Steam Engine Specifications

=Summary=


 * Deliverable: a one cylinder prototype module with scalability, to constitute a single stage of a stageable system (compound or 3 stage) which uses the same module that is scaled to make other stages
 * System consists of cyliner, crank arm, mechanical valve, automatically adjusted cutoff ratio, and constitutes a Steam Engine Construction Set
 * Cutoff ratio controlled by closed loop electronic feedback with some type of linear actuator
 * Applications to stationary, mobile, and solar power

=Cost-Related Features=


 * Lowest materials cost for a given performance
 * Simplest to fabricate, therefore lowest fabrication cost
 * Advanced techniques of fabrication utilized only when necessary to achieve cost
 * Fabrication tooling preferably simple, but secondary to fabrication cost
 * Uses commonly available parts
 * Replicable
 * Materials cost of $50/hp

=Materials Calculations=


 * 20 pounds of weigh per horsepower

Steel weights .2833 pounds per cubic inch

=Flexibility and Performance=


 * Scalable in power output from 1 - 100 hp by scaling or adding modules
 * Power density of 1 hp/10 lb
 * Pressure up to 500 psi
 * Scalable cylinder dimensions, uncoupled staging, and tandem operation allows scaling of power and eficiency from 1-100 hp and up to 25% efficiency
 * Multiple cylinder, in-line configuration is possible by bolting several cylinders together



See the following for steam engine calculations:


 * Steam Engine Construction Set Calculations
 * Steam Engine Efficiency Calculations
 * Steam Engine Efficiency

=Lifecycle=


 * Long lifetime under continuous use (50 years)

=Ecology=


 * Compatible with stationary, solar, and mobile power applications
 * LifeTrac power source
 * Solar Power Generator heat engine
 * CHP with space heating

=Sources=


 * Steam Engine Specifications/Piston Ring Sources
 * Steam Engine Specifications/Cylinder Liner Sources
 * Steam Engine Specifications/Bearing Sources
 * Steam Engine Specifications/Valve Spring Sources

=Parts List=

The following list of parts is based on the initial set of technical drawings linked from Steam Engine Build Instructions.

Steam Engine Parts


 * Piston Assembly
 * Piston (1)
 * Piston Head (1)
 * Piston Stem (1)
 * Piston Stem Pin (1)
 * Piston Stem Pin Washer (1)
 * Piston Stem Pin Cotter (1)
 * Piston Rings (2)
 * Bump Valve Pins (2)
 * Connector Rod (1)
 * Coupler (1)
 * Rod (1)
 * Bearing Case Assembly (1)
 * Bearing Case Top (1)
 * Bearing Case Bottom (1)
 * Quarter Inch Bolts, 3/4" long (2)
 * Quarter Inch Nuts (2)
 * Quarter Inch Lock Whaters (2)
 * Cylinder Assembly
 * Cylinder Liner (1)
 * Cylinder Case (1)
 * Cylinder Pipe (1)
 * Cylinder Flanges (2) - Flanges are missing four bolt holes
 * Valve Seat Plate (1)
 * [Valve Seat Seal ???] - this is a thin, soft metal seal.
 * Cylinder End Mount (1)
 * Plate (1)
 * Flange (1)
 * Half Inch Base Bolts, 1" long (3)
 * Exhaust Plenum
 * Exhaust Plenum Elements (4)
 * Quarter Inch Plenum Bolts, 1.5" long (4)
 * Quarter Inch Plenum Lock Washers (4)
 * Quarter Inch Plenum Nuts (4)
 * Half Inch Cylinder End Bolts (8) - Bolts can be replaced by a threaded rod.
 * Half Inch Cylinder End Lock Washers (8)
 * Half Inch Cylinder End Nuts (8)
 * Valve Assembly
 * Valves (2)
 * Valve Springs (2)
 * Vavle Spring Base (2)
 * Valve Cover (1) - Cover could be extended to eliminate the mounting bracket
 * Valve Holder (1)
 * Valve Cover Plate (1)
 * Valve Cover Flanges (4)
 * [Valve Cover Seal ???] - this is a thin, soft metal seal.
 * Cylinder Mounting Bracket - has two base plate holes, but cylinder end mount has 3.
 * Upright Plate (1)
 * Flange (1)
 * Half Inch Base Bolts (2?)
 * Half Inch Valve End Bolts (8) - Bolts can be replaced by a threaded rod.
 * Half Inch Valve End Lock Washers (8)
 * Half Inch Valve End Nuts (8)
 * Other
 * Base Plate (1)
 * Oil Dribbler - TBD (1)

Crankshaft Parts


 * Shaft
 * Flywheel Shaft (1)
 * Drive Shaft (1)
 * Crank Assembly (1)
 * Crank Pin (1)
 * Crank Counterweight (2)
 * Crank Arm (2)
 * Nylon Bushings, 0.5" long (2)
 * Pillow Block Assembly (2)
 * Pillow Block Bearings (2)
 * Supoprt Element (1 - 2 total)
 * Support Base (1 - 2 total)
 * Support Rods (2 - 4 total)
 * Half Inch Pillow Block Bolts, 2" long (2 - 4 total)
 * Half Inch Pillow Block Lock Washers (2 - 4 total)
 * Half Inch Pillow Block Nuts (2 - 4 total)
 * Half Inch Base Bolts (2 - 4 total)
 * Flywheel Assembly (1)
 * Flywheel (1)
 * Collar (1)
 * Quarter Inch Set Screws, 0.5" long (2)

Techniques


 * Stock parts wherever feasible
 * Lathing for valves and other parts
 * Milling of exhaust plenum and other parts
 * Hole drilling
 * Cylinder boring may be necessary, depending on stock availability
 * Welding of parts in several places

=Specification Decisions=

There are a few key dimensions that need to be specified before the full dimensions of the engine and it's parts are known. These include:


 * Valve Gap - the amount of space open in the valves at top dead center.
 * Initially, we shall use 1/8" (0.125"). This can be adjusted by changing the valve pin length.
 * I.D. of a half inch bolt - needed to determine valve spring holes and valve stem diameter.
 * O.D. is 0.515", I.D. is 0.482". However, this might not be the size of the hole we need.  See valve spring size.
 * Cylinder clearance - space remaining in the bore at top dead center.
 * "Steam Engines" recommends 3-8% of the piston displacement, which is 4". If we assume 6%, this is a clearance of 0.24, which we can round off to 0.25 (1/4 inch).
 * Exhaust port locations - near bottom dead center
 * We will use 3.6" from T.D.C as the left edge of the exhaust holes, which shall be 0.25" in diameter..