Engine Brochure.pdf

High Performance Free-Piston Stirling Engines

Unrivalled Performance | Energy Efficient | Compact | Robust | Long-Lived

Experience the Benefits of Unique Free-Piston Stirling Technology

Benefits of Patented Sunpower

Technology Over Kinematic or Other

Free-Piston Designs

Sunpower free-piston Stirling engines are based on

patented design features which have evolved into today ’ s

technology and an array of available prototypes.

Sunpower designs are highly differentiated from conventional

kinematic Stirling engines. Also, because Sunpower engines operate

on gas bearings, use compact linear alternators and have a

simple mechanical configuration, they offer significant

benefits over other free-piston designs.

By comparison, kinematic Stirling engines are complicated

and expensive to build, and require a lubricant, seals and

mechanical bearings which combine to restrict performance

and limit life. Also, power output is difficult to change in the

kinematic design.

Sunpower ’ s unique combination of gas bearings, compliance

and compact linear alternator delivers the highest efficiency,

lowest mass free-piston Stirling engines available.

Sunpower free-piston Stirling engine technology is protected

by more than 30 United States patents and 80 international

patents.

Product Development Support

Sunpower ’ s free-piston Stirling engine manufacturing

organization is supported by a vibrant R&D group who

work closely with customers to develop new solutions or

engineer Sunpower’s engines into new products. Sunpower

also maintains a healthy intellectual property/licensing business

which can offer customers unique and exclusive positions

to our intellectual property.

Sunpower ’ s free-piston technology is being applied in areas

such as cryocoolers and linear compressors, power generation

and household refrigeration. Some applications include the

world ’ s most efficient refrigerator on sale internationally; natural

gas-fueled household cogeneration systems scheduled to

enter the market in 2007; and nuclear space power systems.

The commercialization of innovative new technologies

enabling unique products requires partnerships and collabora-

tion. For any new product, Sunpower ’ s engineering team is

available to work directly with partners at all stages, from

proof-of-concept demonstration to design for manufacturer

and manufacturing start-up.

Sunpower Free-Piston Stirling Engine Prototype Availability

Prototype

Model

Power

(nominal)

Temperature

Ratio (Th/Tc)

Efficiency

Heat Source

Heat Rejection

Hermetically

Sealed

Mass

Dimensions,

Diameter x Length

in mm (nominal)

EE-35

42W e

2.7

32%

Electric Heater

Air/Water Cooling

1.4 kg

52 x 157

EE-35-H

42W e

2.7

32%

Propane/JP-8

Air/Water Cooling

Yes

0.6 kg

50 x 142

EE-80

95W e

3.0

36%

Propane Burner

Air/Water Cooling

3.7 kg

69 x 193

EE-80-H(*) 95W e

3.0

36%

TBD

Air/Water Cooling

Yes

1.0 kg

65 x 186

EG-1000 1000W e

2.7

32%

Propane Burner

Water Cooling

35 kg

270 x 435

Source: SY Kim., James Huth, James G. Wood; Performance Characterization of Sunpower Free-Piston Stirling Engines, Sunpower Inc.

(*) Projected Values.

For the latest information on Sunpower products, services, corporate news and our online library,

visit our Web site at www.sunpower.com.

Burner

Electric Heater/

Measured Performance, EE-35 and EE-35-H

EE-35 engine with pressure vessel removed

Measured Performance, EE-80 an d EE-80-H

EE-80 engines, opposed pair

Measured Performance, EG-1000

EG-1000 engine with

non-recuperative propane burner

Sunpower Advantages Over Conventional Kinematic

and Other Free-Piston Designs

Patented, non-contact gas bearing compliant design

—Compliant displacer floats on gas bearings,

allowing non-contact operation

—Eliminates lubrication

—Uses space-efficient planar spring

—Reduces number of critical alignments

—Simplifies manufacturing

—Improves efficiency

—Piston support on gas bearings enables

non-contact operation

Highly efficient, low-mass linear alternator with

permanent magnet for direct AC output

—Reduced weight through use of efficient copper coil

with no end turns and zero mean lamination flux

—Minimal power loss because moving magnets

never leave poles

Lightweight, compact size

—Workplace diameter is independent of

displacer spring

Unmatched power-to-mass ratio

Configurable to a variety of heat sources

depending on application requirements

New designs can be developed and engineered

into unique new products

Current commercial, military and aerospace

applications use three different prototypes that

are available for purchase

Sunpower Products and Fuel Source Alternatives

Product Development Potential

Fuel Source

Automotive pre-warmer, battery charger

Gasoline, diesel

Autonomous consumer and commercial appliances

Natural gas, LPG, propane

Electric generation, biomass

Wood pellets, unprocessed biomass

Electric generation, distributed, grid connected

Natural gas, LPG, propane

Electric generation, off-grid

Natural gas, LPG, propane

Electric generation, solar thermal

Solar, solar/natural gas hybrid

Fuel-fired battery

Butane, propane, methanol, kerosene/diesel

Fuel-fired UPS (uninterruptible power supply)

Butane, propane, kerosene/diesel

Heat pump, biomass fueled

Wood pellets, unprocessed biomass

Heat pump, residential

Natural gas, LPG, propane

Vehicle APU (auxiliary power supply)

Gasoline, diesel

Sunpower free-piston Stirling engines now in use or in process offer many product development

opportunities in diverse markets using a variety of fuels.

For more than 30 years Sunpower, Inc.,

the originator of free-piston Stirling engines, has developed

and delivered fully engineered prototypes and preproduction engines

for a variety of applications in aerospace, military, household

appliance and research industries.

Milestones in Free-Piston Stirling Engine Development at Sunpower

William Beale invents the free-piston Stirling engine and is awarded U.S. Patent 3,552,120

1971

RE-1000, the first mature free-piston Stirling engine; delivered

1978

Design, development and testing of machines from 35W to 7.5kW,

and proven operation on numerous heat sources including solar, gaseous

and liquid fossil fuels, biomass and heat pipes

1980 to

present

First demonstration of a tuned dynamic vibration absorber

1985

Demonstration of stand-alone diesel fueled free-piston Stirling engine

generator to the US Army, First use of a heat pipe heater head

1987

Demonstration of high-frequency engine operation (115Hz)

1988

Demonstration of balanced opposed configuration engine arrangement

1989

First successful application of on-sun solar powered free-piston Stirling engine

(development units run through 1994)

1989-

1994

Licensee completes field trial for first free-piston Stirling engine-based

household cogeneration appliance

2001

Manufactured cryocooler launched on the 2002 RHESSI mission

2002

Demonstration of and improvement on highest efficiency of

small free-piston Stirling engine achieved to date

2003-

2005

Demonstration of and improvement on the highest power per unit mass

of small free-piston Stirling engine achieved to date

2003 -

2005

Receipt of NASA funded program to develop next generation Advanced Stirling Convertor (ASC)

2003

Free-piston linear alternator technology available in household refrigerators

2003

Demonstration of dual opposed, low vibration free-piston Stirling engine configuration

at Space Technology and Applications International Forum

2004

Free-piston Stirling cooler technology commercially available

2004

Demonstration of 20% efficiency of JP-8 to electric power out in a prototype

Wearable Power Supply for the US Department of Defense (DoD)

2005

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