2 IJAEST Volume No 2 Issue No 1 Design and Experimental Implementation of an Electro Mechanical Cam Operated Valve for Oscillating Combustion 013 024

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Design and Experimental Implementation of

an Electro-Mechanical Cam operated Valve

for Oscillating CombustionJ. Govardhan*

Department of Mech. Engineering, AVN I E T, Ibrahimpatnam (M), A.P., India

G.V.S. Rao Department of Mech. Engineering, PIRM E C, Chevella, A.P., India

S. RajeshamDepartment of Mechanical Engineering, PRRM EC, Shabad, A.P., India,

J. Narasaiah

Department of Mech. Engineering, PRRM EC, Shabad, A.P., India

Abstract Oscillating combustion is a simple,innovative, low-cost technology can beapplied as a retrofit in the heat transfer industries such as steel mills, glass plants,forging shops and foundry process furnaces toenhance the performance characteristics.Different kinds of oscillating mechanism tocreate oscillations in the combustion usedearlier in the research were electrostrictiveactuators, cyclic valves, solenoid based(EGR) exhaust gas recirculation valves,rotatory plug valves.This paper explains the design anddevelopment of an oscillating valvedeveloped by the author to incorporate and tostudy the influence of amplitude andfrequency of oscillations in an oscillatingcombustion. Unlike other oscillating valvesused earlier a cam operated electro-mechanical valve was used to introduceoscillations in the liquid fuel flow at ambientconditions. The experiments were carried outon a crucible furnace both at steady state andoscillating combustion mode and comparedthe two modes of combustion. The

investigations confirm the benefits of introducing the oscillations during thecombustion and effects of oscillatingcombustion on performance characteristicssuch as heat transfer rate, melting time,specific energy consumption (SEC) andfurnace efficiency.

Keywords: Oscillating combustion,oscillating valve, crucible furnace, heattransfer rate, specific energy consumption

1. Introduction

Oscillating combustion is a gainingimportance these days and attractedsignificant attention as an efficient technologyto meet future fuel economy, energyutilization factor, reduction in emissions andimproved thermal efficiency. Experiments onthe oscillating combustion with differentoscillating valves are ongoing. Furnaces areused with retrofit valves for more promisingtechnological improvements. A clean energycombustion system, Inc. has developed

J. Govardhan et al. / (IJAEST) INTERNATIONAL JOURNAL OF ADVANCED ENGINEERING SCIENCES AND TECHNOLOGIESVol No. 2, Issue No. 1, 013 - 024

ISSN: 2230-7818 @ 2011 http://www.ijaest.iserp.org. All rights Reserved. Page 13



environmental friendly technologies to burnwide range of fuels using oscillatingcombustion. The principle on which the valveworks to introduce oscillations in thecombustion is based on cyclical perturbation

of the fuel line. GTI tests in late 1980‟s used asolenoid valve or solenoid-based exhaust gasrecirculation valve. Air Liquide Chicagoresearch centre used rotatory plug valve.These valves did not have enough life andwere expensive, thereby unsuitable for industrial applications. Ceramphysics, Inc.Ohio, developed a low cost long life valveknown as Solid State Proportionate valve witha flow capacity of only 40 scf/h operating athigh frequency of 20 Hz was used and found

virtually noise free. GTI laboratories are producing SSP valves with variable flowcapacity. Experiments on the oscillatingcombustion technology were conducted onnatural gas with variable conditions.In this article, the author developedindigenously an electro-mechanical camoperated valve which is simple, low-cost,reliable in operation and incorporated in acrucible furnace to experiment the oscillatingcombustion especially on liquid fuel. Theoscillations of the fuel create alternatelysuccessive fuel-rich and fuel-lean zoneswithin the furnace. The fuel-rich zones aremore luminous, longer in length and causesmore heat transfer from flame to the load.Both the zones mix in the furnace only whenthe heat has been transferred from the fuel-rich zone to the load thereby resulting in low peak temperature in the furnace. The effectsof oscillating combustion are low meltingtime, increased productivity rate, reduction inemissions, low specific energy consumptionand increase in furnace efficienBefore presenting the experimental dataresults, a brief mechanism description is presented. The oscillating valve wasintroduced as a retrofit in a fuel fired cruciblefurnace and tested on both steady state andoscillating combustion. Typical furnace

modifications were carried out. These includestream lining the flue gas passage in thefurnace, incorporating manometers, 3-waycock along with burette, piezometer tubes,thermo-couples with digital temperature

indicators and sensing probe. The oscillatingvalve has been tested at a frequency of 5 and10 Hz, amplitude of 100 and 200, different air-fuel ratios varying from 13:1 to 17:1 aboveand below the stoichiometric ratio using 10,15 and 20 kg of aluminum loads. The resultsindicate the optimization at certain parametersused in the tests. The main focus in this paper is on the proposed oscillating valve on thekinematics profile of the cam, variable speedactuator, system modeling, design and control

considerations, fluid mechanical and thermalconsiderations and variation in fuel flowduring the fuel-rich and fuel-lean zones.

Nomenclature

A = amperea.c. = alternating currentA/F = air-fuel ratioD = diameter d.c = direct current

EGR = exhaust gas recirculationF = forcef = friction factor, frequencyg = acceleration due to gravity, gramGTI = gas technology institutekg/h = kilogram per hour k = spring constantkg = kilogramm = massmA = milli ampere N= speed

P = pressure, power rpm.= revolutions per minutescf/h = standard cubic feet per hour SEC = specific energy consumptionSHM = simple harmonic motionSSP = solid state proportionateT = TorqueV = volt





v = velocityZ = datum

Greek symbol

Θ = uniform angular displacementθ0 = cam angle for out strokeμ = viscositye = densityτ θ, = torqueωn = circular frequency of SHMω = angular velocity∆ = small distanceΠ = radian

Subscripts

Fn = natural frequencyFo = maximum acceleration of follower outstrokeFr = maximum acceleration of follower returnstrokeHL = loss of headHz = hertz , cyclesTo = time of outstrokeT

r = time of return stroke

Vo = maximum velocity of follower outstroke.Vr = maximum velocity of the follower returnstroke

2. Kinematics Profile of Cam

2.1. Uniform velocity

For the uniform motion or uniform velocity of the follower, the slope of the displacementcurve will be constant because thedisplacement is directly proportional to timeand time is directly proportional to θ, for thecam running at uniform angular velocity

.

Fig. 1. Displacement, velocity and

acceleration diagrams.

Fig.2. Modified displacement, velocity

and acceleration diagrams





Fig.3. S.H.M of the follower diagrams

Fig.4. Cam with angles

Figure 5. Profile of SHM of the follower

Figure 6. Profile of the cam

It is seen from the Figure 1 that, during the period θd1 the displacement remainsunchanged and so is the case during θd2 Thus,

during θd1 and θd2 the velocity of the follower is zero. During θ0 interval, velocity has adefinite value and again during θd2 it iszero.θ0+ θd1+θr+θd2 = 3600 or one completerevolution of the cam. It may be pointed outhere that at point A, the velocity of thefollower is changed from to a finite value inan infinitely small interval of time thereforethe acceleration to be produced will beinfinitely large. For any small mass of thefollower the inertia forces produced will beinfinitely large causing the high stress levelsand wear. Therefore, uniform velocity of thecam is not a practical proposition. It istherefore, necessary to modify the conditionswhich govern the follower motion, reducingthe values of acceleration to finite value thisis accomplished by rounding the sharpcorners at A,B,C and D, so that the follower reaches the desired velocity gradually at the beginning of the stroke. Shorter rounding theradius the nearer to the undesirable conditionsof the constant velocity profile.

A-B = θ0 = angle of the cam for out stroke(1200)B-C = θd1 = dwell angle (400)C-D = θr = angle of the cam for return stroke(1200)D-E = θd2 = dwell angle (800)





2.2. Uniform acceleration:

In the above Figure 2, the follower motion isassumed with uniform acceleration for thesesmall intervals of time. A radius equal to the

follower displacement is chosen often in practice. Unfortunately, the modified straightline profile does not exhibit very attractivecharacteristics. The derivative of theacceleration called jerk or pulse will haveinfinite spikes in modified straight line case.This is a measure of rate of change of inertiaforce and thus give impact levels impactcauses noise, shortens life due to wear andfatigue.

2.3. Simple Harmonic Motion

Figure 3 shows that, velocity curve is a sinecurve and acceleration curve is a cosinecurve. Obviously, the velocity andacceleration on the return stroke are higher than those on the outward stroke. The samedisplacement is completed during returnstroke in the angular rotation of the camrotation which is half of that on the out strokein the example into consideration.

Letθ = uniform angular displacement;θ0 = angle of the cam for out strokeθr = angle of the cam for return strokeTo = time to perform outstroke θ0/ω;Tr = time to perform return stroke= θr/ωVo = velocity of follower out stroke;Vr = velocity of the follower return stroke;Fo = acceleration of follower out stroke;Fr = acceleration of follower return strokeω = uniform angular velocity;S = Stroke of the follower.

SHM is defined as by the projection on thediameter of point moving at a uniform speedround the circumference or the periphery of acircle with the stroke as the diameter.

For outstroke we have peripheral speed of the point moving along the circle with stroke asdiameter

peripheral speed = π S/2 *1/ to

or = π S /2*(ω / θ0) (1)or the maximum velocity on out stroke alongdiameter is equal to peripheral velocity of point along the cumference of the circle onwhich the point is assumed to move for its projection to execute S.H.M.

Vo = π ω/ θ0 *S/2 (2)

and it occurs at point when cam has turned by

an angleθ = θ0/2also the centripetal acceleration of the point by which SHM defined is given by (duringout stroke)

Fo = V02 / (S/2) (3)

= (πω/θ S/2)2 */S/2

= π2 ω2 / θ0 2 *(S/2) (4)

And this is maximum positive at θ =0 andmaximum negative at θ = θ

0and at θ ≤ θ

0/2 it

is zero. Discussing on the same lines for thereturn stroke we have

Vr = πω / θ*(S/2) (5)

Fr = ω2 π 2 / θr 2 * S/2 (6)

2.2. Non-linear mechanical relations of

spring

The natural frequency and time period of thespring may be derived from “EquilibriumMethod”. This is based on the principle thatwhenever a vibrating system is in equilibrium,algebraic sum of all the forces and momentsacting on it is zero. This is in accordance with





D`Alembert‟s principle, that the sum of theinertia forces and external forces on a body inequilibrium must be zero.

2.2.1. Variable speed actuator

The kinematic profile of the cam positionversus time (amplitude), swivel disc speedversus time (frequency) are of fixed shape andare timed relative to the oscillating valve‟sswivel disc position. An electromechanicallyoperated motor system can control theamplitude and frequency of the valve. Theswivel disc positioned at an angle or partiallyin closed position and allows the amount of

fuel required as per the air-fuel ratio. Fromthis position it can be further partially closedof fully closed to suit to the furnace operationrequirement.In effect, the oscillating combustion valveshould have some features of flexibility.

- The system must operate withminimum power consumption.

- It should not have excessive wear of the cam and follower.

- The system should have soft contact between the cam and follower andshould be noise free.

The follower is connected to the swivel discand is held by a spring in its equilibrium position. The equilibrium position for thismass-spring system is in the middle of thevalve stroke. Such a system possesses itsnatural frequency (fn), mass (m), springconstant (k) and frequency ratio (S). In this,an initial displacement of the valve in thedirection of the spring would result insustained oscillations in the valve at thesystems natural frequency considering anyrequirement of damping. Relatively smallcurrent is consumed during the operation.

Fig.7. Schematic view of the cam profilewith spring (above) and the oscillatingvalve

In the Figure 7 as shown, the spring supportsthe follower with its free end at A-O. When

the follower is shifted by the cam profile thespring is stretched by a distance ∆ (for sustained damping) and B-O becomes theequilibrium position. This ∆ is the staticdeflection of the spring by the cam.

LetS = Stiffness of the spring – Force

required for the unit deflection.In the static equilibrium position, (consideringthe outward movement as upward stroke and

inward movement as downward stroke)Upward force = power of the motor P = T ω (7)

(T = Torque of the motor, ω = angular velocity)

= T x (2ПN/60)= (F x (D/2)) x (2ПN/60)





= (2П DNF) / (120 )Downward force = S*∆*g or S∆ (8)

(g=negligible)

Upward force = Downward force;

or (2П DNF) / (120) = S∆ (9)

Now when the spring is pulled during theoperation by the follower through a distance(Z) m, the forces acting on the spring will be,

Inertia force = downward force

= (2П DNF) / (120) (10)

Spring force or restoring force = S.*X

downward (11)As the sum of inertia and the external force onthe body in any direction is zero (D‟Alembert‟s principle).

Inertia force + spring force = 0

[(2П DNF) / (120) ] + S.*X = 0 (12)

When the motor starts, the spring would startoscillating above and below the equilibrium position. These oscillations would tend tocontinue till the motor is stopped.The above equation can be written as,

+ { S /[(2П DNF)/ (120)] } *X = 0. (13)

The above equation is of simple harmonicmotion and is analogous to + (ωn)

2.x = 0,Where

ωn = natural frequency or circular frequencyof SHM.

and ωn = √ { S / [(2П DNF) / (120)] } andlinear frequency of the vibration systemf n =. ωn/ 2П (14)

and the Time period T =1/ f n (15)

2.3. Non-linear Mechanical

Transformation Relations

„θ‟ is a function of „S‟ and vice-versa. It iseasy to show that the use of non-linear

mechanical transformations implies that thefollowing relations hold between θ and S.

LetS= Stroke length or linear displacement of the

follower.θ= cam angle of the rotation in radians.S = f (θ) → θ= f -1(S) (16)

Therefore the velocity of the follower is given by,

V=dS/dtV=dS/ dθ * dθ/dtV=dS/d θ *ωV= ω dS/dθ (17)

(Slope of the displacement curve at angle θ or time t)Since the cam rotates with uniform angular velocity of ω radians/sec.

dθ/dt =ωAcceleration of the follower is given by

F=dV/dt = dV/d θ * d θ/dt = ω dV/dθ= ω d2S/d θ2 m/sec2

= ω dV/d θ(18)

= (Slope of the velocity curve at angle θ or time t)Also, pulse or jerk is given by,

P=ω3 d3y/d θ3 (19)= (Slope of the acceleration curve at angle θ

or time t)

The non-linear mechanical transformer provides a desirable relation between S and θdomains. By equating the power in the S andθ domains and using the non-linear mechanical transformer characteristics, thefollowing relation results.

τ θ = dS/ dθ. Fs (20)

. .

X

. .

X

. .X

. .

X





Where τ θ, is torque in the θ domain and Fs isthe force in the S domain. At the end of thestroke, the slope of the cam characteristic dS/dθ is very small. This characteristic makes iteasier to control the motor velocity near the

end of the stroke. A mechanical design inwhich the smooth operation follows naturaldynamic trajectories require no longer actuator forces to apply control is the requiredmeans of reducing peak actuator power.

The kinematics of the cam are described byInertial force + Spring force = 0The inertia represents the mass of the cam

and actuator‟s inertia. When the inertia andspring forces are linear, the force balance

becomesm d2s/dt2 + ks = 0 (21) where „m‟ is the mass inertia and „k‟ is springstiffness, respectively.A cam operated electro-mechanical valvewith small spring forces at both ends of thestroke results in smooth cam kinematics andless jerks without large driving forces.

3. Design and control considerations

The views of experimental setup with thetemperature measuring apparatus, oscillatingcombustion valve and swivel disc positionsinside the valve are shown in Figures 8-12.The input supply is fed to the motor through a potential differentiometer or through variableresistance as per the requirement of the speed.The motor sets into motion and makes thecam to rotate (cam is fixed on the spindle of the motor). The cam which is in contact withthe follower which operates against the mass-spring mechanism acts as non-linear mechanical transformer. The swivel valve positioned in the fuel flow chamber isactuated by the non-linear mechanicaltransformer thereby restricting the fuel flowinducing the oscillations.

There are number of important issues in thedesign of the oscillating combustion valve.

1. The fuel flow regulations are to be keenlymonitored. The amount of the discharge

of fuel before installation of the valveshould be maintained after installationtoo. This was ensured by calculating theflow before and after the valve‟sinstallation.

2. There was a slight pressure drop in thefuel system when the valve was positioned. This was taken care byadjusting the fuel flow lever into higher position and also the fuel level in the fueldrum.

3.

Importance is given to precise control of the cam operation with the follower for soft raising and lowering in turn themovement of swivel disc in the valve.

4. The friction between the cam and follower is at its minimum as there are no much of variable loads during the operation.

5. The motor can rotate steadily due to thereason for this characteristic is that a flatslope is used for the cam profile.

6. Oscillating valve is carefully designed andextra care was taken to avoid any kind of fuel leakages and unwanted noise duringthe operation.

The motor can rotate past for 60o of the camin θ domain where as the follower can swayfor about 12 mm in the S domain. [θ domainis in the angle of cam and „S‟domain is theshift of follower from its equilibrium position].Since the mass and inertia of the movingcomponents in the oscillating valve apparatusare as small as possible, the required springconstants and forces grow proportionally withthe mass and inertia of any components of any system. Since the mass and inertia of theswivel disc which restricts the fuel flow in thevalve happened to be very small, soft andlight spring was employed with low springconstant. This was enabled to employ a small





9V d.c. motor, 4 mA current with 600 rpm.The motor was controlled by a potentiometer to get the required operating frequency (5 to10 cycle/sec). 2 modes of frequency and theamplitude of the swivel disc were chosen for

the experimental analysis. The oscillatingcombustion valve along with its accessorieswas placed on a stand and coupled to the fuelline system. A converter used to convert220V a.c. input into 9V d.c and a digitaltachometer was used to ensure the requiredrpm of the motor to be set in.

Fig.8. Experimental setup

Fig. 9. Oscillating valve on fuel line

Fig. 10. Oscillating valve with cam

Fig. 11. Schematic of oscillating valve 3D view

a) closed b) 300 c) 450

d) 600 e) 750 f)900

Fig. 12. Schematic of swivel disc positionsinside the oscillating valve





4. Fluid Mechanical Considerations

The pressure drop or loss of head in thesystem due to the installation of theoscillating valve in the system may not be so

important but is considered.According to Hagen-Poiseuille law the loss of heat or pressure drop for a laminar flow

(P1 – P2 )/ ω = 32 μvl / ωd2 (21)

and Darcy- WeischBack givesHL = (4flv2) / 2gd (22)

Here, the pressure drop is directly proportional to the length of the pipe which is

used is a major concern. Since the pipe usedfor the oscillating valve was very small.Thereby pressure drop can be neglected.Since the fuel is incompressible applying thelaw of Bernoulli‟s Equation and choosing areference line between the oscillating valveand the fuel drum, the pressure loss can befound.i.e. (P1 – P2 )/ ω= (V2

2 / 2g) + Z2 ; (23)

( where ω = eg )e = density of fluid ;g = acceleration due to gravityV2 = velocity at the oscillating valve;Z2 = datum line above height.

The calculations gave small amount of pressure drop which was taken care byadjusting the fuel lever at the entry and byincreasing the fuel level in the fuel drum.

5. Results and comments

The proposed oscillating valve has a swiveldisc incorporated on the fuel flow pipe. Theaxis of the swivel disc is perpendicular to theaxis of fuel flow through the pipe. When theswivel valve is actuated, it rotates either sideof its axis and controls the volume of the pipe.When the swivel disc is oscillated from its

position, due to the cam and follower action itcauses reduction in the volume. Thereby,restricts the fuel flow through the valve to the burner. When the cam resumes its normal position, the spring attached to the follower

brings back the swivel disc to its original position or to its starting point. The swivelvalve could open and close in 1/10th of asecond, and can vary according to the control by potentiometer. The oscillations of theswivel disc are adjusted electromechanicallyand the amplitude of the swivel disc isadjusted according to the size of the cam or cam profile. When the oscillating valve wastested at different oscillations, the fuel flowwas scaled up from 3.0 kg/h average flow to

4.50 kg/h depending upon the air-fuel ratiosand furnace loads. The valve in the position but without oscillations it was tested from 3.0kg/h to 5.0 kg/h at ambient conditions.When oscillations occur, the pressureamplitude is sufficient enough to producesignificant variations in axial velocity withinthe nozzle annulus. These axial velocities canvary during the oscillating combustion. Theswirl vanes on the surface of the fuel gun of the burner would provide combustion air witha tangential velocity of high swirl. Due to thisthe flow around the nozzle‟s annulus ishaving high and low regions of tangentialvelocity convected along the main axial flowof the fuel. The magnitude of heat releasedepends upon the variations in the axialvelocity of the fuel due to the variations inamplitude and frequency of oscillationsintroduced by the oscillating valve and thevariations in the tangential velocity of combustion air. The load heats up faster sinceheat transfer rate from flame to load increasesdue to more luminous fuel-rich zones. Theincreased turbulence and high luminousflames created by the flow oscillations break up the thermal boundary layer In oscillating modes of operation theoscillating valve is able to open and closesteadily at higher amplitude and lower





frequency facilitating break up of thermal boundary layer which shortens heat up time.In the oscillating combustion mode, within areasonable short time the furnace walltemperature becomes more or less uniform

because time scale of the flame propagation isless and its velocity is faster due to moreluminous flame from the fuel-rich zone of theflame. Fuel consumption tends to become lowdue to less time taken for the load to melt.This is due to the oscillations created duringthe operation by the oscillating valveoscillates the air-fuel ratio of 13:1 into aboveand below the stoichiometric ratio, producingalternatively fuel-rich and fuel-lean zones inthe flame resulting in improved efficiency.

Some of the visual observations made after the retrofit of oscillating valve andexperimentation are shown here. Distinctdifference can be noticed between the steadystate combustion to oscillating combustionflames. The oscillating combustion flame wasfound to be highly turbulent, radiative andmore luminous to that of the steady stateflame.

(a) (b) (c)

(d) (e) (f)

Fig.13. Different types of flames and statusof molten metal

(a) Radiant heat in furnace(b) Oscillating fuel-rich flame(c) Steady state flame(d) Melting operation(e) Molten metal

(f) Furnace with sensing probe

Conclusions

The objective of the development of theoscillating valve is to integrate into electro-mechanical controlled experimental test standsupported by thermo-couples, digitaltemperature indicators and sensing probealong with mechanical apparatus, and to carry

out experiments to improve performancecharacteristics of a furnace from steady statemode to oscillating mode of combustion. Theoscillating valve developed was found to beideal for the oscillating combustion as theexperiments carried out on liquid fuel atvarying air-fuel ratios, amplitude, frequencyand load have shown promising results. Theamplitude of the flow rate, the oscillations produced by this valve were adjustedmechanically and electrically, thereby thevalve is considered to be flexible and appear to be easier to scale up for any furnace.

To help the heat transfer industry toswitch on to newer combustion concepts,especially the oscillating combustion which isan advanced technology, introduction of oscillating valve finds answers to manyquestions in terms of low melting time, lowfuel consumption and low specific energyconsumption, increased productivity rate withreduced emissions and increase in thermalefficiency of the furnace. The theoreticalaspects of systems modeling, design andcontrol considerations, fluid mechanicalconsiderations were analyzed. Based on theseconsiderations the embodiment of the valvewas realized.





Acknowledgements

The author is grateful to the Management of A.V.N. Institute of Engineering & Technology,Ibrahimpatnam for their support and P.R.R.M.

Engineering College, Shabad, R. R. Dist.,Andhra Pradesh, India for providing thefacilities for the execution of thisexperimental analysis in the P. T. Laboratoryof the Department of MechanicalEngineering.

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2 IJAEST Volume No 2 Issue No 1 Design and Experimental Implementation of an Electro Mechanical Cam Operated Valve for Oscillating Combustion 013 024