Development of Inlet Valve in an Oil­-free Novel Steam Engine

Abstract: A novel compact steam engine design could be used to replace current combustion engines in the rapidly changing world of renewable energy. Especially with the increased research into alternative fuels such as hydrogen fuel cells and methane, which would vastly improve the efficiency of a steam engine. The thesis focuses on a rotating valve chamber, which is made up of an actuating mechanism, a sealing mechanism, a rotating valve, and its housing. The modern steam engine cannot operate on conventional oil lubrication because it would degrade and clog the steam engine’s micro tubes, making it even more complex due to the rise of tribological issues. As a result, the most difficult challenge is selecting compatible materials for the components in this chamber, which is also subjected to temperatures of 450 degrees Celsius and pressures of up to 25 MPa. In order for the shaft to translate and rotate at the same time, an actuating mechanism was required. Finally, a sealing solution that can withstand the harsh conditions. As a result, a material research followed by material testing using a test rig yielded comparable results across a laser microscope. Furthermore, the actuating mechanism was designed in Solid edge, and structural analysis was conducted in Ansys that was used to validate the optimizations. For ease of understanding, the final design was 3D printed.