The Stirling engine is one of the most promising devices for the recovery of waste heat. Its power output can be optimized by several means, in particular by an optimized piston motion. Here, we investigate its potential performance improvements in the presence of dissipative processes. In order to ensure the possibility of a technical implementation and the simplicity of the optimization, we restrict the possible piston movements to a parametrized class of smooth piston motions. In this theoretical study the engine model is based on endoreversible thermodynamics, which allows us to incorporate non-equilibrium heat and mass transfer as well as the friction of the piston motion. The regenerator of the Stirling engine is modeled as ideal. An investigation of the impact of the individual loss mechanisms on the resulting optimized motion is carried out for a wide range of parameter values. We find that an optimization within our restricted piston motion class leads to a power gain of about 50% on average.

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The recuperation of otherwise lost waste heat provides a formidable way to decrease the primary energy consumption of many technical systems. A possible route to achieve that goal is through the use of Stirling engines, which have shown to be reliable and efficient devices. One can increase their performance by optimizing the piston motion. Here, it is investigated to which extent the cycle averaged power output can be increased by using a special class of adjustable sinusoidal motions (the AS class). In particular the influence of the regeneration effectiveness on the piston motion is examined. It turns out that with the optimized piston motion one can achieve performance gains for the power output of up to 50% depending on the loss mechanisms involved. A remarkable result is that the power output does not depend strongly on the limitations of the regenerator, in fact—depending on the loss terms—the influence of the regenerator practically vanishes.

Jet Electrochemical Machining (Jet-ECM) is a technology for quickly and flexibly generating micro structures and micro geometries in metallic parts independently from the material's hardness and without any thermal or mechanical impact [1]. In the process no tool wear occurs and the machined surface is very smooth [2]. The Jet-ECM process strongly depends on the shape of the electrolyte jet. In a previous study Hackert [3] built a numerical model with COMSOL Multiphysics based on a predefined jet shape. The simulated dissolution results of this model progressively differ from experimental results with increasing processing time. Hence, a multiphysics model which integrated fluid dynamics using the level set method for two-phase flow was created. Furthermore, in the present study the electric boundary resistance at the interface of workpiece and electrolyte is considered. According to the real Jet-ECM process the simulation is divided into two steps. In the first simulation step the jet is formed, and in the second simulation step the anodic dissolution is simulated by deforming the geometry. The dynamic behavior of the electrolyte jet could be simulated during the material removal process. So effects became visible which affect the machining results.

The ideal Stirling cycle describes a specific way to operate an equilibrium Stirling engine. This cycle consists of two isothermal and two isochoric strokes. For non-equilibrium Stirling engines, which may feature various irreversibilities and whose dynamics is characterized by a set of coupled ordinary differential equations, a control strategy that is based on the ideal cycle will not necessarily yield the best performance—for example, it will not generally lead to maximum power. In this paper, we present a method to optimize the engine’s piston paths for different objectives; in particular, power and efficiency. Here, the focus is on an indirect iterative gradient algorithm that we use to solve the cyclic optimal control problem. The cyclic optimal control problem leads to a Hamiltonian system that features a symmetry between its state and costate subproblems. The symmetry manifests itself in the existence of mutually related attractive and repulsive limit cycles. Our algorithm exploits these limit cycles to solve the state and costate problems with periodic boundary conditions. A description of the algorithm is provided and it is explained how the control can be embedded in the system dynamics. Moreover, the optimization results obtained for an exemplary Stirling engine model are discussed. For this Stirling engine model, a comparison of the optimized piston paths against harmonic piston paths shows significant gains in both power and efficiency. At the maximum power point, the relative power gain due to the power-optimal control is ca. 28%, whereas the relative efficiency gain due to the efficiency-optimal control at the maximum efficiency point is ca. 10%.