Republic of the Philippines

BULACAN STATE UNIVERSITY

City of Malolos, Bulacan

DIY STERLING ENGINE

Baluyot, Ryza Jane A.

Castillo, Christine Joy F.
Goze, Pauline Nicole D.
Guilalas, Dexter Martin Z.
Montuya, Rizie Marie B.
Santos, Miracle Joy M.
Sotto, Ashley Allelie M.
Tolentino, Celestino L. III

BSEE – 2B

Submitted in Partial Fulfillment for the

Requirements of the Course Basic Thermodynamics
1st Semester, Academic Year 2024 – 2025

December 2024
 I. Introduction

Stirling engines are a kind of reciprocating external heat engine that uses heat from an external

source to power one or more pistons and produce useful work. They are very different from the

internal combustion engines found in most automobiles. In contrast to internal combustion engines,

which continuously take in and release gas, Stirling engines consistently employ the same gas.

Additionally, unlike conventional gasoline engines, Stirling engines don't involve explosions, which

makes them incredibly silent (Nice, 2024).

These appear to be significant benefits above a standard engine, but because they need external

heat instead of internal heat, they are less useful in most cars. It takes longer for heat from the external

source to enter the engines. Stirling engines have been found to be largely impractical in power plants

due to their low specific power, which means that the engine must be quite large to produce a

relatively small amount of power. This heat transfer makes the engine far less responsive than internal

combustion engines (Nice, 2024).

The Stirling cycle is a thermodynamic process that involves four main stages: isothermal

expansion, isochoric (constant volume) heat addition, isothermal compression, and isochoric heat

rejection. During these stages, the working gas (usually air, helium, or hydrogen) are alternately

heated and cooled, causing it to expand and contract, which drives the pistons. In the isothermal

expansion phase, the working gas is heated at a constant temperature by an external heat source,

causing it to expand and push the piston, doing work on the surroundings. Moreover, during the

isochoric heat addition phase, the gas is moved to a regenerator, where it is heated at a constant

volume, increasing its internal energy without changing its volume. In the isothermal compression

phase, the gas is cooled at a constant temperature, causing it to contract and pull the piston back,

completing the work cycle. Additionally, during the isochoric heat rejection phase, the gas is moved

back through the regenerator, where it releases heat at a constant volume, returning to its initial state

and ready to begin the cycle again.

The main components of a Stirling engine include the displacer, power piston, regenerator, and

heat exchangers. The displacer moves the working gas between the hot and cold regions of the engine.

It does not produce work directly but helps in transferring the gas to different temperature zones. The
power piston converts the expansion and contraction of the gas into mechanical work. It is connected

to a crankshaft, which translates the piston's linear motion into rotational motion. The regenerator is a

heat exchanger that temporarily stores heat from the working gas during the isochoric processes,

improving the engine's efficiency by reusing this heat in subsequent cycles. Heat exchangers transfer

heat to and from the working gas, enabling the thermodynamic cycle to continue.

In understanding these components and their roles, we can know how the Stirling engine operates

efficiently using external heat sources, such as a candle, to produce mechanical work. The use of a

candle as a heat source is particularly interesting because it provides a steady, low-intensity heat,

making it ideal for small-scale and educational projects. However, the lower heat output compared to

other sources limits the engine's power and efficiency.

II. Tools/Materials

Materials Tools

Tin Can Glue Gun

Compact Disc Lighters

Plywood Pliers

Spokes Saw

Steel Wool Scissors

Syringe Cutter

L Connector

Popsicle Sticks
 Candle

III. Procedure

1. Prepare the Tin Can (Engine Cylinder)

 Cut the tin can in half or make a hole at one end to insert the syringe piston.

 Smooth sharp edges with sandpaper or tape for safety.

 Insert the steel wool inside the can to act as a regenerator. Ensure it doesn’t block air

movement completely.

2. Build the Base

 Cut a rectangular piece of plywood as the base.

 Attach vertical supports made from plywood to hold the cylinder in place.

 Secure the can horizontally on the support.

3. Assemble the Piston and Cylinder

 Connect the syringe to the tin can's open end.

 Seal the connection with glue or epoxy to make it airtight.

 Ensure the syringe plunger can move freely and smoothly.

4. Create the Crankshaft

 Use spokes or thin rods to create a crankshaft mechanism.

 Attach the syringe plunger to the crankshaft using a wire or connector, allowing the piston’s

movement to turn the crankshaft.

 Install bearings or plastic tubing on the base to support the crankshaft and ensure smooth

rotation.
5. Attach the Flywheel

 Use part of a tin can or plywood to create a flywheel.

 Attach the flywheel to the crankshaft for rotational stability.

6. Position the Candle (Heat Source)

 Place the candle directly beneath the tin can’s bottom.

 Ensure the flame heats the can evenly but avoid overheating, as this could damage the

assembly.

7. Integrate the Dynamo

 Attach the dynamo to the flywheel or directly to the crankshaft.

 Connect wires from the dynamo to an LED or small load to test the electricity output.

8. Final Adjustments

 Ensure all moving parts (syringe piston, crankshaft, flywheel) move freely without friction.

 Tighten all connections and check for air leaks in the cylinder system.

9. Testing

 Light the candle and place it under the can.

 Observe as the air inside the can heats up, causing the syringe piston to move.

 The piston’s motion should turn the crankshaft, spin the flywheel, and power the dynamo.

10. Fine-tuning and Optimization

 Adjust the position of the heat source and the dynamo for maximum efficiency.

 Experiment with the amount of steel wool to optimize heat transfer and cooling.

IV. Documentation
V.
V. Discussion

Building a DIY Stirling engine using materials like a tin can, compact disc, plywood, spokes, a

syringe, and a candle is an innovative way to explore thermodynamics. However, during the first trial,

the engine failed to function, likely due to several factors. The candle may not have provided

sufficient heat to generate the necessary temperature gradient between the hot and cold sides, which is

crucial for the engine’s operation. Additionally, if the water in the tin can did not heat up properly or

the exterior was not cooled effectively, the required pressure changes for the piston movement could

not occur. Leaks in the connections, such as around the syringe or tubing, could have reduced the

pressure difference, further hindering the engine. Misalignment of components like the spokes,

syringe, or flywheel could have introduced friction, preventing smooth motion, and the flywheel itself

might not have been properly balanced, disrupting its ability to store and release energy. The water

level in the tin can also play a key role; if it was too low, there may not have been enough steam or air

expansion, and if too high, the volume for expansion might have been restricted. Finally, excessive

friction between moving parts could have absorbed energy, preventing the engine from functioning.

By addressing these issues—improving heat source consistency, ensuring airtight seals, aligning

components, balancing the flywheel, and reducing friction—the engine’s performance can be

improved, offering a more successful demonstration of thermodynamic principles.

On the second attempt, the DIY Stirling engine showed remarkable improvement. By replacing the

steel wool with fine iron wool, the heat transfer efficiency increased significantly. This change

allowed the engine to achieve the necessary temperature gradient between the hot and cold sides more

effectively. The candle provided a consistent heat source, ensuring that the water in the tin can heated

up properly, creating the required pressure changes for the piston movement.

Ensuring there were no air leaks was another crucial step. By meticulously sealing all connections,

including around the syringe and tubing, the pressure difference was maintained, allowing the engine

to function smoothly. The alignment of components, such as the spokes, syringe, and flywheel, was

carefully adjusted to minimize friction. This adjustment ensured that the flywheel was properly

balanced, enabling it to store and release energy efficiently. The water level in the tin can was also

optimized. By maintaining an appropriate level, there was enough steam or air expansion to drive the
 piston without restricting the volume for expansion.

Additionally, reducing friction between moving parts helped in conserving energy, allowing

the engine to operate more effectively. With these improvements, the Stirling engine successfully

demonstrated the principles of thermodynamics, showcasing the importance of heat transfer, pressure

changes, and mechanical alignment in its operation. This hands-on project not only provided a deeper

understanding of these concepts but also highlighted the importance of precision and attention to

detail in engineering.

VI. Output

Using a DIY Stirling engine to power a DIY Ferris wheel is a creative and exciting project that

combines basic principles of thermodynamics and mechanical engineering. A Stirling engine works

by turning heat energy into mechanical energy through the expansion and contraction of air or gas

caused by temperature changes. This makes it a unique and interesting choice for powering small

models. However, DIY Stirling engines often produce very little power because of their small size

and simple construction. To make this idea work, the Ferris wheel must be designed to fit the engine’s

power limits. Using lightweight materials like wood or plastic can help reduce the energy needed to

spin the wheel and hold up any things attached to it. The size and weight of the wheel must also be

carefully considered to make sure the engine can provide enough to turn it smoothly.

There are challenges that need to be solved for this setup to work well. For example, keeping the

engine cool is essential because it relies on a temperature difference to run. This might mean adding a

simple cooling system, like a steady supply of cold water. Reducing friction in the wheel’s moving

parts, like the bearings, is also important to avoid wasting energy. Making sure the engine and wheel

are properly aligned and connected will help transfer energy more efficiently.

Even though this project has some challenges, it is a fun and rewarding way to learn about how

energy and machines work. It encourages creativity and problem-solving, as well as hands-on

experience with designing and building. With careful planning and simple solutions, this project can

be a great way to explore engineering concepts while creating something unique and functional.
VII. Conclusion

In conclusion, combining a DIY Stirling engine with a Ferris wheel is a fascinating project that

brings thermodynamic principles to life. It demonstrates how external heat can be converted into

mechanical work using simple materials and creative engineering. However, the project also

highlights key challenges, such as maintaining a consistent temperature differential and ensuring

efficient cooling. Without proper cooling, the engine's performance can degrade, leading to reduced

power output and inefficiency. These limitations emphasize the importance of thermal management

and precise assembly in such systems.

Despite these challenges, the project provides an excellent opportunity for hands-on learning and

innovation. By addressing issues like friction reduction, airtight seals, and exploring alternative

cooling methods, the system's efficiency can be significantly improved. This project serves as a

stepping stone for understanding energy systems, offering insights into real-world engineering

problems and encouraging the development of sustainable solutions. It is a rewarding way to combine

creativity with practical knowledge, inspiring further exploration of mechanical and energy systems.

Additionally, integrating a DIY Stirling engine into a DIY Ferris wheel showcases the

ingenuity of combining thermodynamic principles with mechanical engineering. However, the project

highlights a key limitation of Stirling engines—maintaining a consistent temperature differential. The

engine's reliance on a steady cold-water source for cooling presents practical challenges, particularly

in ensuring efficient energy production. Without this cooling, the engine's performance can degrade,

leading to inefficiency and reduced power output.

For such systems, exploring alternative cooling methods or improving the engine's thermal

management could enhance its reliability and efficiency. While the concept is educational and

creative, it emphasizes the need to address real-world challenges in energy transfer and sustainability.

This project serves as a stepping stone for understanding energy systems, inspiring improvements,

and finding innovative solutions to power small-scale mechanical devices.

VIII. Review of Related Literature

Case Study of a Stirling Engineeric.ed.gov/'q=stirling engine. ERIC - Education Resources

Information Center.

https://eric.ed.gov/?q=stirling+engine&id=EJ1329810

Ej1314371. (n.d.). ERIC - Education Resources Information Center.

https://eric.ed.gov/?q=stirling+engine&id=EJ1314371

Stirling engine - Energy Education. (n.d.).

https://energyeducation.ca/encyclopedia/Stirling_engine

Stirling engines (Book). (1983, January 1). OSTI.GOV | U.S. Department of Energy Office of

Scientific and Technical Information.

https://www.osti.gov/biblio/6402372

Stirling engine design manual, 2nd edition. (2024, October 21). NASA Technical Reports Server

(NTRS). https://ntrs.nasa.gov/citations/19830022057

Stirling Engine. (n.d). | ScienceDirect.

https://www.sciencedirect.com/science/article/abs/pii/S1364032102000539