8-Cylinder Radial Stirling Engine

The Stirling engine was first invented in 1816 by Robert Stirling as a safer and more efficient alternative to the steam engine. It is a closed-cycle regenerative heat engine which operates on the principle of thermal expansion and contraction of a sealed gas.

So how do these engines work? The illustration below shows a small Stirling engine that consists of two cylinders, which are the displacer cylinder and the power cylinder i.e., hot and cold. Both cylinder volumes are connected via a tube which means there is a fixed amount of working air inside. The pressure of this air can be altered by adding or removing heat.

The displacer piston is a loose fit inside the glass cylinder which allows air to flow around it but has a standard sliding fit in the lower section of the cylinder, whereas the power piston is a close sliding fit inside its cylinder. The pistons have connecting rods which are attached to a single crankshaft, with the displacer piston being phased 90° ahead of the power piston.

There is a flywheel connected to the crankshaft to aid engine momentum and an alcohol burner for the external heat source.

The Stirling engine has four phases which are heating, expansion, cooling and compression.

The air inside the displacer cylinder expands as it is heated up, which moves the displacer piston. Some of the heated air passes around the loose-fitting displacer and flows through the connection tube into the top of the power cylinder, this higher-pressure air will drive down the power piston.

Because the power cylinder is cold, the hot air is instantly cooled down which results in a pressure drop. This means less work is required from the power piston on the upward stroke to compress the cooler air back into the displacer cylinder, flywheel momentum helps to overcome resistance and the cycle can begin again.

As there is no combustion taking place these engines are very quiet and virtually emission free, and the ability to use the same gas repeatedly to generate power can prove to be more efficient than internal combustion engines.

The Teratek Stirling engine has 8 equally spaced displacer cylinders and 8 equally spaced power cylinders arranged radially around a vertical shaft. Each piston is connected via their respective connecting rod to an offset internal gear ring which is in constant mesh with a spur gear fixed to the shaft.

There are 2 internal gear rings and each gear ring is located on 4 cranks which constrain the gear rings to an orbital motion, which in-turn rotates the spur gears in the opposite direction. The displacer gear ring is phased 90° ahead of the power gear ring.

Aluminium spacers connect the displacer cylinders to the power cylinders and ensure correct alignment with both internal gear rings. A small diameter bore runs through each spacer for the sealed working air and requires O-rings for an airtight fit.

8 Burners filled with Ethyl alcohol provide the external heat source. Once the burners are lit it takes around 30-45 seconds to heat up sufficiently so that the power gear ring can be spun in a clockwise direction to get the engine running under its own power. It is worth noting that the position of the flame relative to the longitudinal axis of the glass cylinder will affect the engine performance.

As stated, the displacer gear ring is currently phased 90° ahead of the power gear ring, but Stirling engines can be phased between 70° and 120°. The phase angle on this engine can by adjusted by raising the vertical shaft to disengage the gears and then simply moving the displacer gear ring clockwise or counterclockwise by ‘X’ number of teeth, before lowering back the shaft for gear engagement.

My original design had the power cylinders on the bottom deck to keep them as cool as possible, but mounting the alcohol burners higher up required support brackets which wasn’t aesthetically pleasing. The current location of the power cylinders are far enough away not to be affected by the radiant heat from the alcohol burners. The original design also had the gear rings phased at 180° to provide a balanced engine, however this required small bore piping to be routed from each displacer cylinder to the power cylinder that’s positioned 90° from its axis. The increased working air volume (pipe length) would have probably reduced the overall performance.

The engine runs very smoothly with little noise and minimal vibrations as can be seen in the short video clip below. A reasonably heavy 120mm diameter flywheel is required to maintain the engine inertia.

This is an experimental design showcasing the use of internal gear rings for converting the reciprocating movement of pistons into rotational motion, replacing traditional crankshaft design. The efficiency can be considerably improved by changing various parameters like the volume of the working air, cooling of the power cylinders, adding a regenerator and alternative heat sources.

Although Stirling engines have been around a very long time it is worth remembering the advantages they offer over internal combustion engines. These include low emissions, low maintenance, low manufacturing costs, high efficiency and reliability. Also, the external supplied heat can come from various energy sources like solar, geothermal, biomass and waste heat.

For enquiries about this engine please email – info@teratek.co.uk – Thanks for stopping by, Mike.