Group No: 07

Project Proposal
ME4202

Design and Development of Single Cylinder Two

Stroke Linear Engine
By

Share of
Index No. Name
work
120048X J.V.C.Bandara
120340K D.R.D. Liyanage
120644V H.A.H.N.Sumanasekara

Advisors names, associations and signature

Department of Mechanical
Dr.J.G.A.S.Jayasekara Engineering, University of
Moratuwa

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka

22nd July 2016

1 Introduction
The IC engine which is commonly in use has less than 40% efficiency. The major contribution
of inefficiency is caused by the cycle thermal efficiency and also there is a significant
contribution from energy fluctuation and the heavy mass acceleration and deceleration as well.
Also due to the horizontal force component created by the connecting rod (due to rubbing the
piston against the cylinder at small ending bearing) there occurs an energy loss, wear of
cylinder bore and piston and consequently reduce overall engine durability. Also at the TDC,
even though the maximum force is generated, the work done is very low due to low crank
angle. Linear engines which work without a crankshaft and a fly wheel and only have the
reciprocating motion are invented for overcome the above drawbacks of the conventional IC
engines.

2 Context
Developing such a system that can generate electricity without a crank shaft would bring the
IC engine technology to next generation. It has been recognized that the Free piston linear
engine concept convert chemical energy of fuel into electrical energy more efficiently [1].
From this, the kinetic energy generated by the reciprocating motion of the piston can be directly
converted into electrical energy using a linear alternator or generator as a further development.
Then there will be no use of flywheel, crankshaft or a connecting rod to convert reciprocating
motion into the rotational motion resulting no horizontal forces acting on piston therefore less
reaction forces acting among the surfaces of piston and cylinder bore. This would remarkably
increase the performance of hybrid vehicles and emergency power plants due to its lightness,
compactness and increased efficiency [2]. In addition the simplicity of the mechanism would
increase the manufacturability of the product even in a primitive manufacturing environment
with boring, lath and milling facility. Manufacturing of crank shaft and connecting rod usually
needed high end forging technology.

3 Research gap
The free piston engine concept was first presented by Pescar [3] in 1928. Since then there have
been many proposed designs for free piston concept by both many academic and automotive
industrial players as evidenced by many patents that have been published under this topic. The
most recently implemented engine was reported from Toyota in June 2014. It has a thermal
efficiency of 42.5% [4]. Also there are many other industrial players such as Volvo Technology
Corporation, Ford Global Technologies and more recently Mazda, Honda and General Motors
have carried out researches under this topic [5].

Even though it is said that free piston engine is usually restricted to two-stroke cycles, a split
cycle four-stroke version has also been patented [6].

Despite the interest of many research group under this topic, none of them has been able to
commercialize due to practical issues such as starting, piston motion control issue, vibration
issue, lubrication and etc. Therefore the concept has restricted itself in simulation-based studies
or havent stepped up from prototype stage. There is no clear path towards commercialization
1
of this design concept. However the reported developments that have been successfully
demonstrated are not also financially viable for Sri Lankan context. Thus leaving room to
design and develop a single cylinder liner engine which will be practically viable in Sri Lankan
context.

4 Aim and objectives

4.1 Aim
Design and development of a single cylinder two stroke linear engine which has an improved
thermal efficiency and overall performance.

4.2 Objectives
Develop prototype linear engine
Optimize ignition timing to maximize efficiency and/or power output
Thermal and mechanical performance assessment

5 Methodology
Comprehensive literature survey
Design and simulation of two stroke single cylinder gasoline engine that can be built using
available engine parts in the market
Determine the correct compression ratio and the maximum crank housing volume
Determine the spring specifications suitable for the engine
Develop a suitable ignition timing mechanism
Design and develop a brake horse power measuring apparatus
Design and develop a starting mechanism
Assemble all the accessories that are needed to run the engine
Run the engine at predefined speed and ignition set point
Measure the mechanical energy generated for given amount of fuel
Determine the maximum thermal efficiency of the engine at optimum ignition timing.
Analyse the magnitude and the resonance frequency of vibration.

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6 . Work plan

3
7 Budget
Item Amount (LKR)
Engine parts (Cylinder bore, Head, Piston, Piston rings) 10,000
Carburettor 5,000
Material (Aluminium, Steel) 15,000
Cooling fan 2,000
Spring 5,000
Spark plug 500
Manufacturing cost 20,000
Ignition timing mechanism 5,000
Total 62,500

8 References
[1] R. Mikalsen, Applied Thermal Engineering, A. P. Roskilly, Ed. University of Newcastle
upon Tyne, Newcastle upon Tyne NE1 7RU, United Kingdom, 2007.

[2] D. Carter and E. Wechner, "The Free Piston Power Pack: Sustainable Power for Hybrid
503 Electric Vehicles," SAE International, vol. 2003-01-3277, 2003.

[3] Pescara RP. Motor compressor apparatus, US Patent 1,657,641, 1928.

[4] M. Hanipah, R. Mikalsen, and A. Roskilly, "Recent commercial free-piston engine

developments for automotive applications." 2015. [Online]. Available:
http://eprint.ncl.ac.uk/file_store/production/208377/F450F3ED-AADC-4739-AE7F-
EE74B9C8D59C.pdf. Accessed: Jun. 21, 2016.

[5] K. Hidemasa, O. Yuichi, H. Yoshihiro, N. Kiyomi, and A. Kosuke, "Free-piston type

Generator (I)," Japan Patent JP2012202385A, 2012.

[6] R. Mikalsen and A. P. Roskilly, "A review of free-piston engine history and applications.,".
[Online]. Available: http://www.mikalsen.eu/papers/FPEreview.pdf.