Introduction: Single Cylinder Air Engine Smaller Edition

Picture of Single Cylinder Air Engine Smaller Edition

Single Cylinder Air Engine Smaller Edition is the smaller sibling of my previous Single Cylinder Air Engine here: https://www.instructables.com/id/Single-Cylinder-.... While Single Cylinder Air Engine Smaller Edition was designed as a test platform for another design, the test video I posted on Youtube caused a few people to message me to ask for the model, so here it is. I've included a video that shows this engine in a new design I have yet to complete.

Having a smaller total displacement than my previous design, this engine runs longer on balloon power but as a trade off delivers less torque. Also, being smaller and having a crank shaft that is assembled in place requires even more fine scraping, sanding and/or filing and meticulous assembly steps to make this engine work at its peak efficiency, so be patient during the printing, preparing and assembly process.

I probably forgot a file or two or something, so if you have any questions, please feel free to ask.

Designed using Autodesk Fusion 360, sliced using Cura 2.3.1, and printed in PLA on an Ultimaker 3 Extended.

Step 1: Print and Prepare the Parts.

Picture of Print and Prepare the Parts.

I printed my parts on an Ultimaker 2+ Extended and an Ultimaker 3 Extended using .1mm vertical resolution and 100% infill.

Print two each of "Journal Crankshaft 4mm.stl" and two each of "Journal Crankshaft 10mm.stl". Print one each of the remaining parts.

"Base.stl" must be printed using supports. "Cylinder.stl" must not be printed with supports.

Prior to assembly, test fit and trim, file, sand, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on the colors you chose and your printer settings, more or less trimming, filing and/or sanding may be required. Carefully file all edges that contacted the build plate to make absolutely sure that all build plate "ooze" is removed and that all edges are smooth. I used a flat jewelers file and plenty of patience to perform this step.

Study "Assembly.stl" carefully noting the locations and positions of the various components as assembly proceeds.

Step 2: Install the Piston Rod, Piston and Valve.

Picture of Install the Piston Rod, Piston and Valve.

Slide "Rod Piston.stl" into "Base.stl" carefully noting the orientation of the hole in "Rod Piston.stl".

Next, press "Piston.stl" onto "Rod Piston.stl" until it is exactly 28mm from the end.

Finally, slide "Valve.stl" into "Cylinder.stl", carefully noting the orientation of "Valve.stl".

Step 3: Attach the Cylinder Assembly to the Base.

Picture of Attach the Cylinder Assembly to the Base.

Carefully position the cylinder assembly into the base assembly and press it fully into place.

When fully in position, the piston rod and valve should easily fall in and out of the assembly when tilting the assembly up and down. If not, it's time to disassemble and continue filing and sanding.

Step 4: Attach the Piston Arm to the Piston Rod.

Picture of Attach the Piston Arm to the Piston Rod.

Using "Pin Arm Piston.stl", attach "Arm Piston.stl" to "Rod Piston.stl".

Once attached, "Arm Piston.stl" should swing freely on "Rod Piston.stl".

Step 5: Attach the Valve Arm to the Valve.

Picture of Attach the Valve Arm to the Valve.

Using "Pin Arm Valve.stl", attach "Arm Valve.stl" to "Valve.stl".

Once attached, "Arm Valve.stl" should swing freely on "Valve.stl".

Step 6: Assemble in Place the Piston Journal.

Picture of Assemble in Place the Piston Journal.

Assemble the piston journal in place using both "Journal Crankshaft 10mm.stl" parts.

Once assembled, the entire piston drive train should rotate freely.

Step 7: Assemble in Place the Valve Journal.

Picture of Assemble in Place the Valve Journal.

Assemble the valve journal in place using both "Journal Crankshaft 4mm.stl" parts carefully noting the position of this journal assembly with that of the piston journal assembly.

Once assembled, the entire piston and valve drive train should rotate freely.

Step 8: Attach the Wheels.

Picture of Attach the Wheels.

Attach "Wheel Piston.stl" to the piston journal.

Attach "Wheel Valve.stl" to the valve journal.

At this time, if you have successfully scraped, sanded and filed all parts, the entire assembly should rotate with ease.

Congratulations, and I hope you enjoy it!

Comments

mbniceguy made it! (author)2018-01-05

I printed and followed all instructions and it seems either the valve arm or the valve is too long, when the cylinder goes all the way in the valve can not go in when all connected, it really is a shame I've been studying air engines for a while looks like it would work if this was corrected, I'm trying to level out the cylinder while bringing it out a little but then I don't think the air function would work........ any help on this would be very helpful thank you.

gzumwalt (author)mbniceguy2018-01-05

Sorry for the difficulties you are experiencing. From the attached photograph, I cannot tell if the journals are positioned correctly.

Make sure the the journals are in the correct locations. Journal Crankshaft 10mm are used for arm piston, and Journal Crankshaft 4mm are used for arm valve.

Also make sure the journal orientations in relation to each other are correct.

Greg

mikeb643 made it! (author)gzumwalt2018-01-05

Hi Greg mike here, here are the pictures of the orientations of the journal crankshaft, still not working, piston side is going up and valve side going right

gzumwalt (author)mikeb6432018-01-05

Hi Mike, I am again truly sorry for the difficulties you are experiencing with this model.

I've attached a photograph showing the dimensions between the chassis cylinder mount surface and the center of the valve plate attachment hole, which is 12.5mm. Will your valve plate easily attain this dimension? If not, the valve plate may be warped.

mbniceguy (author)gzumwalt2018-01-05

I'm not sure I think it could be that because I've just gotten done takeing the piston rod and valve off and on, but when it starts it doesn't want to push by a balloon or compressor it actually stops it would you recommend another easier air engine I could print and make? And thanks for all the responces, all your stuff is really awesome, wish I could have this one though, might try and print it again sometime..... MB

gzumwalt (author)mikeb6432018-01-05

Also, remove arm piston from the assembly and see if the valve portion of the assembly rotates smoothly. If not, find out why.

Next, remove the arm valve from the assembly and see if the piston portion of the assembly rotates smoothly, and again if not, find out why.

Keep me posted.

Greg

Anybodysguess (author)2017-03-17

I began printing this, but I beleive the cylider is wrong, it doesn't match your pictures, and doesn't fit the base.

gzumwalt (author)Anybodysguess2017-03-17

I'm very sorry about that, I've uploaded the correct cylinder. I inadvertently uploaded the cylinder for the vehicle.

Also note that "Head.stl" is not used for the engine, again, it is for the vehicle.

Guess I should wait until the morning hours to upload things. Again, I'm very sorry.

Anybodysguess (author)gzumwalt2017-03-19

Done printing, not done sanding, probably not the best model to use to redial in my printer after rebuilding it. Anyways, is the valve arm too long? The valve goes all the way in, but the arm is too long and doesn't line up with the cam.

gzumwalt (author)Anybodysguess2017-03-19

It appears that the arm is correct. I'll check the model files when I return to the computer.

Sorry for the problems.

About This Instructable

3,485views

35favorites

License:

Bio: Formerly the owner of a company that designed software for avionics (EFIS, FMS, etc.) and video games (Tetris, Robocop, Predator, Michael Jordan in Flight, and ... More »
More by gzumwalt:WiFi Kit 32 NTP ClockHeltech WiFi Kit 32 Based Network ScannerMoney Maker!
Add instructable to: