Automotive Stirling Engine Development Program Quarterly Technical Progress Report

This report covers the first 3 months effort of the Ford/DOE Automotive Stirling Engine Development Program, specifically Task I which is Fuel Economy Assessment. At the beginning of this contract effort the projected fuel economy of the 4-215 Stirling engine was 21.16 MPG with a confidence level of 29 percent. Since that date, the fuel economy improvement projection of the 4-215 Stirling engine has been increased to 22.11 MPG, with a confidence level of 29 percent. Collection of fuel economy improvement data is directly related to engine durability. Engine durability has been limited. Since September 19, 1977 a total of 47.7 hours of engine running time has been accumulated using two engine builds. Progress is reported in sub-task studies of burners, preheaters, engine drive, blower system, power control, air-fuel ratio control, cooling system, and cycle control. (LCL).

The objectives of the Automotive Stifling Engine (ASE) Development project were to transfer European Stirling engine technology to the United States and develop an ASE that would demonstrate a 30% improvement in combined metro-highway fuel economy over a comparable spark ignition (SI) engine in the same production vehicle. In addition, the ASE should demonstrate the potential for reduced emissions levels while maintaining the performance characteristics of SI engines. Mechanical Technology Incorporated (MTI) developed the ASE in an evolutionary manner, starting with the test and evaluation of an existing stationary Stirling engine and proceeding through two experimental engine designs: the Mod I and the Mod II. Engine technology development resulted in elimination of strategic materials, increased power density, higher temperature and efficiency operation, reduced system complexity, long-life seals, and low-cost manufacturing designs. Mod Ii engine dynamometer tests demonstrated that the engine system configuration had accomplished its performance goals for power (60 kW) and efficiency (38.5%) to within a few percent. Tests with the Mod II installed in a delivery van demonstrated a combined fuel economy improvement consistent with engine performance goals and the potential for low emissions levels. A modified version of the Mod II was identified as a manufacturable ASE design for commercial production. In conjunction with engine technology development, technology transfer proceeded through two ancillary efforts: the Industry Test and Evaluation Program (ITEP) and the NASA Technology Utilization (TU) project. The ITEP served to introduce Stirling technology to industry, and the TU project provided vehicle field demonstrations for thirdparty evaluation in everyday use and accomplished more than 3100 hr and 8,000 miles of field operation. To extend technology transfer beyond the ASE project, a Space Act Agreement between MTI and NASA-Lewis Research Center allowed utilization of project resources for additional development work and emissions testing as part of an industry-funded Stirling Natural Gas Engine program.