Design of Free-Piston Linear Generator

Hydrocarbon fuels have high energy density compared to batteries (reference); hence, converting the energy of fuels through conventional engines into electrical energy with the help of rotary generators is a common practice. But this process involved lot of inefficiencies. Coupling of two new concepts, i.e. free-piston engine and linear electric generation, may prove to be an efficient way and can act as mileage range extender for electric/electrified vehicles. Idea behind this project was to use geometrical parameters of conventional single cylinder diesel engine and check if same parameters can be used for free-piston engine (FPE) using simulations. Conventional diesel engine CFD model was prepared in CONVERGE CFD software and was validated with experimental data. Same engine was then modified to simulate as a free-piston engine and the piston motion was analysed. To check efficient linear electric generation, a simple generator circuit was prepared with help of MATLAB–Simulink module. The electricity output was analysed adding a sample battery into the Simulink circuit. Based on the simulation results obtained, a free-piston layout for simple structure, proper balancing, and linear electric generator to avoid mechanical losses concluded as possible solution for efficient electricity generation