Abstract
A single-stage axial microturbine has been developed with a rotor diameter of 10 mm. This turbine is a first step in the development
of a microgenerator that produces electrical energy from fuel. The turbine is made of stainless steel using die-sinking electro-discharge
machining. It has been tested to speeds up to 160,000 rpm and generates a maximum mechanical power of 28 W with an efficiency of
18%. When coupled to a small generator, it generates 16 W of electrical power, which corresponds to an efficiency for the total system
of 10.5%.
2003 Elsevier B.V. All rights reserved.
Keywords: Microturbine; Microgenerator; Power MEMS; EDM
1. Introduction
2. Microturbines-scale effects
Most portable devices use batteries for their power supply. Current Li-ion batteries have energy densities up to
0.5 MJ/kg but still offer limited autonomy to for instance
laptops and cellular phones. Charging times also pose problems. Fuel, on the other hand, offers a much higher energy
density of about 45 MJ/kg, and the reservoir can easily be
refilled. Therefore, several groups are working on the development of micro power generators based on fuel cells [13],
thermo-electric devices [4,5], Stirling engines [6,7], reciprocating internal combustion engines [8,9], Wankel motors
[10], and gas turbines [1114].
Specific about the microturbine presented in this paper is
that it is an axial turbine produced with electro-discharge
machining (EDM). The microturbine developed at MIT [11]
is a radial turbine with a rotor diameter of 4 mm, produced
lithographically in Si or SiC. The microturbine developed
at Stanford [12] is an axialradial turbine with a rotor diameter of 12 mm. The silicon nitride rotor is produced by a
gel-casting technique using a wax mould. Teams at Tohoku
University [13] and the University of Tokyo [14] use as well
radial as axial-radial designs.
The reduction of scale has several effects on the performance and construction of the turbine, and on the fuel
choice.
0924-4247/$ see front matter 2003 Elsevier B.V. All rights reserved.
doi:10.1016/j.sna.2004.01.003
(1)
(2)
(3)
P
1
V
D
(4)
uL
,
(5)
87
3. Turbine design
In a first phase of the project, the problem has been scaled
down to a turbine powered by compressed air. Compressor, combustion chamber, and generator have been left out
and will be addressed in a later phase. The microturbine is
a single-stage axial impulse turbine (Laval turbine). Expansion of the gas takes place in the stationary nozzles and not
88
between the rotor blades. This type of turbine has been chosen because of its simple construction.
Fig. 1 shows an exploded view and an assembly of the
microturbine design. The compressed air enters via a standard pneumatic connector (1) and expands over the stationary nozzles (3) where it is deflected in a direction tangential
to the turbine rotor (5). After the air has passed the rotor
blades, it leaves the device through the openings in the outlet
disc (6). Screwing the pneumatic connector in the housing
(8) presses the stationary nozzle disc against a shoulder in
the housing. The rotor blades, wheel and axis are one monolithic part. The rotor is supported by two ball bearings (4),
one mounted in the stationary nozzle disc and one mounted
in the outlet disc. The outlet disc is locked in the housing
by a circlip (7).
The diameter of the turbine rotor is 10 mm. The housing
has a diameter of 15 mm and is 25 mm long. All parts, except the pneumatic connector and the circlip, are made of
stainless steel.
The nozzles are designed for subsonic flow and, therefore,
have a converging cross section. Sonic speed is reached for a
relative supply pressure of 1 bar. The exit losses (remaining
kinetic energy in the exhaust) are minimal when the turbine
is designed for a u/c1 ratio of 0.5, with u the circumferential
speed and c1 the absolute speed at the nozzle exit. At 1 bar,
c1 reaches sonic speed resulting in an optimal turbine speed
of 420,000 rpm. As this is too high for the bearings, the
turbine has been designed for a u/c1 ratio of 0.25, and is
operated below its optimal speed of 210,000 rpm.
4. Turbine production
The different parts of the turbine are produced by turning
and EDM. The nozzle disc and rotor are the most complex
parts. In a first step, their cylindrical surfaces are machined
on a lathe. In a second step, the nozzles and blades are
created by die-sinking EDM as illustrated for the rotor in
Fig. 2. The rotor is clamped in a rotary head which is indexed
with steps of 30 . A prismatic copper electrode with a cross
section having the shape of the air channels between the
blades is sunk into the turbine wheel by EDM. The electrode
Fig. 3. Subassembly of nozzle disc, turbine rotor, and bearings. The rotor
has a diameter of 10 mm.
5. Generator
The turbine has been coupled to a small brushless dc
motor that is used as a three-phase generator (see Fig. 4).
The motor (Faulhaber, type 1628 T024B K312) has about
the same size as the turbine: 16 mm in diameter and 28 mm
long. Turbine and generator are coupled to each other by
an elastic tube that serves as a flexible coupling.
6. Mechanical output
Torque and power of the turbine have been tested up to a
speed of 100,000 rpm. For this purpose, a 30 mm diameter
89
3.5
1 bar
Torque (Nmm)
3
2.5
0.8 bar
0.7 bar
1.5
0.6 bar
0.5 bar
Friction torque
0.5
0
0.2 bar
0
20
40
Inertia wheel
100
120
3
x 10
25
20
0.8 bar
15
0.7 bar
0.6 bar
10
0.5 bar
5
0
Friction loss
0.2 bar
0
20
40
60
80
Speed (rpm)
100
120
3
x 10
18
16
Turbine efficiency (%)
60
80
Speed (rpm)
0.8 bar
14
0.7 bar
0.6 bar
0.5 bar
12
10
8
6
4
Turbine
Vane
Photosensor
Fig. 5. Set-up to measure the mechanical output of the turbine. The output
torque is derived from the acceleration of the inertia wheel.
20
40
60
80
Speed (rpm)
100
120
3
x 10
90
18
16
10
1 bar
14
12
0.9 bar
10
8
0.8 bar
0.7 bar
6
0.6 bar
0.5 bar
0.4 bar
0.3 bar
0.5 bar
1 bar
0.2 bar
0.4 bar
0.2 bar
20
0.3 bar
40
60
80
100
Speed (rpm)
120
140
160
20
40
x 10
60
80
100
120
140
160
3
x 10
Speed (rpm)
7. Electrical output
To measure the electrical power output of the system,
the generator is connected to a variable three-phase load
consisting of three potentiometers (range: 2 k, 10 turns).
In contrast with the mechanical tests, the electrical tests are
performed at constant speed. The speed of the turbine, which
is measured from the frequency of the generator voltage, is
controlled by varying the load. Fig. 9 shows the electrical
power measured for different supply pressures and speeds.
At a pressure of 1 bar, the maximal electrical power is 16 W
and is reached at a speed of 100,000 rpm. Measurements
show that the air flow and input power depend only on the
supply pressure and not on speed or load. Therefore, the
input power is the same as in the mechanical test at 1 bar,
i.e. 152 W. Fig. 10 shows the total efficiency (compressed
air to electricity) as a function of speed and for different
supply pressures. The maximal total efficiency is 10.5% and
is reached at a speed of 100,000 rpm.
Input power
152 W - 100 %
Expansion losses
15 W - 9.8 %
Leak flow around rotor
4 W - 2.6 %
Obstruction losses
1 W - 0.7 %
Incidence losses
2 W - 1.3 %
Mechanical
power
28 W - 18.4 %
8. Sankey diagram
The energy flow and the different losses are illustrated
in the Sankey diagram shown in Fig. 11. The diagram
is generated for a supply pressure of 1 bar and a speed
of 100,000 rpm. This corresponds to the working point
at which the maximal electrical power and maximal total
efficiency are reached. Input power, mechanical power,
electrical power and the combination of ventilation losses
(6) and bearing friction (7) are measured values. This last
Electrical power
16 W - 10.5 %
Legend
Measured
Calculated
Difference from
other values
Fig. 11. Sankey diagram for a supply pressure of 1 bar and a speed of
100,000 rpm.
91
L-1
Ship
M -1/3
Power system
10
1
10
100
1000
10000
100000
Mass (kg)
9. Power density
Table 1 gives the masses of the different parts. The turbine housing and pneumatic connector are not optimised towards mass and are responsible for about 86% of the weight.
Therefore, the mass of the turbine can be substantially reduced by optimising these parts.
The mechanical power density of the turbine, defined as
the mechanical power output of the turbine (28 W) divided
by the mass of the turbine (36 g), is about 780 W/kg. As a
comparison, Fig. 12 shows the power density of commercial
gas turbines for helicopters, tanks, ships and power generators from General Electric, Rolls-Royce, and Pratt & Witney. Most of these turbines have a power density between 4
and 10 kW/kg. The tank turbine has a lower power density
of 1 kW/kg. The power density of the current microturbine
is thus 510 times lower than the power density of large turbines. This figure can be improved by optimising the mass
of the connector and housing, but on the other hand, a compressor and combustion chamber have to be added to obtain
a turbine comparable to the ones mentioned in Fig. 12. A
comparison can also be made with a silicon air turbine with
a rotor diameter of 4.2 mm developed at MIT [15]. It generates 5 W of power and achieves a power density of more
than 4 MW/m3 (about 2 kW/kg), about 2.5 times more than
the turbine presented in this paper.
Table 1
Masses of the different parts
Part
Mass (g)
Turbine
Pneumatic connector (1)
Ring (2)
Nozzle disc (3)
Small bearing (4)
Large bearing (4)
Rotor (5)
Outlet disc (6)
Circlip (7)
Housing (8)
Generator
36
15.8
0.77
1.78
0.03
0.07
1.63
0.35
0.27
15
30
66
Fig. 12. Power density of commercial gas turbines. Data from General
Electric, Rolls-Royce, and Pratt & Witney. The line represents the evolution of the power density as predicted by the scale laws.
10. Conclusion
A 10 mm diameter axial microturbine with generator has
been developed and successfully tested to speeds up to
160,000 rpm. It generates a maximum mechanical power of
28 W with an efficiency of 18%. Power and efficiency are
mainly limited by the maximal speed of the ball bearings.
The main losses are the blade profile losses (32%) and the
exit losses (34%). Higher speeds can considerably reduce
the exit losses and therefore increase efficiency and power.
Currently, the power density is 780 W/kg, about 510 times
lower than for large turbines. However, higher speeds and
optimisation of the housing can considerably increase this
figure. When coupled to a small generator, the system generates 16 W of electrical power, corresponding to a total
efficiency of 10.5%.
92
[11]
[12]
[13]
Acknowledgements
This research is sponsored by the Belgian programme
on Interuniversity Poles of Attraction (IAP5/AMS) initiated
by the Belgian State, Prime Ministers Office, Science Policy Programming. The authors assume the scientific responsibility of this paper. The authors wish to thank Michael
Poesen and Pieterjan Renier for their contribution to this
work.
[14]
[15]
[16]
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Biographies
Jan Peirs Graduated as mechanical engineer (K.U. Leuven, 1993). He
started his activities as a research assistant at the Division of Production
Engineering, Machine Design and Automation (PMA) of K.U. Leuven
in 1993. He received a PhD degree in mechanical engineering in 2001
from K.U. Leuven. Currently, he is working as a Postdoctoral researcher
at PMA. His research interests include the design of micro-actuators,
medical microsystems, micro-powergenerators, and micromechanical
systems in general.
Dominiek Reynaerts Graduated as mechanical engineer (K.U. Leuven,
1986). He started his activities as a research assistant at the Division
of Production Engineering, Machine Design, and Automation of K.U.
Leuven in 1986. Within the framework of the Erasmus student exchange
program, he stayed as a PhD student at the Scuola Superiore S. Anna
in Pisa in 1990. In 1993, he became a research manager of the division
PMA. He received a PhD degree in mechanical engineering in 1995 from
K.U. Leuven. Currently, he is associate professor at K.U. Leuven. His
current research interests include design and control of multi-fingered
robot grippers, shape memory alloy actuators, precision mechanics, and
micromechanical systems.
93
till 2002, he worked as a Postdoctoral researcher of the Fund for Scientific Research, Flanders (F.W.OVlaanderen) at the same university and
became assistant professor in 2002. His research focuses on industrial
safety, explosion safety, heat transfer enhancement techniques, design of
thermal systems and turbomachinery.