Tin Can Stirling Engine
Tin Can Stirling Engine
Table of Contents
Step 1: Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 4: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 5: Displacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Intro: Tin Can Stirling Engine
How I built a hot air engine almost entirely from junk. I've wanted to build one of these ever since discovering stirling engines in about 2003. Spending the weekend
making things in Steveastrouk's workshop gave me the opportunity to make the precision parts I'd need, and I knew most of the engine was going to be made of
improvised materials, so decided to see if I could make the entire thing out of scrap or unwanted materials.
If you aren't familiar with how Stirling engines work, there are plenty of resources online- the Wikipedia page is a good place to start.
Step 1: Design
The "core" of a gamma stirling engine of this design is a large cylinder that holds the displacer, connected to a smaller power cylinder providing the power strokes. I
decided to follow Darryl Boyd's "walking beam" design, where the power cylinder sticks out of the side of the dis[placer cylinder, because it suited the materials I had and
it looks cool :)
I found that an aluminium drinks can would fit neatly inside a steel soup can, so decided to use that for the displacer on the grounds of being cheap, light and easy to
work with. The steel soup can provides a sturdy body for the engine and also meant I could ake the bottom removable to allow maintenance.
I found some decking to use as the base, some 1" x 1/2" pine to use as supports for the moving parts, and a piece of 3/4" aluminium strip to use as the beam. The
engine is a messy combination of metric and imperial units- that's what happens when you use scrap materials!
Two empty steel food cans, at least one with a tapering bottom
Displacer
An aluminium drink can that fits closely inside the soup can without touching the sides
Two thin metal discs (eg lids from food cans)
Power cylinder
Power piston *
Flywheel
Beam
About 12" of metal or wood thick enough not to bend too much
Frame of engine
Thin wood (1" x 1/2" or larger) for supports, at least 24" (600mm) long
A piece of plank at least 12" long and 4" wide (300 x 100mm) for the base
Other
Thin brass tube 1/8" inside diameter and steel rod 1/8" diameter- about 12" of each (the precise measurement of these isn't as important as the rod being a snug sliding
fit inside the tube)
Wire coathanger
Two terminal blocks
JB Weld or other high temperature epoxy
Fast-setting epoxy (eg Araldite)
Necessary tools
Hacksaw
Power drill
Wood saw
Desirable tools
Others have made pistons by casting JB Weld inside their chosen power cylinder. You can read more about that here- I didn't do this because I had the machined
piston/cylinder combo, but it seems to be quite a popular method.
The piston is a 20mm x 20mm solid cylinder with a 1/8" hole bored in one end. A short section of steel rod was glued into the hole, and a section of brass tube glued over
that. The end of the tube was flattened and drilled to 2.5mm to accept a conrod made of coathanger wire. In engine terms, this is the small-end bearing.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Step 4: Flywheel
The flywheel is a wheel that I think came from a VCR. I used it because the bearing ran smoothly and the wheel looks quite nice as a flywheel :) The axle hole for the
bearing was conveniently almost exactly the size of the brass tubing I had, so that would work for an axle.
I initially tried gluing a short piece of brass tubing to the surface of the wheel to act as a crank, but the glue bond between the metal surfaces was weak and kept
breaking. Drilling a small hole into the wheel and gluing a piece of coathanger wire into that made a much stronger crank. A piece of wood with a short section of brass
tubing fixed into a hole drilled through it provided a support for the flywheel.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Step 5: Displacer
The displacer is a section cut from an aluminium beer can, with lids taken from other cans glued over the ends to make a flat-ended cylinder. This made the displacer air-
tight, so to avoid the risk of it pressurising and exploding in the engine I made a small "breather" hole with a needle. The top end plate was drilled in the middle and a
section of steel rod glued into it. The steel rod I had is a sliding fit in the brass tubing, which offers low friction but an almost airtight seal, so was ideal for the displacer
rod seal.
The length of the displacer is important- it should take up about two thirds of the space inside the cylinder. I worked out how far the crank on my engine was going to
move (the "throw", about 20mm), and subtracted that from the length of the displacer cylinder (90mm) to find the largest size the displacer could be (70mm).
I actually glued the rod into the displacer with it inside the engine once I had assembled the displacer cylinder to make sure the two lined up- if everything was measured
with sufficient precision this would be unnecessary. I used JB Weld for this join as fast-setting epoxies tend to soften at high temperatures.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Step 6: Displacer cylinder
To make the displacer cylinder, I cut the bottom off a can with a can opener which removes the entire end of the can. I then cut the bottom two inches off another can of
the same size with a tapered end, which I could force into the first can to form an airtight seal, but which could be removed if I needed access to the inside of the cylinder
later.
The top of the displacer cylinder was drilled in the centre and a section of brass tubing glued in with JB Weld to form the displacer rod seal. A hole large enough to
accommodate the power cylinder was cut into the side using a rotary tool and the power cylinder glued in.
When assembled, a short section of brass tube was glued onto the end of the displacer rod, flattened and drilled like the power piston to provide a joint for the beam
conrod.
I also cut out the bottom of a tuna can and glued that around the top of the displacer cylinder to use as a water jacket for cooling, but this was actually less effective than
plain air cooling, and developed a leak that was letting water into the cylinder so I removed it.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Image Notes Image Notes
1. Small hole on top of displacer cylinder for displacer rod 1. Large hole cut into side of displacer cylinder to fit brass power cylinder
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Step 7: Connecting rods
The conrods are made of coathanger wire. Where a joint is only required to rotate a small amount these are simply 90 degree bends in the wire fit into 2.5mm holes, with
a dab of hot glue on the end to keep the wire in place. Where the conrods make a continuously rotating joint (where the power piston and beam conrods attach to the
crank on the flywheel) these were made of drilled brass pieces from a section of "terminal block" electrical connector.
These are a very convenient size and shape to join the end of a piece of wire perpendicularly to another piece. One of the screws was removed and a hole drilled
sideways all the way through the brass, and the other screw used to clamp the end of the conrod in the connector. I got this idea from reukpower's Coke Can Stirling
Instructable.
The conrods all have a Z-shaped bend in the middle which allows for length adjustment by tweaking the bends.
Image Notes
1. Use screw to clamp connecting rod in this end
2. Drill through both sides here to form the "bearing" for the crank
Image Notes
1. S-bend in conrods allows easy length adjustment
2. Wire "hooks" through drilled holes work fine for joints which don't rotate
much
3. Small drop of hot glue stops connecting rods from falling out of hinges
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Image Notes
1. Brass terminal blocks are used for bearings on the crank which undergoes
continuous rotation
Despite working out all the dimensions beforehand, my apparent inability to drill a hole straight through a piece of wood coupled with my cheap wobbly power drill
resulted in a certain amount of trial and error being applied to the placement of the engine parts.
Image Notes
1. 12" piece of decking plank
2. Aluminium strip (of unknown provenance)
In case the video embed doesn't work, the first run video is here on YouTube.
After all these mods, the engine runs more reliably than any fuel source I have to test it with :) It will run at approximately 150-200rpm on a decent candle flame, and has
run at nearly 500rpm when I accidentally overheated it slightly with a large meths burner. The engine is mechanically sound at that speed- my concern is the displacer
overheating and the epoxy that keeps it attached to the rod failing.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Image Notes Image Notes
1. Pennies glued to the back of the flywheel to increase angular momentum 1. The engine looking moody and steampunk-ish (except for the CD)
Related Instructables
Comments
50 comments Add Comment view all 78 comments
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Phil B says: Feb 24, 2011. 6:15 PM REPLY
Thank you for a very nice Instructable. Stirling engines are interesting, and I would like to learn more about them. Your Instructable provided some
information I have not seen in others on a Stirling engine. You also have some very clever adaptations of common items. I had the thought that layering
three or four CDs would probably also give you more mass for the flywheel.
I am in the process of gathering parts to built a large sterling something like this to run off my wood stove, I have my second VCR just ready to crack open to
see what goodies are inside.
My solenoid beam engine is a practice piece before I attempt to build a flash aluminium sterling.
Can you post any info more info or links to the design as this looks exactly the kind of design i have been looking for, I really like walking beams.
Jerry
Just realize that this power source it a very viable power source.
After all, it's simplicity provides a very simple source of power and makes it very efficient.
I'm sure the wheel was just pushed around for giggles and grins before someone realized they could use that thing.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
PKM says: Mar 5, 2011. 4:03 AM REPLY
It is beautifully simple, yes, but (in this scale) not really efficient or viable.
The temperature a stirling engine runs at determines how much of the heat you put in gets converted to work output- its efficiency. For a commercial
solar-powered engine, that might be 25%, but for the low temperature engines that run from the heat of someone's hand it's below 1%.
The useful output of an engine like this might be enough to run a few LEDs or a radio but it's never going to power your house. There are more efficient,
less junky engines around which can produce useful amounts of power but they need a machine shop to build and a wood stove or large solar dish to
power them, not a few candles.
I do oil the crank bearings and the sliding displacer rod- it's possible I hadn't done that when I recorded the video, but it doesn't squeak as much now.
That was only running on one candle, though. Heating it with a small cup of meths, it will run at several revolutions per second- it might go faster but I'm
afraid to let it run that fast in case something gets damaged in the process. I'll take a video of it running fast and post it in the comments when I have
time.
I think it was overheating at the time- with better cooling and a more suitable generator I figure I could get perhaps one or two hundred milliwatts out of it.
Efficiency is pretty poor, I think an average candle puts out something like a hundred watts of heat so we are talking about something like 0.1%. Not
great!
Europe has a lot of CHPs (Combined Heat and Power plants) installed, using biomass to generate heat and electrical energy in housing areas, base
stirling engines. Of course these engines by no way can be compared to the ones you will find at instructables.com, but these are real hitech produc
running 30,000 hours and more needing only a small amount of maintenance.
There are small CHPs (15 kW heat and 3 kW electrical energy), just take a look at
http://ec.europa.eu/environment/life/project/Projects/index.cfm?fuseaction=home.showFile&rep=laymanReport&fil=LIFE99_ENV_D_000452_LAYM
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Hungary based FlexEnergy is builing a generator (38 kW output) running on landfill gas (methane) only.
Now you can continue to state "...Stirling engines are at best a curiosity though..."
http://www.google.com/images?um=1&hl=en&safe=off&tbs=isch:1&&sa=X&ei=s7FrTY7PPIO88gaU4LyQCw&ved=0CC8QBSgA&q=40+kW+die
I think we need to distinguish between fantasy and reality but that's just me.
[pfred2: There is likely more steam piston engines still in operation than Stirling engines today. ]
Of course there is. Steam is still one of the most efficient and most powerful systems there is. If there wasn't a problem with steam
production and storage we'd still be using them in our cars. You're not making a case for yourself. How exactly do you think
nuclear power plants work? That's right...steam...
[pfred2: I think we need to distinguish between fantasy and reality but that's just me. ]
I guess the sources that Hebinho mentioned are fantasy and not reality? I don't think "we" need to distinquish between fantasy
and reality, I think just "you" do.
No I'm not making a case with you! Because you are an unreasonable individual.
I'm supposed to accept a few sources but it is OK for you to ignore the overwhelming number I present? At this point I really
don't care what you think.
[I'm supposed to accept a few sources but it is OK for you to ignore the overwhelming number I present? ]
Overwhelming number of what? You have produced zero evidence that "stirling engines are at best a curiosity".
pfred2 says:
Sure it is it, just takes more power to operate than can be gotten from it. If fusion reactor engineering impossibilities are ever ove
pennies from heaven on that day!
http://www.google.com/images?um=1&hl=en&safe=off&tbs=isch:1&&sa=X&ei=s7FrTY7PPIO88gaU4LyQCw&ved=0CC8QBSgA
That took all of a tenth of a second for our favorite search engine to cough up but you conveniently choose to ignore. Go argue s
with like extra terrestrials or the Easter Bunny. That ought to be a good one, least you'll have baskets pretty soon as proof!
& Don't argue the stupid position of proposing ethanol, that would require energy to make energy, wasting time &
power.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/
Vengence says: Mar 3, 2011. 4:36 AM REPLY
[pfred2: Sure it is it, just takes more power to operate than can be gotten from it. ]
No, it's not. You're basically saying so in the latter part of your statement. Will you ever stop being
wrong(Apparently not)? It's not supposed to take a continual energy feed to keep the reaction going. It's only
supposed to take energy to start the reaction, and it should keep going for as long as it's stable. You understand
what stable means right? ITER is expected to produce a minimum stable reaction of 480 seconds but could be as
much as 1,000 seconds, producing 5(on the low end) to 10(on the high end) times as much energy as was needed
to start the reaction.
[pfred2: That took all of a tenth of a second for our favorite search engine to cough up but you conveniently choose
to ignore. ]
You posted the same exact useless link again? That's proving that stirling engines are a curiosity how?(I'll give you
a hint: it's not) With the national average for diesel being $3.716 per gallon and some places as high as $3.964, tell
me again which one you think is actually more practical? Do you have to keep paying the sun to receive and
convert it's energy? A link to diesel generators proves nothing about stirling engines. You'd have to be delusional to
think the diesel generator is more practical.
You just choose not to see the relationship. They pointed out one example of a 37kW generator I pointed out
153,000 of similar in just one other technology. Now if diesel wasn't more practical then how come there are so
many more examples?
By the same example 100 years ago you would be saying coal powered steam engines were the only
solution earth ever needs, claiming petrol engines were a fad.
100 years before that, you would be mocking anyone even thinking anything but a horse could move a cart.
You would probably also be saying that since 90% of carts were drawn by horses, that those carrying
heavier loads which required bullocks to pull them should be regarded as imaginary?
[pfred2: Now if diesel wasn't more practical then how come there are so many more examples? ]
How about I answer your question with more questions? If diesel is more practical, why are there more
gasoline engines on the road today? Why are hybrids just now being sold when the technology necessary
to develope them has been around for at least 30 years?
The reasons are political, not reasons of practicality...
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Vengence says: Mar 12, 2011. 4:23 AM REPLY
Looks like I've decimated this debate. Sorry, couldn't help but rub it in your face. }B^P
[pfred2: You're obviously a coward who made up this "Vengence" account merely
to attack me being as you've done nothing else with it as all. Another easily
discernible FACT! ]
Like I said, the idiocy is overwhelming. You still don't seem to know what facts
are, and you're still just wrong. Are you ever right about anything in life? The real
fact is you can't even do something as simple as count. You do know Sep 24,
2007 comes way before Apr 14, 2009 right? Of course you don't; that was the
point I was making.
Decimated.
How this site is formatted I did not notice you had more than 2 comments
beyond the ranting you've done in this thread. But viewing them all now I see
you're always that way. You must also excuse my difficulty reading white text
on a white background. Fact is you're really not worth looking at too closely.
The less I know about you the better off I am!
Decimate
Like I said you're being a bit too optimistic. The only point you have is the one
on top of your head.
http://www.instructables.com/id/Tin-Can-Stirling-Engine/