We present a novel design of a single-cylinder free piston engine linear generator (FPELG) incorporating a linear motor as a rebound device. A systematic simulation model of this FPELG system was built containing a kinematic and dynamic model of the piston and mover, a magneto-electric model of the linear generator, a thermodynamic model of the single-cylinder engine, and a friction model between the piston ring and cylinder liner. Simulations were performed to understand the relationships between pre-set motor parameters and the running performance of the FPELG. From the simulation results, it was found that a motor rebound force with a parabolic profile had clear advantages over a force with a triangular profile, such as a higher running frequency and peak cylinder pressure, faster piston motion, etc. The rebound position and the amplitude of rebound force were also determined by simulations. The energy conversion characteristics of the generator were obtained from our FPELG test rig. The parameters of intake pressure, motor frequency, and load resistance were varied over certain ranges, and relationships among these three parameters were obtained. The electricity-generating characteristic parameters include output power and system efficiency, which can measure the quality of matching the controllable parameters. The output power can reach 25.9 W and the system efficiency can reach 13.7%. The results in terms of matching parameters and electricity-generating characteristics should be useful to future research in adapting these engines to various operating modes.

The free-piston gasoline engine linear generator (FPGLG) is a new kind of power plant consisting of free-piston gasoline engines and a linear generator. Due to the elimination of the crankshaft mechanism, the piston motion process and the combustion heat release process affect each other significantly. In this paper, the combustion characteristics during the stable generating process of a FPGLG were presented using a numerical iteration method, which coupled a zero-dimensional piston dynamic model and a three-dimensional scavenging model with the combustion process simulation. The results indicated that, compared to the conventional engine (CE), the heat release process of the FPGLG lasted longer with a lower peak heat release rate. The indicated thermal efficiency of the engine was lower because less heat was released around the piston top dead centre (TDC). Very minimal difference was observed on the ignition delay duration between the FPGLG and the CE, while the post-combustion period of the FPGLG was significantly longer than that of the CE. Meanwhile, the FPGLG was found to operate more moderately due to lower peak in-cylinder gas pressure and a lower pressure rising rate. The potential advantage of the FPGLG in lower NO_x emission was also proven with the simulation results presented in this paper.

The free-piston engine linear generator (FPELG) is being investigated by many researchers because of its high thermal efficiency and its variable compression ratio. However, all researchers focused on the FPELG characteristics with mono-fuel. Therefore, in this paper, the performance of the FPELG that has adopted gasoline with hydrogen as fuel is investigated. The method of coupling the zero-dimensional dynamics model with the multi-dimensional CFD (Computational Fluid Dynamics) combustion model was applied during the simulation process. According to the results, the piston TDC (Top Dead Center), the piston peak piston velocity, and the system operation frequency show a negative correlation with the increase of hydrogen fractions. However, the peak in-cylinder pressure was increased with the hydrogen volume fraction increase, due to the fast flame speed and short combustion duration characteristics of hydrogen. Meanwhile, the indicated efficiency of the free-piston engine was increased from 32.3% to 35.3% with the hydrogen volume fraction change from 0% to 4.5%, when the free-piston engine operates at stoichiometric conditions with fixed ignition timing. In addition, with the ignition timing advance increase, the piston TDC was decreased. The peak piston velocity and the peak in-cylinder pressure were in negative correlation with the ignition timing advance. While the engine indicated that the efficiency was increased with the equivalent degree of ignition timing from 20° to 16°. Therefore, the ignition timing of the FPELG under the spark-ignition combustion mode is supposed to be an effective and practical control variable.

For a compression ignition (CI) free piston engine linear generator (FPLG), injection timing is one of the most important parameters that affect its performance, especially for the one-stroke starting operation mode. In this paper, two injection control strategies are proposed using piston position and velocity signals. It was found experimentally that the injection timing’s influence on the compression ratio, the peak in-cylinder gas pressure and the indicated work (IW) is different from that of traditional reciprocating CI engines. The maximum IW of the ignition starting cylinder, say left cylinder (LC) and the right cylinder (RC) are 132.7 J and 138.1 J, respectively. The thermal-dynamic model for simulating the working processes of the FPLG are built and verified by experimental results. The numerical simulation results show that the running instability and imbalance between LC and RC are the obvious characters when adopting the injection strategy of the velocity feedback. These could be solved by setting different triggering velocity thresholds for the two cylinders. The IW output from the FPLG under this strategy is higher than that of adopting the position feedback strategy, and the maximum IW of the RC could reach 162.3 J. Under this strategy, the prototype is able to achieve better starting conditions and could operate continuously for dozens of cycles.

Free-piston engine linear generators (FPELGs) are an innovative linear power device that exhibits the distinctive dynamics of pistons and performance of free-piston engines. Furthermore, the single-cylinder/single-piston FPELG structure type has more advantages than other FPELG structure types, including a straightforward structure and ease of control. However, when coupled with various rebound devices, the operational characteristics and piston and engine performance of single-cylinder/single-piston FPELGs are quite different. Therefore, this paper aims to quantitatively compare the dynamics of the piston and engine performance of single-cylinder/single-piston FPELGs coupled with various types of rebound device. The results indicate that when the equivalent stiffness of the gas spring is greater than that of the mechanical spring, the operating frequency of the piston of the FPELG coupled with a gas spring will be higher than that when coupled with a mechanical spring. During the compression stroke, the piston velocity of a FPELG coupled with a mechanical spring changes linearly, while the piston velocity of a FPELG coupled with a gas spring changes nonlinearly. FPELGs coupled with gas springs have shorter compression and expansion durations compared to those coupled with mechanical springs. In addition, the indicated powers of FPELGs coupled with ideal gas springs and mechanical springs are 1.5 kW and 1.3 kW, respectively. However, due to leakage, the thermal efficiency of a FPELG coupled with an actual gas spring is reduced by approximately 2.5% compared with the FPELG coupled with the ideal gas spring. Furthermore, the operation frequency of the piston is positively correlated with the stiffness of the mechanical spring. In addition, as the stiffness of the mechanical spring increases, the combustion process of the engine becomes close to an isovolumetric process. The changes in piston dynamics and engine performance when increasing the initial gas pressure of the gas spring are similar to those when increasing the stiffness of the mechanical spring.