GOVERNMENT POLYTECHNIC COLLEGE

MATTANNUR

(Board of Technical Education, Kerala)

SEMINAR REPORT

ON

FIVE STROKE ENGINE

SUBMITTED BY

ANEES NK

(Reg. No: 15021418)

DEPARTMENT OF MECHANICAL ENGINEERING

2017-18
 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that this seminar report titled report FIVE STROKE ENGINE presented by

ANEES NK Register No.15021418 during the year 2017-2018 the partial fulfillment of

the requirement for the award of Diploma in Mechanical Engineering of the Department of

Technical Education Kerala.

Seminar Co-ordinator Head of Section

Internal Examiner External Examiner

 DECLARATION

I hereby declare that the report of the seminar work entitled “FIVE STROKE ENGINE”
which is being submitted to the Govt. Polytechnic College, Mattannur in partial fulfillment of the
requirement for the award of diploma in MECHANICAL ENGINEERING is a bonafide report of the
work carried out by me. The material contained in this report has not been submitted to any institute for
the award of any degree.

Place: Mattannur ANEES NK

Date: 14/01/2018
 ACKNOWLEDGMENT

I would like to take this opportunity to extend my sincere thanks to people who helped me to make
this seminar possible. This seminar will be incomplete without mentioning all the people who helped me
to make it real.

Firstly, I would like to thank GOD, almighty, our supreme guide, for bestowing his blessings upon
me in my entire endeavor.
I would like to express my deepest gratitude Mr. SHAREEF HUSSAIN. K.P(Principal GPTC,
Mattannur), Mr.RAJEEVAN.T (Head of Department Mechanical Engg.,Seminar co-ordinator), for the
help rendered by him to prepare and present this seminar in proper way.

Moreover I am very much indebted to Mr.SAMJYOTH KUMAR T.V(Lecturer

Mechanical,ClassTutor)Mr.VINODAN.M(Lecturer,Mechanical),Mr.RAMESAN.K(Lecturer,Mechanical
), Mr.SARATHLAL(Lecturer, Mechanical) for their advice.

I am also indebted to all my friends and classmates who have given valuable suggestion and
encouragement.

ANEES NK
CONTENTS

ABSTRACT -4

BACKGROUND -5

INTRODUCTION -6

CONSTRUCTIONAL DETAILS OF NEW CONCEPT ENGINE -7

WORKING CONCEPT AND OPERATING PRINCIPLE -11

TECHNICAL DATA -14

CALCULATION AND DETAILS -16

CONCLUSION -21

REFERENCES -23
FIVE STROKE ENGINE Page 4 of 23

ABSTRACT
In this paper a new design of an IC engine is presented which has better characteristic features than its
predecessors

and can add up to technological advancements in the field. Technically, the concept is to add one more
stroke in a classical four stroke cycle in order to extract more work. This design shows an IC engine which
has three cylinders

(two are high pressure cylinders and the third is comparatively low pressured) and totals five strokes.

The four stroke engine exhaust gases at high temperatures having energy which could be used further to
extract more work to increase the global efficiency and reduce emissions temperatures. With this concept
of extracting more work, a new design is made with the ultimate target of increased efficiency and
decreased structural weight.

It is found that, addition of one more stroke in a four-stroke IC engine results in increase of expansion ratio
and thermal efficiency. It is made possible with the help of an extended expansion stroke which is carried
out in a low

pressure cylinder which has larger volume compared to the two high pressure cylinders. The extended
stroke helps

in producing more power output and torque, consuming less amount of fuel-mixture and hence making it
more efficient. A five-stroke engine of total volume of 750cc can produce same power output as that of a
1200cc classical four-stroke engine. With the help of this new conceptual design, BSFC of 226gm/kW-hr
with an overall fuel conversion capacity of 36.1% can be achieved which could deliver an effective power
output of 40kW and torque

of 90N-m at 3500-4000rpm of working range. Also, this 20% lighter IC engine can give a brake power of
32.5kW

at 4000rpm. This new design has higher ratings and compact size, higher thermal efficiency, comparatively
lower emissions of harmful gases and low exhaust temperatures. The design is effective in certain aspects
and can be used

in various automotives with existing manufacturing technologies.

Keywords: Five-stroke, thermodynamic efficiency, lower emissions, higher ratings, lighter structure.
FIVE STROKE ENGINE Page 5 of 23

BACKGROUND

The internal combustion engines which are generally used in automobiles works on the principle of

a classical four stroke cycle which have been made in many different ways and configurations in

order to increase the power density and efficiency and to reduce the fuel consumption. The

introduction of turbo and supercharger concepts in order to increase the power density of the

engine has made appearances but the load pressures in them too are limited due to mechanical¹

and thermal stresses and geometrical factors¹ and also due to the uncontrolled ignition for the

gasoline types. The four stroke cycle has expansion and compression ratios which are almost

identical and in order to make an engine more efficient we require higher expansion ratios² and

lower compression ratios so as to limit the stresses due to mechanical and thermal factors. In

order to make a better and efficient IC engine these limitations should be overcome and this was

made possible with the help of introduction of a new cycle or a fifth stroke, also called as the

recycle³ stroke in the existing four stroke cycle. By this extra stroke a configuration has been

achieved which has independent or different expansion and compression ratios. The higher

expansion ratios² help in extracting more and more thermal energy to convert into mechanical

energy and lower compression ratios provides a mammoth range of load pressures. Hence, the

necessity to increase engine quality parameters and make it eco- friendly by reducing fuel

consumption gave birth to a new engine, called a ‘Five Stroke Internal Combustion Engines’.
FIVE STROKE ENGINE Page 6 of 23

INTRODUCTION

The twin-valve turbocharged direct injection five stroke internal combustion engine is the latest
technological advancement in the field of the automobiles with an emphasis on increasing the overall
vehicular efficiency. The efficiency of an IC engine is mainly linked with its expansion ratio which helps in
converting more thermal energy into mechanical energy and in order to make improvements in efficiency
of an engine the compression ratios cannot be decreased but the increase in the expansion ratios can
boost the efficiency of an IC engine. This non-symmetric configuration¹ of the cycles can avoid and
overcome the geometrical limits. The creative and innovative concept of having dual expansion cycles has
made possible to develop an engine with high efficiency and large power range extenders which gives
lower heat emissions and harmful gases. The engine generates the power output by the help of five
strokes which are injection, compression, power, extended expansion (recycle stroke), exhaust³. The
engine has two high pressure (HP) cylinders and one low pressure (LP) cylinder, the volume of the low
pressure cylinder is almost double¹ of that of the high pressure cylinder. The two high pressure compact
cylinders help in maintaining lower compression ratios and works on the principle of four stroke cycle.
While the low pressure cylinder helps in extracting more work by an additional expansion stroke by taking
the burnt fuel mixture from the high pressure cylinders which results in higher expansion ratios and lower
temperature of the exhaust emissions. Since, the engine exhales from only one cylinder and hence its
exhaust system can be made simpler and can also create more efficient impulse charging. The construction
details, working concept and principle and the technical advancements are then discussed in the paper
which is followed by the applications and conclusions.
FIVE STROKE ENGINE Page 7 of 23

FIVE STROKE ENGINE HISTORY

The 5stroke engine build in 2007 by the english company ILMORS

engineering ltd.was a simple test bed engine without any complex
engineering;it immediately produced a measured specific fuel
consumption of 226g/Kw h.This level of consumption is not achieved
by even the most modern OTTO-cycle engines.

In 2009 a German car manufacturer simulated a 5 stroke engine of

litres capacity using the GT-Power software and calculated specific fuel
consumption value of 204g/KWh.This value was based on a simple test
bed engine without modern engineering features such as eg.variable
value timing or direct injection.This value cannot be achieved by Otto-
cycle engines are able to achieve such low specific consumptions.
FIVE STROKE ENGINE Page 8 of 23

CONSTRUCTION DETAILS OF THE NEW CONCEPT ENGINE

The engine consists of three cylinders which are mounted on a single crankshaft which

rotates with a predetermined configuration required for the movement of the cylinders

during the different strokes at different instants of time.

As shown in the Figure 1 the engine block has three cylinder configurations. The latter

consists of two high pressure cylinders which works alternatively and have low volume

when compared to the low pressure cylinder which has almost double volume as that of

the high pressure ones. The low pressure cylinder is mounted in between the two high

pressure cylinders which work in a cycle coordinating with the two high pressure cylinders

and helps in providing more energy extraction by the help of an extra expansion stroke

boosting the overall efficiency of the engine

The figure 2 shows the exterior view of the five stroke engine block, made up of an alloy

which is manufactured by casting process and has space for three cylinders which are fitted

inside the chamber.

FIVE STROKE ENGINE Page 9 of 23
FIVE STROKE ENGINE Page 10 of 23

The figure 3 shows various important components of the engine assembly i.e., cylinders

(HP-1, HP-2, LP), connecting rods, cams, valves, camshaft, crankshaft, etc. along with the

respective degrees of freedom. It is clearly shown that the rotation of the shafts in required direction

ultimately helps in the movement of the valves as well as the cylinders to work in the

proper manner.

As shown in figure the five stroke engine works with the concept of two high pressure

cylinders working in a four stroke cycle and a low pressure cylinder in an alternate cycle to

give the power output. The reduction in many components..

FIVE STROKE ENGINE Page 11 of 23

WORKING – CONCEPT AND OPERATING PRINCIPLE

limiting the number of cylinders to three on the single shaft, the weight of the
engine is reduced significantly and leads to a more compact yet efficient engine.

The first stroke comprises of the direct injection of the air-fuel mixture into one
of the high pressure cylinder [HP-1] through the inlet channel [1] when the
piston is initially at the TDC and the inlet valve [3] is opened, the injection
causes longitudinal piston movement and it further moves to the BDC and
FIVE STROKE ENGINE Page 12 of 23

intake the fuel mixture and further expansion takes place. The piston is then
again moved to the TDC to a predetermined distance³ in order to complete the
compression stroke which helps in compressing the fuel mixture at the high
pressure which is required for the effective burning of the fuel, both valves
[3],[5] being closed.

After completing the compression stroke, the spark plug ignites the gasoline
mixture which is already at a very high pressure and this result into an explosion
due to which the piston moves to the BDC and this stroke of burning of the fuel
mixture is called as the power stroke. When the mixture is burned, the piston
movement takes place and it moves to TDC and the exhaust valve [5] is opened
in order to exhaust the burnt mixture. This burnt mixture is taken into a low
pressure cylinder [LP] which extracts more heat from the vapors exhausted at
very high temperatures from the high pressure cylinder [HP-1] by the help of
another stroke which is called as an extended expansion stroke during which
the exhaust valve [7] is closed and after completing one cycle the gases are
exhausted to the atmosphere through the exhaust channel [8]. Another high
pressure cylinder [HP-2] works in the similar manner but alternatively and the
burnt mixture is exhausted to the low pressure cylinder [LP] in an alternative
cycle. During the intake of the air-fuel mixture in the high pressure cylinder [HP-
1], the process of power generation takes place in the second twin cylinder [HP-
2] and the process continues vice versa. The low pressure cylinder [LP] consists
of only two cycles which are extended expansion and then ultimate exhaust to
the atmosphere.
FIVE STROKE ENGINE Page 13 of 23

The table [1], describes the sequences of the various strokes (1),(2),(3),(4),(5)
which helps in producing power output from the two cylinders [HP-1/2], [LP].
When there is an intake stroke taking place inside the first high pressure
cylinder [HP-1], the second twin cylinder [HP-2] generates power through a
power stroke and the low pressure cylinder is at the TDC exhausting the air-fuel
mixture to the atmosphere. When there is compression process taking place
inside first high pressure cylinder [HP-1], the second cylinder exhausts the burnt
mixture into the low pressure cylinder [LP] which processes an extended
expansion stroke in order to extract more amount of work from the mixture
which is already burnt and is at a very high temperature range. The three
cylinders work in the same order and hence, producing the continuous power
output in an effective manner and the cycles continues vice-versa.

This effective process helps in generating a power output of 40kW¹ as the upper
limit in the working range between 3500-4000 rpm¹ of the engine which is made
possible by the high expansion ratio. The peak torque of 160Nm and a
horsepower of over 185 per liter can be achieved by a 700cc three cylinder five
stroke engine. It can deliver a brake power output of 32.5kW¹ at the working
range of 4000rpm with a very low BSFC of 226g/kW-hr¹ with an overall
efficiency of 36.1%¹. The engine delivers a high power density and can deliver
the same power output with the volume of 750cc as a 1200cc classical four
stroke internal combustion engine could deliver which makes high power
density generation in more compact size and hence it results in the reduction of
the overall weight of the engine which can be up to 20% lighter. The extended
FIVE STROKE ENGINE Page 14 of 23

stroke also helps in lowering the exhaust temperature and further lower
emissions of harmful gases increasing the therm

The technical specifications of the typical 5-stroke engine are shown in the
Table 2. The engine consisting of three cylinders has an overall volume of
750cc(150+150+450) and the LP and HP cylinders have corresponding bore and
stroke dimensions as shown in the table.
FIVE STROKE ENGINE Page 15 of 23

Advantages
1-For gasoline engine the engine ,the engine has an expansion ratio near that of diesel

engine about 14:5:1

2-Adjustable compression

3-Higher mean effective pressure with less fuel due to expansion cylinder

4-Use standard engine parts no special one of a kind parts

5-A secondary cylinder provides an additional expansion process enabling extra work to be

extracted ,hence increasing thermodynamic efficiency

6-minimise the pumping work due to the downsizing effect from highly rated firing

cylinders

7-The compression ratio can be reduced to delay knock onset without a reduction in

perfomance Because the firing cylinders can be very highly rated the engine is relatively

compact

8-The fuel consumption does not rise as rapidly with increasing BMEP as retarding reject

more energy into the expansion cylinder

9-The energy uses 100% conventional technology and no new manufacturing techniques
FIVE STROKE ENGINE Page 16 of 23

CALCULATION & RESULTS

The engine was simulated in virtual environment to analyze the behavior at different load

conditions between the range of 5% to 100% at the engine speed of 4000rpm.

Fuel Economy

The calculated results shows that the range of fuel economy of 5-S vs. 4-S varies from 37.8%

(at 5% load) to 16% (at 100% load)v when the engine speed is of 4000 rpm
FIVE STROKE ENGINE Page 17 of 23
FIVE STROKE ENGINE Page 18 of 23

Current prototype is for motorcycle use :-

3 cylinder (two high power and one low power)

700cc 2HP cylinder

1478cc total 3 cylinders (HP and LP)

130horsepower @7000rpm

166Nm @5000rpm

226g/kWH
FIVE STROKE ENGINE Page 19 of 23

Disadvantages

1-Increased costs due unique design. not mass produced yet

2-two cam shafts per engine

3-two diffrent cylinder sizes

4-more complex than 2 cylinder engine

5-The entire construction requires current manufacturing technology

FIVE STROKE ENGINE Page 20 of 23

CONCLUSION

This paper presents the new and validated technological development in the design for the internal
combustion engines, the five stroke engine which has better characteristic features and is thermally more
efficient and delivers significantly good power output at a low BSFC. This new engine concept has higher
ratings and is 20% lighter has higher expansion ratios and is thermally efficient too. Moreover, it employs
existing manufacturing technology for its manufacturing and has extreme downsizing opportunity. The
overall fuel consumption is also decreased and the overall efficiency is increased by 36.1% which is
different at the different range of working of the engine. Its compact ignition chamber helps in reducing
the variation in the volume which can prevent an excessive temperature drop of the flame during the
combustion. This new design can lead to difficulty in designing mass equilibrium due to the cylinders
having different masses and needs a carefully designed cooling system because of increased heat loss
density in the HP cylinders. The maintenance cost might be high because of requirement of skilled labor to
operate the engine. Ultimately, it could be stated that this new concept of five stroke internal combustion
engine can be adopted in the automobile industry to lead towards an effective and sustainable
development. Since, the engine has more efficiency and exhausts gases at lower temperatures with
minimum content of harmful gases and vapors. Also, it is an environment friendly design which consumes
less amount of the primary energy and helps in contributing towards sustainable development.
FIVE STROKE ENGINE Page 21 of 23
REFERENCES

[1] A. Kéromnès , B. Delaporte , G. Schmitz , L. Le Moyne. Development and validation of a 5 stroke engine
for range extenders application. Energy Conversion and Management, 2014, 82, pp. 259–67.

[2] Marcin Noga, Bronis³aw Sendyka. Determination of the theorethical and total efficiency of the
fivestroke SI engine. International Journal of Automotive Technology, 26 November 2014, 15(7), pp. 1083-
89.

[3] Lennox G. Newman, Five stroke internal combustion engine, Patent US6776144B1, USA; Aug. 17, 2004.

[4] Marcin Noga, Bronisław Sendyka. New Design of the five-stroke engine, Journal of KONES Powertrain
and Transport,

2013, 20(1), pp. 239–46.

[5] Schmitz G., Five-stroke internal combustion engine, Patent US6553977B2, USA; April 29, 2003.

[6] Schmitz G., Five-Stroke Internal Combustion Engine-A new concept for internal combustion engines,
St.Vith 2011, Belgium;

5T Beschreibung & Studie.