que ses différents modes d’utilisation dans le domaine résidentiel. Les différentes technologies sont passées en revue.Les équations de la mécanique sur lesquelles se fondent le contrôle du couplage thermoélectrique du cogénérateur et sa stabilité y sont définies. Le générateur électrique est modélisé en vue de calculer les grandeurs électriques des équations à bobines couplées et les grandeurs du schéma électrique équivalent, ce schéma permet d’inverser le modèle.Les résultats des modèles analytiques sont validés par des mesures faites sur des maquettes spécialement conçues. Une étude paramétrique de la structure du générateur a permis d’optimiser ses performances. Les équations de la mécanique et le modèle électrique sont utilisés pour poser les bases d’une optimisation ‘système’ du cogénérateur. / This thesis focuses on the development of a residential cogenerator which consists of a linear induction generator driven by two Stirling engines, free-piston double-acting operating mode. The criteria characterizing such cogenerator are described and its various modes of use in the residential sector. The various technologies are reviewed.The equations of mechanics that underlie the control of the coupling of thermoelectric cogeneration and stability are defined.The electric generator is modeled to calculate the electrical coil coupled equations and the magnitudes of the equivalent circuit, this scheme allows us to reverse the pattern. The results of analytical models are validated by measurements on specially designed models. A parametric study of the structure of the generator has optimized its performances. The equations of mechanical and electrical model are used to lay the groundwork for optimization of all the cogenerator, considered as a system.

Le moteur Stirling a été développé il y’a 200 ans. Cependant son développement n’a jamais connu un grand essor. Le contexte énergétique actuel a relancé l’intérêt porté à ces machines. En effet la possibilité de le faire fonctionner à partir de n’importe quelle source de chaleur externe lui permet d’être associé à des sources d’énergie renouvelable comme l’énergie solaire. Au-delà des avantages écologiques, le développement par W. Beale à la fin des années 1960 d’un moteur Stirling à pistons libres (ou FPSE pour Free Piston Stirling Engine) a ajouté de nouveaux intérêts à un tel moteur. Cette nouvelle architecture permet au moteur de fonctionner sans système d’entrainement des pistons. Dans de telles machines, le mouvement des pistons n’est plus déterminé par la géométrie du système d’entrainement. Ces derniers sont mis en mouvement par les forces de pressions occurrents à l’intérieur du moteur. La dynamique des pistons et la thermodynamique du système sont alors couplées, rendant plus complexe la modélisation complète du système.Cette thèse présente une nouvelle technique de modélisation des machines Stirling à pistons libres, intitulée LHA5V pour Linear Harmonic Analysis 5 Volumes, permettant de coupler la thermodynamique du système et la réponse mécanique des pistons libres. Celle-ci repose alors sur la décomposition du moteur Stirling en cinq sous systèmes ouverts : deux espaces à volume variables, deux échangeurs de chaleur et le régénérateur. Nous supposons que les variables d’état varient périodiquement et le modèle détermine comment celles-ci varient en valeur moyenne, en amplitude et en phase afin de satisfaire les équations de conservation de la masse et de l’énergie. L’aspect innovant du modèle thermique repose sur la prise en compte implicite des pertes inhérentes au fonctionnement. Celles-ci ont en effet un impact direct sur le mouvement des pistons. Par ailleurs cette thèse présente également un modèle de génératrice électrique linéaire pouvant être couplé à la partie thermique. Le modèle électrique repose sur un calcul analytique de la force de poussée du stator sur la partie mobile. Le calcul des flux et du niveau d’induction dans le circuit magnétique est effectué à partir d’un réseau de perméances judicieusement paramétré.Que ce soit pour la modélisation thermique ou la modélisation électrique, chacun des modèles a été conçu pour avoir un temps de calcul faible, tout en restant le plus précis possible sur la prédiction des performances. Ceux-ci ont à chaque fois été confrontés à des données expérimentales, ou à d’autres techniques de modélisation plus fines de façon concluante. / Though the Stirling engine was invented two centuries ago, it has never really grown to a fully marketable level. The current energy context has renewed the interest in this engine. Their ability to work with any external source of heat allow them to be associated with renewable energy such as solar energy. Beyond its ecological benefits, the invention of the free piston Stirling engine by W. Beale at the end of the 1960’s further increased the interest in Stirling engines. This novel structure allows the engine to operate without mechanical interface between pistons, which are driven entirely by the gas or other spring forces. In such engines, the pistons kinematics and the system thermodynamics are intimately coupled, thus increasing the complexity of the complete system computer modelling.This PhD presents an innovative technique to model a free piston Stirling engine that takes into account the coupling between the system thermodynamics and the mechanical response of the free pistons. This technique has been named LHA5V standing for Linear Harmonic Analysis 5 Volumes. It consists in splitting the engine in five open sub-systems: the compression and expansion spaces, the heater, the cooler and the regenerator. We hypothesize that the state variables are periodic, and the model then determines the variations of their mean, amplitude and phase values in order to satisfy the mass and energy conservation equations. This PhD also presents a model for a linear electric alternator, which can be coupled to the power piston. This electrical model is based on an analytical calculation of the thrust between the stator and the magnets. Magnetic flux and induction in the iron are determined by a carefully tuned reluctance network.Both thermal and electrical models have been designed to optimize both computing time and accuracy. The models generated have systematically been compared to experimental data or finite element analysis, with satisfactory results.

<p>The introduction of hybrid powertrains has made it possible to utilise unconventional engines as primary power units in vehicles. The free-piston energy converter (FPEC) is such an engine. It is a combination of a free-piston combustion engine and a linear electrical machine. The main features of this configuration are high efficiency and a rapid transient response.</p><p>In this thesis the free-piston energy converter as part of a hybrid powertrain is studied. One issue of the FPEC is the generation of pulsating power due to the reciprocating motion of the translator. These pulsations affect the components in the powertrain. However, it is shown that these pulsations can be handled by a normal sized DC-link capacitor bank. In addition, two approaches to reduce these pulsations are suggested: the first approach is using generator force control and the second approach is based on phase-shifted operation of two FPEC units. The latter approach results in higher frequency and lower amplitude of the pulsations, which reduce the capacitor losses.</p><p>The FPEC start-up requirements are analysed and by choosing the correct amplitude of the generator force during start-up the energy consumption can be minimised.</p><p>The performance gain of utilising the FPEC in a medium sized series hybrid electric vehicle (SHEV) is also studied. An FPEC model suitable for vehicle simulation is developed and a series hybrid powertrain, with the same performance as the Toyota Prius, is dimensioned and modelled.</p><p>Optimisation is utilised to find a lower limit on the SHEV's fuel consumption for a given drivecycle. In addition, three power management control strategies for the FPEC system are investigated: two load-following strategies using one and two FPEC units respectively and one strategy based on the ideas of an equivalent consumption minimisation (ECM) proposed earlier in the literature.</p><p>The results show a significant decrease in fuel consumption, compared to a diesel-generator powered SHEV, just by replacing the diesel-generator with an FPEC. This result is improved even more by using two FPEC units to generate the propulsion power, as this increases the efficiency at low loads. The ECM control strategy does not reduce the fuel consumption compared to the load-following strategies but gives a better utilisation of the available power sources.</p>

The growing global demand for energy and environmental implications have created a need to further develop the current energy generation technologies (solar, wind, geothermal, etc.). Recovering energy from low grade energy sources such as waste heat is one of the methods for improving the performance of thermodynamic cycles. The objective of this work was to achieve long-term steady state operation of a Free-Piston Linear Expander (FPLE) and to compare the FPLE with the currently existing expander types for use in low temperature energy recovery systems. A previously designed FPLE with a single piston, two chambers, and linear alternator was studied and several modifications were applied on the sealing and over expansion. An experimental test bench was developed to measure the inlet and outlet temperatures, inlet and outlet pressures, flow rate, and voltage output. A method of thermodynamic analysis was developed by using the first and second law of thermodynamics with air as the working fluid. The experimental tests were designed to evaluate the performance of the FPLE with varying parameters of inlet air pressure, inlet air temperature, and electrical resistance. The initial and steady-state operation of the FPLE were successfully achieved. An uncertainty analysis was conducted on the measured values to determine the accuracies of the calculated parameters. The trends of several output parameters such as frequency, average root mean square (RMS) voltage, volumetric efficiency, electrical-mechanical conversion efficiency, isentropic efficiency, irreversibility, actual expander work, and electrical power were presented. Results showed that the maximum expander frequency was found to be 44.01 Hz and the frequency tended to increase as the inlet air pressure increased. The FPLE achieved the maximum isentropic efficiency of 21.5%, and produced maximum actual expander work and electrical work of 75.13 W and 3.302 W, respectively.

The re-entry space vehicles encounter high temperatures when they enter the earth atmosphere and the high temperature air in the shock layer around the body undergoes partial dissociation. Also, the gas molecules injected into the shock layer from the ablative thermal protection system (TPS) undergo pyrolysis which helps in reducing the net heat flux to the vehicle surface. The chemical species due to the pyrolysis add complexity to the stagnation flow chemistry (52 chemical reactions) models which include species like NOx, CO and hydrocarbons (HCs). Although the ablative TPS is responsible for the safety of re-entry space vehicle, the induced chemical species result in variety of adverse effects on environment such as global warming, acid rain, green house effect etc. The well known three-way-catalyst (TWC) involves simultaneous removal of all the three gases (i.e, NOx, CO, Hydrocarbons) present in the shock layer. Interaction of such three-way-catalyst on the heat shield materials or on the wall of the re-entry space vehicle is to reduce the heat flux and to remove the gases in the shock layer, which is an important issue. For the re-entry vehicle the maximum aerodynamic heating occurs at an altitude ranging about 68 to 45 km during which the vehicle is surrounded by high temperature dissociated air. Then the simplest real gas model of air is the five species model which is based on N2, O2, O, NO and N. This five species model assumes no ionization and no pyrolysis gases are emitted from the heat shield materials. The experimental research work presented in this thesis is directed towards the understanding of catalytic and non-catalytic surface reactions on high temperature materials in presence of strong shock heated test gas. We have also explored the possibility of using shock tube as a high enthalpy device for synthesis of new materials. In the first Chapter, we have presented an overview of re-entry space vehicles, thermal protection system (TPS) and importance of real gas effects in the shock layer. Literature survey on TPS, ablative materials and aerothermochemistry at the stagnation point of reentry capsule, in addition to catalytic and non-catalytic surface reactions between the wall and dissociated air in the shock layer are presented. In Chapters 2 and 3, we present the experimental techniques used to study surface reactions on high temperature materials. A brief description of HST2 shock tunnel is presented and this shock tunnel is capable of generating flow stagnation enthalpies ranging from 0.7 to 5 MJ/kg and has an effective test time of ~ 800 µs. High speed data acquisition system (National Instruments and Yokogawa) used to acquire data from shock tube experiments. The experimental methods like X-ray Photoelectron Spectroscopy (XPS), Scanning Electron Microscopy (SEM), X-ray diffraction (XRD), Raman and FTIR spectroscopy have been used to characterize the shock-exposed materials. Preliminary research work on surface nitridation of pure metals with shock heated nitrogen gas is discussed in Chapter 2. Surface nitridation of pure Al thin film with shock heated N2 is presented in Chapter 3. An XPS study shows that Al 2p peak at 74.2 eV is due to the formation AlN on the surface of Al thin film due to heterogeneous non-catalytic surface reaction. SEM results show changes in surface morphology of AlN film due to shock wave interaction. Thickness of AlN film on the surface increased with the increase in temperature of the shock heated nitrogen gas. However, HST2 did not produce sufficient temperature and pressure to carry out real conditions of re-entry. Therefore design and development of a new high enthalpy shock tunnel was taken up. In Chapter 4, we present the details of design and fabrication of free piston driven shock tunnel (FPST) to generate high enthalpy test gas along with the development of platinum (Pt) and thermocouple sensors for heat transfer measurement. A free piston driven shock tunnel consists of a high pressure gas reservoir, compression tube, shock tube, nozzle, test section and dump tank connected to a vacuum pumping system. Compression tube has a provision to fill helium gas and four ports, used to mount optical sensors to monitor the piston speed and pressure transducer to record pressure at the end of the compression tube when the piston is launched. Piston can attain a maximum speed of 150 m/s and compress the gas inside the compression tube. The compressed gas bursts the metal diaphragm and generates strong shock wave in the shock tube. This tunnel produces total pressure of about 300 bar and temperature of about 6000 K and is capable of producing a stagnation enthalpy up to 45 MJ/kg. The calibration of nozzle was carried out by measuring the pitot tube pressure in the dump tank. Experimentally recorded P5 pressure at end of the shock tube is compared with Numerical codes. Calibrated pressure P5 values are used to calculate the temperature T5 of the reflected shock waves. This high pressure and high temperature shock heated test gas interacts with the surface of the high temperature test materials. For the measurement of heat transfer rate, platinum thin film sensors are developed using DC magnetron sputtering unit. Hard protective layer of aluminum nitride (AlN) on Pt thin film was deposited by reactive DC magnetron sputtering to measure heat transfer rate in high enthalpy tunnel. After the calibration studies, FPST is used to study the heat transfer rate and to investigate catalytic/non-catalytic surface reaction on high temperature materials. In Chapter 5, an experimental investigation of non-catalytic surface reactions on pure carbon material is presented. The pure carbon C60 films and conducting carbon films are deposited on Macor substrate in the laboratory to perform shock tube experiments. These carbon films were exposed to strong shock heated N2 gas in the shock tube portion of the FPST tunnel. The typical shock Mach number obtained is about 7 with the corresponding pressure and temperature jumps of about 110 bar and 5400 K after reflection at end of the shock tube. Shock exposed carbon films were examined by different experimental techniques. XPS spectra of C(1s) peak at 285.8 eV is attributed to sp2 (C=N) and 287.3 eV peak is attributed to sp3 (C-N) bond in CNx due to carbon nitride. Similarly, N(1s) core level peak at 398.6 eV and 400.1 eV observed are attributed to sp3-C-N and sp2-C=N of carbon nitride, respectively. SEM study shows the formation of carbon nitride crystals. Carbon C60 had melted and undergone non-catalytic surface reaction with N2 while forming carbon nitride. Similar observations were made with conducting carbon films but the crystals were spherical in shape. Micro Raman and FTIR study gave further evidence on the formation of carbon nitride film. This experimental investigation confirms the formation of carbon nitride in presence of shock-heated nitrogen gas by non-catalytic surface reaction. In Chapters 6 and 7, we present a novel method to understand fully catalytic surface reactions after exposure to shock heated N2, O2 and Ar test gas with high temperature materials. We have employed nano ZrO2 and nano Ce0.5Zr0.5O2 ceramic high temperature materials to investigate surface catalytic reactions in presence of shock heated test gases. These nano crystalline oxides are synthesized by a single step solution combustion method. Catalytic reaction was confirmed for both powder and film samples of ZrO2. As per the theoretical model, it is known that the catalytic recombination reaction produces maximum heating on the surface of re-entry space vehicles. This was demonstrated in this experiment when a metastable cubic ZrO2 changed to stable monoclinic ZrO2 phase after exposure to shock waves. The change of crystal structure was seen using XRD studies and needle type monoclinic crystal growth with aspect ratio (L/D) more than 15 was confirmed by SEM studies. XPS of Zr(3d) core level spectra show no change in binding energy before and after exposure to shock waves, confirming that ZrO2 does not change its chemical nature, which is the signature of catalytic surface reaction. When a shock heated argon gas interacted with Ce0.5Zr0.5O2 compound, there was a change in colour from pale yellow to black due to reduction of the compound, which is the effect of heat transfer from the shock wave to the compound in presence of argon gas. The reduction reaction shows the release of oxygen from the compound due to high temperature interaction. The XPS of Ce(3d) and Zr(3d) spectra confirm the reduction of both Ce and Zr to lower valent states. The oxygen storage and release capacity of the Ce0.5Zr0.5O2 compound was confirmed by analyzing the reduction of Ce4+ and Zr4+ with high temperature gas interaction. When Ce0.5Zr0.5O2 (which is same as Ce2Zr2O8) in cubic fluorite structure was subjected to strong shock, it changed to pyrochlore (Ce2Zr2O7) structure by releasing oxygen and on further heating it changed to Ce2Zr2O6.3 which is also crystallized in pyrochlore structure by further releasing oxygen. If this heating is carried out in presence of argon test gas, fluorite structure can easily change to pyrochlore Ce2Zr2O6.3 structure, which is a good electrical conductor. Due to its oxygen storage capability (OSC) and redox (Ce4+/Ce3+) properties, Ce0.5Zr0.5O2 had been used as oxygen storage material in three-way-catalyst. Importance of these reactions is that the O2 gas released from the compound will react with gas released from the heat shield materials, like NOx, CO and hydrocarbon (HCs) species which results in reduction of temperature in the shock layer of the re-entry space vehicle. The compound Ce0.5Zr0.5O2 changes its crystal structure from fluorite to pyrochlore phase in presence of shock heated test gas. The results presented in these two Chapters are first of their kind, which demonstrates the surface catalytic reactions. In Chapter 8, we present preliminary results of the oxygen recombination on the surface of heat shield material procured from Indian Space Research Organization (ISRO) used as TPS in re-entry space capsule (Space capsule Recovery Experiment SRE-1) and on thin film SiO2 deposited on silicon substrate. The formation of SiO between the junctions of SiO2/Si was confirmed using XPS study when shock exposed oxygen reacted on these materials. The surface morphology of the ablated SiO2 film was studied using SEM. The damage induced due to impact of shock wave in presence of oxygen gas was analyzed using Focused Ion Beam (FIB) microscope. The results reveal the damage on the surface of SiO2 film and also in the cross-section of the film. We are further investigating use of FIB, particularly related to residual stress developed on thin films due to high pressure and high temperature shock wave interaction. In Chapter 9, conclusions on the performance of FPST, synthesis of high temperature materials, catalytic and non-catalytic surface reactions on the high temperature material due to shock-heated test gases are presented. Possible scope for future studies is also addressed in this Chapter.

Auf dem Gebiet der mobilen Arbeitsmaschinen und Nutzfahrzeuge zeigen aktuelle Arbeiten weltweit ein verstärktes Interesse an leistungsverzweigten Antriebskonzepten auf Basis elektrischer und hydraulischer Hybridlösungen. Die Kombination beider Technologien verspricht wartungsarme, energieeffiziente Antriebssyteme mit hoher Steuer- und Regelbarbeit sowie hoher Kraftdichte. Die primär erzeugte mechanische Antriebsleistung der Wärmekraftmaschine kann meist für die Arbeitsprozesse und zur Versorgung zugehöriger Hilfsfunktionen nicht direkt verwendet werden. Diese muss je nach Anforderungen gewandelt bzw. angepasst oder bedarfsgerecht mittels zusätzlichen, wiederaufladbaren Speichern bereitgestellt werden. Solche hybriden Lösungsansätze führen jedoch gegenüber konventionellen Antrieben zu einer steigenden Komplexität sowie einem erhöhten technischen Aufwand. Nach dem Stand der Technik erfolgt die Erzeugung hydraulischer und elektrischer Leistung mit Hilfe mindestens dreier Komponenten: Verbrennungsmotor, Hydraulikpumpe und Generator. Für künftige antriebstechnische Innovationen ist daher aus funktionellen und energetischen Gründen ein einfaches, preiswertes Primäraggregat zur gleichzeitigen, bedarfsgerechten Bereitstellung hydraulischer und elektrischer Leistung wünschenswert, welches unnötige Umwandlungsverluste vermeidet und zusätzlich Kosten spart. Das Forschungsprojekt „Theoretische Grundlagen zur Verknüpfung von thermohydraulischer und thermoelektrischer Leistungswandlung in einem Aggregat – Thermohydraulischer Lineargenerator“ befasst sich mit einer belastbaren Abschätzung der technischen Realisierbarkeit und des technischen Aufwands eines derartigen neuen Antriebskonzeptes mit frei wählbarer Bereitstellung hydraulischer und elektrischer Leistung auf Basis des Freikolbenprinzips. Die grundlegenden Untersuchungen widmen sich der Kopplung zweier unterschiedlicher Leistungswandlungen, einer stabilen Prozessführung sowie der Analyse und Bewertung der physikalischen Prozessgrößen in Bezug auf eine zukünftige Auslegung eines Prototyps. Der Beitrag erklärt das Grundkonzept, zeigt den aktuellen Stand des Projekts auf und stellt die zum gegenwärtigen Zeitpunkt vorliegenden Ergebnisse vor.

The introduction of hybrid powertrains has made it possible to utilise unconventional engines as primary power units in vehicles. The free-piston energy converter (FPEC) is such an engine. It is a combination of a free-piston combustion engine and a linear electrical machine. The main features of this configuration are high efficiency and a rapid transient response. In this thesis the free-piston energy converter as part of a hybrid powertrain is studied. One issue of the FPEC is the generation of pulsating power due to the reciprocating motion of the translator. These pulsations affect the components in the powertrain. However, it is shown that these pulsations can be handled by a normal sized DC-link capacitor bank. In addition, two approaches to reduce these pulsations are suggested: the first approach is using generator force control and the second approach is based on phase-shifted operation of two FPEC units. The latter approach results in higher frequency and lower amplitude of the pulsations, which reduce the capacitor losses. The FPEC start-up requirements are analysed and by choosing the correct amplitude of the generator force during start-up the energy consumption can be minimised. The performance gain of utilising the FPEC in a medium sized series hybrid electric vehicle (SHEV) is also studied. An FPEC model suitable for vehicle simulation is developed and a series hybrid powertrain, with the same performance as the Toyota Prius, is dimensioned and modelled. Optimisation is utilised to find a lower limit on the SHEV's fuel consumption for a given drivecycle. In addition, three power management control strategies for the FPEC system are investigated: two load-following strategies using one and two FPEC units respectively and one strategy based on the ideas of an equivalent consumption minimisation (ECM) proposed earlier in the literature. The results show a significant decrease in fuel consumption, compared to a diesel-generator powered SHEV, just by replacing the diesel-generator with an FPEC. This result is improved even more by using two FPEC units to generate the propulsion power, as this increases the efficiency at low loads. The ECM control strategy does not reduce the fuel consumption compared to the load-following strategies but gives a better utilisation of the available power sources. / QC 20101116

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One of the characteristics of the high speed ows over blunt bodies is the detached shock formed in front of the body. The distance of the shock from the stagnation point measured along the stagnation streamline is termed as the shock stand o distance or the shock detachment distance. It is one of the most basic parameters in such ows. The need to know the shock stand o distance arises due to the high temperatures faced in these cases. The biggest challenge faced in high enthalpy ows is the high amounts of heat transfer to the body. The position of the shock is relevant in knowing the temperatures that the body being subjected to such ows will have to face and thus building an efficient system to reduce the heat transfer. Despite being a basic parameter, there is no theoretical means to determine the shock stand o distance which is accepted universally. Deduction of this quantity depends more or less on experimental or computational means until a successful theoretical model for its predictions is developed. The experimental data available in open literature for spherical bodies in high speed ows mostly lies beyond the 2 km/s regime. Experiments were conducted to determine the shock stand o distance in the velocity range of 1-2 km/s. Three different hemispherical bodies of radii 25, 40 and 50 mm were taken as test models. Since the shock stand o distance is known to depend on the density ratio across the shock and hence gamma (ratio of specific heats), two different test gases, air and carbon dioxide were used for the experiments here. Five different test cases were studied with air as the test gas; Mach 5.56 with Reynolds number of 5.71 million/m and enthalpy of 1.08 MJ/kg, Mach 5.39 with Reynolds number of 3.04 million/m and enthalpy of 1.42 MJ/kg Mach 8.42 with Reynolds number of 1.72 million/m and enthalpy of 1.21 MJ/kg, Mach 11.8 with Reynolds number of 1.09 million/m and enthalpy of 2.03 MJ/kg and Mach 11.25 with Reynolds number of 0.90 million/m and enthalpy of 2.88 MJ/kg. For the experiments conducted with carbon dioxide as test gas, typical freestream conditions were: Mach 6.66 with Reynolds number of 1.46 million/m and enthalpy of 1.23 MJ/kg. The shock stand o distance was determined from the images that were obtained through schlieren photography, the ow visualization technique employed here. The results obtained were found to follow the same trend as the existing experimental data in the higher velocity range. The experimental data obtained was compared with two different theoretical models given by Lobb and Olivier and was found to match. Simulations were carried out in HiFUN, an in-house CFD package for Euler and laminar own conditions for Mach 8 own over 50 mm body with air as the test gas. The computational data was found to match well with the experimental and theoretical data