Journal of Electrical and Electronics Engineering 111

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Linear Generator for a Free Piston Stirling Engine

OROS (POP) Teodora Susana, VADAN Ioan, POP Radu, BRAD Claudiu

Technical University of Cluj-Napoca, Romania

Faculty of Electrical Engineering, Department of Power Engineering and Management,
Memorandumului 28, 400114, Cluj-Napoca, teodoraoros_87@yahoo.com

Abstract. In this paper we present some aspects
about the design of a Stirling engine driven linear
generator. There are summarised the main steps of
the magnetic and electric calculations with
application to a particular case of a cogeneration
plant bassed on Stirling engine. The designed linear
generator is of fixed coil and moving magnets type.
There are presented and a finite element method
(FEM) simulation of magnetic field. The linear
generator design starts with the characteristics of the
rare earth permanent magnets existing on the
market.
internal combustion engines, at the Stirling engine,
fuel supply and flue gas discharge may be missing. If
a clean external heat source is used, the Stirling engine
can become an alternative to internal combustion
engines which emit some hydrocarbons and other
pollutans. The Stirling engines works after a repetitive
cycle in four-stroke which forming so-called Stirling
cycle (figure 1) [1].

Keywords: free-piston Stirling engine; linear

generator; magnetic field analysis.

I. INTRODUCTION

The Stirling engine is an example of the broader

class of thermal machines designed for to convert
thermal energy. Internal combustion engines, engines Fig. 1. Stirling cycle (P-V diagram), [1].
Otto or Diesel, uses a fuel combustion of inside
pressurised volume, while Stirling engine uses an In figure 2 is presented a Stirling engine with two
external heat source to heat the working fluid. The pistons and the four stages of the Stirling cycle [2].
heat may come from to the fuels of combustion, from The four-stages of the Stirling cycle are:
the sea, from the combustion of biomass or any other
source. Making it possible to run a Stirling engine is
the temperature difference. Compared with the

Fig.2 The four different stages of the Stirling cycle, [2].

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(1ĺ2) Isothermal compression – The gas is
compressioned at constant temperature. The piston on
the right has a role to compress, while the left piston
remains fixed. For to maintain constant temperature
the gas transfers the heat QC to the cold source at
temperature TC.
(2ĺ3) Warming at constant volume – At the
constant volume, the gas temperature is increased
from TC to TH. The piston down left and the right
piston rises so that the volume remains constant at V1.
The air not moving from right room to the left room.
At passage through wire mesh gas recovers the heat
stored in the wire mesh.
(3ĺ4) Isothermal expansion – The gas engine
extends at constant temperature. The left piston moves
down and the right piston remain fixed. For to
maintain the constant temperature, the working gas
absorbs heat quantity QH from a heat source.
(4ĺ1) Cooling at constant volume –At the constant
volume, the gas temperature decreases from TH to TC.
The left piston compresses and the right piston
expansions so that the volume remain constant.
Because the gas passes through a wire mesh, this gives
off its heat. Futher, the cycle repeats indefinitely
starting with 1-2.
The Stirling engines can be classificated into three
types: alpha, beta and gamma. Figure 3 displays an
outline of each type of engine [2].
The efficiency of this cycle is:
Fig. 3 The Stirling engines types: a) alpha, b) beta, c) gamma [2].
WH −WC pHVH − pCVC mRTH − mRTC
η= = = =
WH pHVH mRTH
(1)
T −T T
= H C = 1− H
TH TC
The Stirling engines for fuels are designed as
hermetically sealed units with the alternator
incorporated in a pressurised crankcase just like
hermetic compressors for refrigeration, where the
electric motor is incorporated in a hermetically
sealed unit. Only static seals are necessary and the
only connection from the inside of the hermetic
crankcase to the surroundings is the cable
connection between the alternator and the grid [4].
An innovative way of accomplishing the Stirling
cycle is employed in the free-piston engine. This type
of the Stirling engine is presented in the next
paragraph.
II. THE FREE PISTON STIRLING GENERATOR
In this configuration, the power piston is not
mechanically connected to an output shaft. It bounces
alternately between the space containing the working
gas and a spring (usually a gas spring). In many
designs, the displacer is also free to bounce on gas
springs or mechanical springs (figure 4).
This configuration is called the Beale “free-piston”
Stirling engine after its inventor, William Beale [3].
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 The working fluid is therefore moved out of the

compression space through the regenerator to the
espansion space. When the working space has no fluid
the dumping chambre pressure will force the piston
and the displacer to go back. In some free piston
engines instead of this gas spring is used membrane
spring or other planar springs. Now the gas will begin
to flow again from the espansion space to the working
space by heating and the cycle is repeating. This is a
simplified esplanation of how a free piston works. It
can be seen that free piston engines are self starting
Fig. 4 Basic components of Beale “free-piston” engines.
Stirling engine [3].
III THE STIRLING ENGINE DESIGN
Piston stroke, frequency, and the timing between
the two pistons are established by the dynamics of the The design stands with the developed power
spring/mass system coupled with the variations in formula [5]. Beale indicated that the power output of
cycle pressure. several Stirling engines observed could be calculated
To extract power, a magnet can be attached to the from the equation:
power piston and electric power is generated as it
moves past stationary coils [2]. These Stirling P = 0.015 ⋅ pm ⋅ f ⋅ V p (2)
engine/alternator units are called “free-piston” Stirling where: 0.015 is the Beale number, P is the engine
converters. power output in Watts, pm the mean cycle pressure in
In figure 5 is presented the constructive scheme of a bar, f the cycle frequency in Hz, and Vp is the
free piston Stirling engine which drives an electric displacement of power piston in cm3.
linear generator [5]. The Beale number was modified by West as
There is a big diversity of free-piston Stirling follows:
engines. This kind of Stirling engine has two spaces, a TH − TC
compression chambre and an expansion chambre, P = F ⋅ pm ⋅ f ⋅ V p ⋅ (3)
whose volumes are cyclically varied. All version of TH + TC
this type of engine comprise three separate masses, where the factor F=0.25-0.35 can be used for practical
piston, cylinder and the displacer. Usually, the use, TH is the hot side temperature and TC is the cold
cylinder is rigidly fixed to a solid foundation of so side temperature.
great mass as to represent an infinite mass compared From this we can calculate:
with the other two [6]. P T +T 200 766
Consider a free-piston Stirling engine presented in VP = ⋅ H C= ⋅ = 117cm3 (4)
F ⋅ pm ⋅ f TH − TC 0.25⋅ 3 ⋅10 180
figure 5.
Let the system be initially at rest in an arbitrary where P=200 W is the power rate of the engine as
position. design datum, pm=(0+6)/2=3 bar, f=10 Hz, TH=473 K
The pressure and the temperature are the same in all and TC=293 K.
the spaces. Now let the espansion space to be heated The oscilating amplitude must be as high as pole
by the heater. If the temperature in the espansion pitch, which has been chosen as high as permanent
space is increased, the presure in the working space magnet height:
will also be increased and the displacer and the piston A = τ = hm = 0.0133m = 1.33cm . (5)
will be moved in the cylinder, but the displacer The oscilating amplitude A give us the swept
accelerates more than the piston because it has a much volume of power piston.
lower mas (10:1). V p = A ⋅ Ap , (6)
where Ap is the power piston area:
V p 117cm3
Ap = = = 88cm 2 . (7)
A 1.33cm
Now we can calculate the power piston diameter:
4 ⋅ Ap 4 ⋅ 88
Fig. 5 Constructive scheme of a free piston Stirling dp = = = 10.6cm = 106mm . (8)
engine [5]. π π
1 - cylindre; 2 – expansion chamber; 3 - piston This dimension was used in the drawing of the
displacer; 4 - regenerator; 5 – piston rod pusher; 6 – designed “free-piston” Stirling engine presented in
compression chambre; 7 – working piston; 8– damping figure 6.
chamber; 9 –permanent magnet; 10 – electric generator
coil;
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B. The Coil Design

The indus coil design will be made according to the
voltage that is aimed to be induced in the coil.
We considered an induced voltage at 10 Hz
frecvency of U=24 Vca voltage. The magnetic flux by
this coil varies between + Φmax and -Φmax so that the
magnetic flux variations:
∆Φ = Φ max − (− Φ max ) = 2Φ max = 2 Bm Am . (11)
The permanent magnet area is:
π (D2 − d 2 ) π (402 − 202 )
Am = = ⋅10−6 m2 =
4 4 (12)
−6 2
= 942⋅10 m .
Now, the magnetic flux variation is:
Br
∆Φ = 2 Bm ⋅ Am = 2 ⋅ ⋅ Am = Br ⋅ Am =
2 (13)
−6 2 −6
= 1.2T ⋅ 942 ⋅ 10 m = 1130 ⋅ 10 Wb.
The turn voltage is:
∆Φ
e= = f ⋅ ∆Φ = 10Hz ⋅1.13 ⋅ 10−3Wb =
T , (14)
= 11.3 ⋅ 10−3V / turn
considering f=10Hz from mechanical design stage.
For a voltage of U=24Vef we will need:
2 ⋅U 2 ⋅ 24
N= = = 3000 turns. (15)
Fig. 6 The designed free-piston Stirling engine. e 11.3 ⋅ 10 − 3
The magnetic circuit window where the coil is
IV THE LINEAR GENERATOR DESIGN placed has the area:
Af = a ⋅ b = 20 ⋅ 30 = 600mm 2 (16)
A.The Magnet Circuit Design
The coil conductor cross-section area is:
This alternator is of the synchronous type with
excitation from the permanent magnets. From the A f ⋅ k1 600 ⋅ 0.6
figure 7 it can be seen that field line passes the air gap
sc = = = 0.12mm 2 , (17)
N 3000
for two times, so the necessary magnetomotive force where k1=0.6 is the winding filling factor.
is: Now we can calculate the fixed coil conductor
B0 1 diameter:
Fmm = ⋅ 2 ⋅δ = −7
⋅ 2 ⋅ 1 ⋅ 10−3 = 1592 A (9)
µ0 4π ⋅ 10 4 ⋅ sc 4 ⋅ 0.12
where B0=1T is the mean value of magnetic flux dc = = = 0.4mm. (18)
density in the air-gap, į=1mm is the air-gap lenght
π π
and ȝ0 is the magnetic permeability of the air.
V. LINEAR GENERATOR MAGNETIC FIELD
For the magnetization I chose two ring permanent
ANALYSIS
magnets of the type EURONEOS 40x20x13.3, which
have the properties presented in the table 1. . We will evaluate the magnetic induction in the air
gap by 2 methods:
TABLE I. The permanent magnets properties of the type 1) Analytic, with the reluctances method of
EURONEO 3 40X20X13.3
equivalent magnetic circuit;
Materi Br Hc BHmax D d h
al [T] [kA/m] [kJ/m3] [mm] [mm] [mm] 2) Numerical analysis of magnetic field, with
N35 1.2 868 280 40 20 13.3 two-dimensional finite element method.

The magnetomotive force of the one magnet will
be:
Fmm = H m ⋅ h = 500 ⋅ 0.0133 = 6,65kA (10)
Can be seen that 6.65kA=6650A>1592A, therefore,
the magnets were chosen correctly.
A. The Reluctances Method
In figure 7 is presented a magnetic field line in the
situation of maximum magnetic flux – with the
moving armature displaced in the lower position with
the maximum amplitude of vibration.
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Air-gap reluctance calculations [Ra]:

1 į 1 į
Ra = ⋅ = ⋅ =
ȝ 0 A p ȝ 0 ʌ ⋅ De ⋅ h p

1 1 ⋅10 −3
= ⋅ =, (22)
4 ʌ ⋅10 − 7 ʌ ⋅ 40 ⋅10 −3 ⋅14 ⋅10 −3
= 4.52 ⋅105 A / Wb
where:
• δ=1mm – întrefierul,
• hp=14mm the height of polar piece, and
• De=40mm the outer diameter of the moving
armature of the linear generator.
The equivalent reluctance of the magnetic circuit
(figure 8) is:
Re = Rmp + 2 ⋅ Ra = 112.4 ⋅105 + 2 ⋅ 4.52 ⋅105 =
(23)
= 121.44 ⋅105 A /Wb.
Fig. 7 The maximum magnetic flux line.
Now, we can calculate the maximum value of the
Fig. 8 shows the magnetic circuit suitable for a main magnetic flux:
magnetic field line. The magnetic reluctances of iron F 6650 A
parts of magnetic circuit have been neglected. Also,
ĭ max = mm = =
have been neglected the stray magnetic flux.
Re 121,44 ⋅ 10 5 A / Wb (24)
All the reluctances of the equivalent circuit have to = 55,95 ⋅10 − 5 Wb.
be determined based on the below formulas:
This value is very closed to the value used in the
1 l design stage of the linear generator
R= ⋅ , (19)
µ S
B Finite Element Method
µ = µ0 ⋅ µ r , (20) We used two-dimensional software FEMM (Finite
where: Elements Magnetic) delivered free by David Meeker
• µ - the magnetic permeability of the [7], used for defining, solving and post-processing 2D
environment, planar and axi-symmetric problem of magneto-statics
• µ0=4π*10-7H/m – the magnetic permeability (figure 9).
of the vacuum,
• µr - relative permeability of the environment
compared to vacuum,
• S - area of the active zone of the volume,
• l- length of the active zone.
Permanent magnet reluctance [Rmp] calculations:
1 hm 1 13.3 ⋅ 10 −3
Rmp = ⋅ = ⋅ =
µm Am 4π ⋅ 10− 7 942 ⋅ 10 − 6 (21)
= 112.4 ⋅ 105 A / Wb.

Fig. 8 Equivalent magnetic circuit. Fig. 9 The magnetic field calculation domain.
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The Maxwell equations adapted to this problem are: Can be seen that the magnetic flux of 0.005384 Wb
 ∇ × H = J    (25) is very closed to the magnetic flux calculated with
reluctances method 0.0005475 Wb.
 ∇ ⋅ B = 0    (26) In figure 11 is presented the magnetic flux density
 B = ȝ ⋅ H    (27) distribution in the air gap.

 B = ∇ × A    (28)
§ 1 ·
 ∇ × ¨¨ ⋅ ∇ × A ¸¸ = J  (29)
© ȝ (B) ¹
where:
• H is the magnetic field intensity;
• B is the magnetic flux density;
• A is the magnetic vector potential.

Were considered the following boundary conditions:

1) Dirichlet conditions A = 0, on the outer
boundary of the field and to the axis of symmetry;
∂A
2) Neumann conditions = 0 , conditions
∂n
implied by magnetic metal surface.
Mesh field is automatically created and is shown
also in figure 9. The permanent magnet is introduced
through equivalents curents calculated by soft, based
on magnetic material N40. The results of magnetic
field simulation are shown in figure 10.
Fig. 11 The magnetic flux density in the air gap.
It can be seen that the average value of magnetic
flux density in the air gap is very closed to the value
of 1 T taken in the design stage.
VI. CONCLUSIONS
In this paper a tubular type linear-generator for a
“free-piston” engine is analysed and designed. The
ring-shaped iron rotor with the rare earth axially
magnetized permanent magnets is used as magnetic
pole of the mover because in the case of simetric
structure the leakage is smaller than that of the flat
type one. Also, the quantity of copper coil is less and
there is no end coil than that in the case of flat-type
generator. A prototype of 200W of “free-piston” linear
generator is calculated and designed. This prototipe
will be manufactured in the near future.

REFERENCES

[1] D.G. Thombare, S.K. Verma, “Tehnological

development in the Stirling cycle engine”, Science
Direct Renewable and Sustainable Energy Reviews 12
(2008) 1-38, Elsevier, 2008.
[2] Ioan Vadan, Radu Munteanu, Sorin Pavel, Remus
Ghemes, Florina Leach, The Developing of a Biomass
Micro-CHP, Procc. of UECDA International
Conference, 27 – 28 November 2009, Arad, Romania.
[3] Beale, W., “Stirling Engines for Developing
Countries”, U.S. Energy for Rural Development, 1981.
[4] ***WUDAG DEZENTRALE ENERGIESSYSTEME,
“Biomass Stirling Prozess”,
www.stirling-energie.de/en/biomasse-stirling-prozess.
[5] Adrian Homutescu, “Introducere în Motoare Stirling”,
Cermi Publishing House, Iaúi, 2003.
[6] Walker G., Senft J. R., “Free piston Stirling Engines”,
Springer Verlag, Berlin, 1985,.
[7] FINITE ELEMENTS METHOD MAGNETIC,
Fig. 10 The magnetic field simulation results. http://www.femm.info