用油漆罐自制斯特林发动机

1、如何使油漆罐斯特林发动机Assembly Instructions (1)Make the Pressure ChamberThe finished pressure chamber will be 1 1/2” tall.  It will be made from the top and the bottom of the paint can.2011-4-20 05:19 上传下载附件(41.79 KB) 斯特林发动机 Remove the paint can lid and mark a line around the side that is exactly 5/

2、8 down from the top.  Mark another line around the outside that is exactly 5/8” up from the bottom.  Cut carefully along this line.  Cut carefully so that you also preserve the center section of the can.  You are going to use the center section to cut some add

3、itional parts.2011-4-20 05:19 上传下载附件(36.87 KB) 斯特林发动机 I use a sheet metal nibbler to cut my paint cans.  I drill a small hole (about 1/4”) to start the cut, insert the nibbler, then work my way around the can.2011-4-20 05:19 上传下载附件(40.11 KB) 斯特林发动机 Use tin snips to cut the center band of t

4、he paint can.  Make a vertical cut parallel to the weld that is in the side of the can. Measure and cut a strip of metal from the bottom of the can that is exactly 1 3/16” tall.  This cut is parallel to the cut made when you removed the bottom of the can.  This piece of

5、 metal will be used to make the pressure chamber sidewall.2011-4-20 05:20 上传下载附件(36.66 KB) 斯特林发动机 The pressure chamber sidewall will be glued to the inside of the top and bottom can parts.  Use the high temp silicone glue for this.  Glue all three pieces together at the same time

6、 (top, side, and bottom).  Start by gluing the sidewall to the inside of the pressure chamber top.  (The top is the piece with the lid.)  Use enough silicone to get an air tight seal everywhere.  I used a small piece of metal (about 1/2” x 1 1/8”) to reinforce

7、 the seam in the sidewall.  Set this assembly aside until the glue is completely cured.2011-4-20 05:21 上传下载附件(38.59 KB) 斯特林发动机 Make a DisplacerThe displacer is cut from a piece of 3/16” thick foam core poster board.  Measure the opening of the paint can.  The displacer

8、will have to fit into this opening, so it must be made a little smaller.  Use a compass to mark a circle on the poster board that is exactly 1/8” smaller in diameter than the opening of the paint can.  This will provide 1/16” clearance between the edge of the displacer and the op

9、ening of the can.  Cut carefully on the line.2011-4-20 05:21 上传下载附件(32.75 KB) 斯特林发动机 Cut a 3” piece of 1/16” music wire.  The easiest way to cut music wire is to score it with a file and then bend it and break it.  Good quality music wire is very hard and will break lik

10、e tool steel when it is scored and bent.  Place a 90 degree bend in the music wire 3/4” from one end.  This bend should be as close to 90 degrees as you can get it to be.  2011-4-20 05:21 上传下载附件(95.81 KB) 斯特林发动机 If you have a drill press you can use it to create a simpl

11、e jig for gluing the displacer rod to the displacer.  Simply drill a 3/32” hole through a flat board.  This hole will hold the displacer rod at the correct angle while the glue is curing.2011-4-20 05:21 上传下载附件(18.81 KB) 斯特林发动机 Press the long end of the displacer rod through the c

12、enter of the displacer and down through the hole in the jig.  Apply enough pressure to compress the poster board just a little bit around the center.  Fill the depression with epoxy glue and set it aside until the glue has cured.  Once the glue cures remove the assemble

13、d part from the jig and check the alignment.  The rod must be perpendicular to the surface of the displacer and in the exact center of the disk.2011-4-20 05:23 上传下载附件(29.37 KB)Prepare the Drive CylinderDrill a 7/16” hole in the center of the bottom of the film can.  This hole is

14、drilled to fit the short pipe nipple that is used to connect the drive cylinder to the pressure chamber lid.2011-4-20 05:23 上传下载附件(47.02 KB)Drill a hole in the center of the lid and carve it out until it is as large possible, until only a ring remains.  This ring will be used to seal the d

15、iaphragm to the drive cylinder.2011-4-20 05:23 上传下载附件(8.07 KB)Prepare the Pressure Chamber Lid Use a compass to find the center of the paint can lid.  To do this, set the compass to match the radius of the lid, and then use it to draw a line near the center of the lid.  Rotate th

16、e lid 90 degrees and repeat the process.  Continue to rotate the lid and draw marks with the compass until you have established the center point of the lid.2011-4-20 05:23 上传下载附件(42.12 KB)Drill a 1/4” hole through the center of the lid.Locate the position of the drive cylinder.  

17、The drive cylinder will be positioned as close to the edge of the lid as possible while still being mounted to the flat surface of the lid.  Mark the position of the hole using the film can as a guide.  Drill the hole with a 7/16” drill bit.2011-4-20 05:23 上传下载附件(37.3 KB)Make and

18、 Attach the Pressure Chamber GlandThe “gland” allows the displacer rod to pass through the top of the pressure chamber without causing a leak and without creating significant friction.  UHMW plastic is a good choice for this purpose.  It is naturally slippery.Cut a piece of UHMW

19、plastic to be 1” x 1” x 3/8”.  Locate the center of the square and drill a 1/16” hole using a drill press (if you have one).  Test the fit with a piece of 1/16” music wire.  If it is a snug fit that does not allow the music wire to slide easily, the hole must be enlarge

20、d.  Increase the drill size by 1/64” (to 5/64”) and drill it again.  Test the fit again.  1/16” music wire is actually slightly oversized and should be a good match with a 5/64” hole.Use RTV silicone to attach the gland over the center hole of the lid.  Keep t

21、he silicone away from the center hole in the UHMW as it will cause friction if it gets in the way of the displacer rod.Assembly Instructions (2)Attach the Drive CylinderUse RTV silicone, the pipe nipple, and the hex nuts to attach the film can to the paint can lid.  Place enough silicone a

22、round the hole to provide an air tight seal.  Set the hex nut on the inside of the lid so that very little (as little as possible) of the tube protrudes into the pressure chamber.  It is OK if a little extra tube protrudes into the film can.  But you want to maintain as

23、 much clearance for the displacer as you can.2011-4-20 05:27 上传下载附件(17.62 KB)2011-4-20 05:27 上传下载附件(42.25 KB)Make and Attach the CrankShaftTowerOpen a can of chili.  Heat and serve the chili.  Now get back to work on the engine.  Wash out the can and remove the bottom o

24、f the can with a can opener.Drill or punch two holes near the top of the can.  These will be your crank shaft bearings.  The holes should be about 1/64” larger than the diameter of your coat hanger wire.  The holes need to be as even as possible so that the crank shaft

25、is level when mounted.Cut access holes in the front and back of the can.  The access holes are about 2” wide and about 3 1/4” tall.  2011-4-20 05:27 上传下载附件(20.91 KB)The chili can is mounted to the top of the pressure chamber lid with small metal brackets and 5 minute epoxy. 

26、 Cut some small scraps of tin from the paint can scraps and bend them to 90 degrees and use them to brace the can in place.2011-4-20 05:27 上传下载附件(44.16 KB)The can needs to be aligned so that it is centered over the gland.  The crank shaft needs to be centered over the drive cylinder.&

27、#160; Place a piece of straight coat hanger wire in the bearing holes so that you can easily check the alignment as you glue the chili can in place.2011-4-20 05:28 上传下载附件(41.36 KB)Make a Shaped Drive Diaphragm from the Vinyl GloveThermoforming allows you to create a flexible vinyl diaphragm tha

28、t is shaped perfectly to fit the drive cylinder (film can) and the piston assembly.  This makes for a very efficient drive mechanism that is free of leaks and offers very little friction.Create a small vacuum table by drilling some 1/8” holes in a thin piece of wood and attaching a vacuum

29、cleaner hose.  It doesnt have to be fancy.  It just has to be big enough to support the pieces for this project.2011-4-20 05:28 上传下载附件(8.74 KB)Cut a film can to create a tube that is 3/4 inches long.  This will be the “form” for the thermoforming process.2011-4-20 05:28

30、 上传下载附件(6.69 KB)Cut a vinyl glove to create a flat sheet of vinyl fabric.  Stretch the vinyl over a frame to hold it flat for the thermoforming process.  In the illustrations here the vinyl is held on the end of an empty roll of masking tape.2011-4-20 05:28 上传下载附件(10.02 KB)Place

31、the form upright on the vacuum table and switch on the vacuum.  Use a heat gun or a hot hair dryer to warm the vinyl fabric.  When the fabric becomes relaxed and smooth it is ready to be pressed over the form.  Press it down onto the form and allow the vacuum to pull it

32、 to the shape of the form.  Remove the heat.  Allow 10 to 20 seconds for the vinyl to cool and then switch off the vacuum.  Remove the vinyl from the form and trim off the excess material.2011-4-20 05:30 上传下载附件(8.84 KB)The piston is made from two flat disks cut from a d

33、isposable coffee cup lid.  Use a quarter to trace two circles on the lid and carefully cut them out with scissors.  Mark the center of each disk and drill a hole to fit a #4-40 x 1” bolt.2011-4-20 05:30 上传下载附件(8.42 KB)Place one disk on the inside of the shaped diaphragm, and plac

34、e the other on the outside.  Place a small drop of silicone between the plastic disks and the vinyl.  Use a sharp object to carefully pierce the vinyl at the center of the disks.  Pass the #4-40 x 1” bolt through the outside disk, through the vinyl, and through the insi

35、de disk.  Thread a bolt onto the shaft and hand tighten it to hold the piston assembly and diaphragm together.  Place two more nuts on the bolt and set it aside until the glue cures.2011-4-20 05:30 上传下载附件(8.22 KB)Make the Crank ShaftCut a piece of straight coat hanger wire so tha

36、t it is 7” long.  The first crank will be over the center of the engine and will lift the displacer.  The second crank will be over the drive cylinder and will be connected to the drive piston. The two crank sections are offset by 90 degrees.  As the crankshaft rotates

37、the second crank is following 90 degrees behind the first crank.The first crank allows the displacer to move to within 1/16” of the pressure chamber top and bottom.  If your paint can went together like this one, there will be about 3/4” of travel available to the displacer.  But

38、 you should measure to be sure.  The formula for determining the size of the offset for the first crank is:  Offset=(DT-1/8”)/2 where DT = Displacer Travel.  So if your displacer travel is 3/4” it would look like this: Offset=(3/4”-1/8”)/2.  The answer in this

39、 case is 5/16”.  The first crank must be 5/16” from the centerline of the crank shaft.The second crank over the drive piston will have a 1/8” offset, which means the drive piston will have a total traveling distance of 1/4”.  Remember that there is a 90 degree offset between the

40、two cranks.Draw two parallel lines on a sheet of paper that are the same distance apart as the offset for the displacer crank.  Use these lines as a guide in bending the coat hanger wire.  Work with diligence to insure that all sections of the crankshaft are parallel and true.201

41、1-4-20 05:31 上传下载附件(8.42 KB)Draw two parallel lines on a sheet of paper that are 1/8” apart.  Use these as a guide for bending the section of the crank shaft that attaches to the drive piston.  Remember that there is a 90 degree offset between the two crank sections, and that eac

42、h segment must remain straight and true to help prevent friction and wobble.2011-4-20 05:31 上传下载附件(8.22 KB)Install the bent crank shaft in place on the chili can.Make and Attach the FlywheelUse sandpaper to remove the non-stick coating from the inside center of a paint can lid.  Use epoxy

43、to glue a small block of wood to this bare spot in the center.  After the glue cures you can carefully drill a hole in the wood.  (Use the compass again to find the center of the flywheel.)  This hole should be a snug fit for the coat hanger wire.  Attach the

44、flywheel to the end of the crank shaft.2011-4-20 05:31 上传下载附件(8.7 KB)Assembly Instructions (3)Make and Attach the Connecting Rods2011-4-20 05:32 上传下载附件(31.92 KB)The first step is to create an attachment point for the top of the displacer shaft.  The music wire is very stiff and difficult t

45、o work with in tight places, so I prefer to not bend the top of the displacer shaft.    I make the top piece from soft craft wire that is easy to form.  For this application I formed the hook shaped wire on another piece of music wire, then slipped it off and placed it on the dis

46、placer shaft.  It is held in place with a small drop of epoxy.  If I ever need to, I can disassemble the pieces to take it apart and work on it.2011-4-20 05:32 上传下载附件(45.22 KB)I use the same soft craft wire to make connecting rods for the drive piston and for the displacer. 

47、 The displacer connecting rod has a “Z” bend in it.  This is to simplify the adjustment process.  If the shaft needs to be adjusted in length, simply grab the middle of the “Z” and give a slight twist to make the shaft slightly longer or shorter.2011-4-20 05:32 上传下载附件(67.79

48、KB)The shaft connecting the drive piston to the crank shaft does not need to have the “Z” twist because it can be adjusted by moving the nuts up or down on the bolt that holds the piston together.2011-4-20 05:32 上传下载附件(49.52 KB)Assemble the EngineSecure the lid to the pressure chamber body by pressi

49、ng it into place.  Do not bang on it with a hammer.  Pounding with a hammer will dent the lid and cause a leak.  If you feel it must be tapped into place, put a block of wood over the seam and tap the wood lightly with a hammer until the lid is seated all the way around

50、.Attach the displacer connecting rod and adjust it so that the displacer does not touch the pressure chamber top or the pressure chamber bottom.Attach the connecting rod from the drive piston to the crank shaft.  Adjust the length of the connecting rod so that the piston can move freely.&#

51、160; It should not go down low enough to pull the fabric of the diaphragm completely tight.  And it should not go high enough to extend above the top of the drive cylinder.  It should have about 1/4” of travel from top to bottom.Make a StandThe stand that is pictured here wa

52、s made from another paint can.  (But you can get quite creative if you like.  The video of the first running of this engine shows it perched between two soup bowls.)  The paint can stand works well.  The top is open because the lid from this can was used to ma

53、ke the flywheel.  A large hole is cut in one side of the can.  The hole does not extend all the way to the top of the can.  This is so the hot air from the candle will be trapped in the top of the chamber.  The candle used in these illustrations is s liquid wa

54、x candle.  It is not quite as hot as a wax candle, but it burns very clean and will last for about 24 hours of burn time if you dont modify it.  If you want a larger flame you can pull the wick a little higher.  The instructions on the candle advise against this, so be

55、careful.2011-4-20 05:33 上传下载附件(42.4 KB)2011-4-20 05:33 上传下载附件(18.16 KB)2011-4-20 05:33 上传下载附件(39.66 KB)Fire It Up!Lubricate the crank shaft at every point where it comes in contact with another piece of metal.  Use light 3-in-1 oil.  Place a drop of the same 3-in-1 oil on the dis

56、placer shaft.  This will lubricate the shaft as it passes in and out of the gland, and will also help prevent pressure leaks through the gland.  Light up the candle and place it in the stand.  Put the engine on top.  Let it warm up for about 30 seconds and then rotate the flywheel to start the engine.The direction of rotation is determined by the 90 degree offset between the displacer and the drive piston.  The displacer always moves ahead of the drive cylinder.  Rotate in the