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Thanks to Everyone Who Voted for My Engine !

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RodRico

Automotive
Apr 25, 2016
508
The results are in! My entry was in the Top 100 overall (of 868) and the Top 5 in the Aerospace and Defense category (of 115). The judging panel included 76 experts in their field from around the world. Though winning is always gratifying, I’m happy with the result. Thank you to all who voted!

By the way, the design continues to evolve based on inputs from my consultant and my own efforts to focus tightly on the aviation market (which will likely be last to be disrupted by battery electric systems), reduce risk, and cut prototyping costs. The first prototype will be a 50cc engine of 4.75" diameter and 3" thickness (including air cleaner and fuel injectors but not the electric motor/generator) having 8 cylinders completing 6 cycles each per revolution of the output shaft producing 3.3 HP at 2,626 RPM (low to eliminate the need for a propeller reduction unit) with 55% efficiency at up to 18,000 foot altitude. The engine will be machined using the $5,000 5-axis Pocket NC V2 mill and demonstrated using an off-the-shelf radio-controlled RQ-7 model (about 1/2 scale).

Many aspects of the design have come into clearer focus as I've continued working. I'll now concede that the engine is variable compression, that the use of two pistons for the HCCI process is not required from a thermodynamic perspective (the second piston serves primarily to effect a piston gated port in a position that facilitates uniflow scavenge while simultaneously facilitating rapid piston motion via its low mass). Note peak pressure is now below 220 bar to prevent ignition of lubricating oil, max temperature is below 2100K to prevent NOx formation, and ignition occurs after compression is complete in all cases.

 
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RodRico
Congratulations: I see your engine showed up on page 22 of the November Tech Briefs as having an honorable mention.
B.E.

You are judged not by what you know, but by what you can do.
 
Thank you Berkshire. I didn't know I'd be in the print mag. I wish I could download the issue, but I can't find it anywhere. :(
 
Rod,
Why don't you write to them at Tech Briefs Media Group , 261 Fifth Avenue, Suite 1901 New York New York 10016. Explain who you are and ask for a copy of the magazine.
Or you could call them at 212 490 3999.
B.E.

You are judged not by what you know, but by what you can do.
 
Berkshire,

Good idea, thanks! I used to work in aerospace and defense, and have also asked former collegues if anyone has a copy.

Rod
 
I'll wait till we see a running example, and proof test for durability etc.
 
Many of the engineers on my old R&D team said "until you have test results, you can't be sure it will work as you claim." They seem to have forgotten the way I used to get them work was by writing technical proposals describing things we hadn't yet built. They made a living for about 20 years off my selling ideas I could substantiate with preliminary analysis but not prove. Of course my customer was the military R&D labs, so they understood that starting something requires a leap of informed faith.
 
Now you are all set then.
B.E.

You are judged not by what you know, but by what you can do.
 
I will be interested to see how long the hydrodynamic cam followers survive, given the high surface speed and the varying curvature of the cams.

I wish you well with the challenges that await.


Mike Halloran
Pembroke Pines, FL, USA
 
Mike,

I'm interested too!

As part of my de-risking efforts and focus on the aviation market, I've cut RPM to 2,626 (just a convenient number... half 5252). That should go a long way in reducing cam issues.

I will be performing some critical experiments before building the full prototype (though at 50cc displacement, many would say it's already far from "full"). One of the first experiments will entail spinning the cams using electric motors and applying follower loads so I can measure cam friction (indirectly via reaction torque) and general operation. There will be other experiments in the area of full engine motoring friction, fuel spray, etc.

Thanks for your good wishes!

Rod
 
Congrats!

I would not mention you want to machine it on the Pocket NC machine however if you want to be taken seriously!

All the best,

Brian,

 
Brian,

Tool bias? LOL! A 50cc engine is a perfectly legitimate engine size for prototype, and there's no need for a large CNC to make it. My investors would be happy to see how carefully I'm planning the prototype effort in order to reduce cost (I'm the only investor, and I'm happy). Besides, if I can get what I need and also give a leg up to a guy with a great idea, why not? The Pocket NC started on Kickstarter and has done well for itself because it fills a need.

Rod
 
Small displacement cylinder and low RPM will be fighting an uphill battle against leakdown and heat transfer losses.

My 125cc motorcycle is happy in the 8,000 to 10,000 rpm range. It's not happy below 5000 rpm aside from idling ... idle speed is 1600 rpm.
 
Brian,

Heat transfer does suffer a bit from the small displacement and the fact that the stroke is so short relative to the bore. Average piston speed, however, is near that of a high performance crankshaft driven two stroke; each full cycle completes in only 60 degrees so 2,626 RPM so average piston speed is comparable to that of a crankshaft driven two stroke running at 15,756 RPM (likewise, idle speed at 200 RPM is equivalent to 1,200 RPM in the two stroke). The cams drive several risks in the design, but they do have three key advantages; they allow precise control of timing, enable multiple cycles per revolution, and eliminate the need for a transmission in many cases (but not a clutch).

Rod
 
I think, for the parts you're trying to make, you're going to be pretty disappointed in the accuracy and repeatability of the Pocket NC.

Not to say it isn't a cool machine, but it's not capable of holding close enough tolerances to, say, reliably produce slip fits on mating parts.
 
BrianGar amd jgKRI,

Comments regarding the Pocket NC drove me to do some research and I think I now understand why it may not be the right machine; it's very low mass with no visible means of vibration damping, and the cantilever trunnion table is likely not rigid enough for what I need. I'm now off learning more and considering alternatives (including Xometry or Proto Labs, though it would be more fun and I would learn more doing the machining myself).

Rod
 
I think, for what you're trying to achieve, that's a good move.
 
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