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John Corey
Clever Fellows Innovation Consortium, Inc.
302 Tenth St., Troy, NY 12180
518-272-3565, fax 51 8-272-3582
ABSTRACT
This paper describes recent results in aproject at KUBOTA to
develop a gas engine-driven Stirling heat pump using both
engine shaft power and engine exhaust heat source. The
design, simulation, and test results of the third prototype
three-cylinder machine (C-3) are presented.
The threecylindermachine is modeled as a combination of two Stirling
sub-systems, one a power producer and one a heat pump.
These have been separately optimized, then joined into the
three-cylinder heat-assisted heat pump case. Shaft power is
augmented by thermal power. Performance is effectively
controlled by the phase shifting of the third piston to adjust
the absorbing of thermal power. The test results of the C-3
prototype machine are given and are shown to compare well
with predictions made in the Sage simulation code.
INTRODUCTION
Under the sponsorship of the New Energy and Industrial
Technology Development Organization (NEDO), through a
contract with the Energy Conservation Center (ECC), KUBOTA
is developing the Multi-Tcmperature Heat Supply System (ECC
1995).
This system consists of a gas-fueled internal
combustion engine and a novel Stirling heat pump utilizing
shaft power and thermal power in a hybridof several cylinders.
The heat pump is mainly driven by engine shaft power and is
partially assisted by thermal power from engine exhaust heat
source. The heat pump includes a specialized cylinder, which
is heated by the exhaust gas of the driving engine and phased
to produce added mechanical power.
This arrangement
recaptures some of the waste heat in the exhaust to reduce shaft
power needed for driving the heat pump. The system is
controlled by phase shifting of the cylinder to match the
engine heat balance and to match heat demand characteristics.
The system simultaneous 1y sup p 1ies four-temperature heat
sources (263 K, 280 K, 3 18 K, and 353 K) for air-conditioning,
hot water supply, and refrigeration. ?his compares with other
heat pumps using helium in a g a s cycle, including Stirling and
Vuilleumier (VM) machines. They utilize either shaft power
1033
MOTOR
TORQUE
METER
HEATING DEVICE
,/
(263- 280K)
COLD
DC POWER
SUPPLY
L - HEX
H - HEX
COOLING
DEVICE (318K)
REGENERATOR
WITH PIPING
HEAT F L O W
Figure 2 shows a heat flow diagram of the three-cylinder heat
pump. The heat pump comprises two 2-cylinder Stirling subsystems: one between high andmedium temperature (H-M); one
between medium and low temperature (M-L). The M-L subsystem acts as a heat pump andthe H-M sub-system serves as a
power producer which assists with extra shaft power. The
downstream heat of the H-M sub-system, which is waste heat of
the sub-system, is also utilizedas an additional heating output.
Taking both shaft power and thermal power, the three-cylinder
produces coolingirefrigeration and heating water.
3 - CYLINDER
STIRLING
HEAT PUMP
COOLING /
REFRIGERATION
1034
FIGURE 3
SIMULATION
The three-cylinder heat pump was modeled as shown in Figure
4. The C-type three-cylinder model was modified from the
two-cylinder machine by adding the thirdcylinder (H-cylinder),
the second regenerator (H-M regenerator), and heaters (H-hex).
The M-Lsub-system was constructed as a Stirling cycle, whose
pistons were set in constant phase difference. The third
piston phase can be arbitrarily set. The H-M part was
connected to the M-L sub-system using a common midtemperature cylinder (M-cylinder) and a heat exchanger (Mhex).
The Sage simulation code has been applied to analyze and
optimize this model. The two sub-systems were separately
optimized, then joined in to the three-cy 1inder heat-ass i s ted
HOT HEAT FLOW
M-L REGENERATOR
H-M
REGENERATOR
.INDER
-@
..........
HCYLINDER
ABSORPTIONOF
THERMAL POWER
1035
power PVh, and the indicated shaft power PVnet arc plotted
there. The simulation results arc shown by continuous curves
in the same figure as well. PVnet is summation of PVs at Ccylinder, M-cylinder, and H-cylinder and it means net shaft
power. The indicated work from thermal power input had the
maximum value at the phase of 170 deg. At that phase, the
shaft power was most assisted by the thermal power. The
COPind-c derinedas the ratio of PVc to PVnet and the maximum
value was around the same phase.
The machine has two major features. The first is that the
assistedpower is varied by altering hot piston phase, in other
words, input ratio of shaft power to thermal power can b e
changed. When the system uses an engine, it can be operated
to accommodate with engine heat balance. The secondis that
the phase has a large effect on the cooling andheating capacity
as well. Capacity control of the heat pump is available by
changing the H-phase. The cooling andheating capacity can
be changedaround 30 % in upward anddownward from the best
efficiency operating point in this machine. Capacity control
of the heat pump by phasing is different from the conventional
capacity control by changing speed The simulation results
agree with the test results within 10% accuracy. PVc and PVh
in the simulations are nearly coincident with test results,
however PVm deviates from them. Then PVnet and COPind-c
as calculated results are not so g o o d lhe PVm in the test may
have phasing effects from local, unmodeled turbulence or
restrictions, especially near the three way mixing zone,
PV diagrams of C-cylinder, M-cylinder, and H-cylinder at the
mean pressure of 1.6 MPa and 600 rpm are shown in Figure 6.
The indicated work at each cylinder had a goodoval shape and
the presstire ratio is around 1 . I . The simulation results were
agreed well with the test results.
5.0
800
700
600
0
.O
z>
e
500
4.0
PVh
PVnet
,A
3.0
400
2.0
300
200
1.0
100
0.0
60
80
100
120
140
160
180
200
PHASE [DEG]
FIGURE 5 C-3 PROTOTYPE PERFORMANCE VS. PHASE
1036
220
1.75
1200,
-am
z>
0
0
r_
W
o
0
600
3
W
a
a
400
200
200
100
400
300
500
400
1000
800
-o
600
-A
>
a
400
6.0
PVC
Qc
PVm
Qm
PVh
PVnet
5.0
3.0 -
l.O
1.o
1000
1.5
2.0
2.5
-.
t
1.o
0-
0-
0.5
PRESSURE [MPa]
4.0
2.0
0.5
800
200 -
600
FIGURE 6 PV DIAGRAMS
PVC
QC
PVm
Qm
PVh
800 -
1000
1.5
CoPind-c
COPind-m
2.0
1
2.5
PRESSURE [MPa]
EFFECT OF REVOLUTION S P E E D
Figure 7 shows the speed dependence of the machine at the
mean pressure of 1.6 MPa, keeping 170 deg for the H-cylinder
phase. Qc, Qm, and PVh were almost proportional to the
revolution speed at this test range. The simulation results
shown by continuous or dottedlines agree with the test results.
The maximum cooling capacity was 500 W a n d the maximum
heating capacity was 900 W at the revolution speed of 1,000
rpm. The bayonet heat exchangers in cold and hot spaces
showed good performance and the efficiency defined as Q to PV
exceeded 85 YO.
The actual COPc andCOPm are not shown there and they were
decreased by the large mechanical loss in the prototype
1037
1038