SIX STROKE ENGINE 1504102

INTRODUCTION

Engine work successfully only when it follows a cycle of operation in a sequential

manner. In IC engines, operating on different cycles have one common feature,
combustion occurring in the cylinder after each compression, resulting in gas
expansion that acts directly on the piston (work) and limited to 180 degrees of
crankshaft angle. The six-stroke engine is an internal combustion engine with an
advance feature of more power generation. This engine consists of similar
components Present in the four-stroke engine with addition of two more cylinders
and have similar working concept to the actual internal reciprocating combustion
engine as piston is in reciprocal movement which is converted into a rotating
movement with the help of connecting rod and crankshaft. In four stroke engine, the
cycle of operation take place in four stroke which are Suction or intake stroke,
compression stroke, expansion or power stroke and exhaust stroke. In starting the
inlet valve opens and the charge consisting of fuel air mixture is drawn into the
cylinder and then piston moves from top dead Centre to bottom dead Centre Then
the intake and exhaust valves closes instantaneously. During the compression stroke,
the piston moves upward compressing the air-fuel mixture in the clearance volume.
But before the piston reaches its highest position, the spark plug injected the air-fuel
mixture and the mixture ignites, increasing the pressure and temperature of the
cylinder. The high-pressure gases which are emitted from previous cylinder force the
piston down, which in turn forces the crankshaft to rotate, producing a useful work
output during the expansion or power stroke. At the end of this stroke which is
Exhaust stroke, the piston is at bottom dead centre moves to top dead centre pushes
the combustion product to top dead centre during this process the exhaust valve is
open and inlet valve is closed. Thus, the piston completes four strokes which give
two complete revolutions to the crankshaft. But in six stroke engines the exhausted
gases are used which are left after combustion in next stroke for generating steam
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from water. Then water is injected in superheated cylinder. The hot gases which emit
from fourth stroke is used to changes the phase of water to steam as the
temperature of the hot gases is high so this steam will work as working fluids which
will forces the piston down. This movement will give an additional two stroke for the
same cycle. In four stroke coolant is required but in six stroke engines, there is no
need of external cooling system because water which is used as working fluid will
cools the system. So, in six stroke, fuel consumption is reduced and increases its
power. It reduces the weight and complexity of the engines head by as much as 50%.
Torque is increased by 35% and increases its efficiency. The first six stroke engines.
Which is Bajulaz Six Stroke Engine was invented in 1989 by the Bajulaz S A company,
based in Geneva, Switzerland. The design of Bajulaz six stroke engines is similar to a
regular combustion engine. There was a modification to the cylinder head, in which
he used two supplementary fixed capacity chambers, a combustion chamber and an
air preheating chamber above each cylinder is done. The combustion chamber
present in engine receives a charge of heated air from the cylinder and then the
injection of fuel begins, at the same time it burns which increases the thermal
efficiency compared to a burn in the cylinder. The high pressure achieved from
previous cylinder is then released into the cylinder to work as power or expansion
stroke. Whereas a second chamber which blankets the combustion chamber has its
air content which is heated to a high degree by heat passing through the cylinder
wall? This heated and pressurized air is used to power an additional stroke of the
piston. The advantages of this engine include reduction in fuel consumption by 40%,
multi-fuel usage capability as we use water, and a dramatic reduction in pollution.

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HISTORY OF SIX STROKE ENGINE :

The term six stroke engine describes two different approaches in the internal
combustion engine, developed since the 1990s which are as follows:

In the first approach, the engine captures the waste heat from the four stroke Otto
cycle or Diesel cycle and uses it to get an additional power and exhaust stroke of the
piston in the same cylinder. Designs either use steam or air as the working fluid for
the additional power stroke. As well as extracting power, the additional stroke cools
the engine and removes the need for a cooling system making the engine lighter and
giving 40% increased efficiency over the normal Otto or Diesel Cycle. The pistons in
this six stroke engine go up and down six times for each injection of fuel. These six
stroke engines have 2 power strokes: one by fuel, one by steam or air. The currently
notable six stroke engine designs in this class are the Crower's six stroke engine,
invented by Bruce Crower of the U.S.A; the Bajulaz engine by the Bajulaz S A
Company, of Switzerland; and the Velozeta’s Six-stroke engine built by the College of
Engineering, at Trivandrum in India.

The second approach to the six stroke engine uses a second opposed piston in each
cylinder which moves at half the cyclical rate of the main piston, thus giving six piston
movements per cycle. Functionally, the second piston replaces the valve mechanism
of a conventional engine and also it increases the compression ratio. The currently
notable six stroke engine designs in this class include two designs developed
independently: the Beare Head engine, invented by Australian farmer Malcolm
Beare, and the German Charge pump, invented by Helmut Kottmann.

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TYPES OF SIX STROKE ENGINES

1. Crower six stroke engine.
2. Beare Head Six Stroke engine.
3. Bajulaz six stroke engine.

1. Crower six stroke engine :

In a six-stroke engine patented in the U.S. by Bruce Crower, after the exhaust stroke,
fresh water is injected into the cylinder, and is quickly turned to superheated steam,
which causes the water to expand to 1600 times its volume and forces the piston
down for an additional stroke. This design also claims to reduce fuel consumption by
40%.

 Crower's six stroke engine features :-

 No cooling system required

 Improves a typical engine’s fuel consumption
 Requires a supply of distilled water to act as the medium for the second
power stroke.

2. Beare Head Six Stroke engine :

This engine simply replaces the conventional Four Stroke Engines Cylinder Head. The
manufacturers Four Stroke bottom end remains unchanged. The Engine utilises an
overhead short stroke Crankshaft and Piston arrangement which opens and closes
Inlet and Exhaust Ports leading through the Upper Cylinder Liner. The Beare Head
Technology can be fitted to new production engines or retro-fitted via aftermarket
replacement.

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The top and bottom Crankshaft are connected via a drive chain or toothed belt. The
top Crankshaft and Piston become positive power contributors to the overall power
output, thus increasing the amount of power/torque generated by up to a possible
35%, in essence, The Engine results in having Two Pistons Operating and producing
power within each cylinder. The absence of valves, springs, retainers and guides,
mean that the Engines bottom end has been freed up from labouring and is allowed
to spin up producing more power. The additional torque and power further
generated by the Top Piston/Crank of the Cylinder Head is then channelled via the
connecting drive chain to the Bottom Crank. The net result of the Engine is Tractor
type pulling torque never before realised from a Four Stroke Internal Engine, the sort
of steady locomotive type performance gained can only be likened to Steam
Locomotives or Diesel Engines.

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The net result is:

- Power/torque increases of 35% (conservative)
- Simpler and less expensive manufacturing and tooling
- Reduction of cylinder head reciprocating parts
- Lower maintenance costs due to less wearing parts (cylinder head)
- Longer service intervals possible due to lower operating temperatures recorded
- Increased economy due to the ability to operate and produce full operating power
of much higher AIR to FUEL ratios
- Reduction of exhaust emissions due to less fuel being consumed and the real
prospect of meeting EURO-4 emissions standards, doing away with the catalytic
converter
- Possible one piece engine block and head casting, saving more manufacturing costs
- Usable torque at as low as idle means suitability for lower RPM operation and
adaptation to CVT (Constantly Variable Transmission)

3. BAJULAZ SIX STROKE ENGINE :

1) Intake valve
2) Heating chamber valve
3) Combustion chamber valve
4) Exaust valve
5) Cylinder
6) Combustion chamber
7) Air heating chamber
8) Wall of combustion chamber
9) Fuel injector
10) Heating plug
11) Piston
12) Crankshaft

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Fig. Bazulaz six stroke engine

The Bajulaz six stroke engine is similar to a regular combustion engine in design. But
however there are some modifications to the cylinder head, with two supplementary
fixed capacity chambers, a combustion chamber and an air preheating chamber
above each cylinder. The combustion chamber receives a charge of heated air from
the cylinder and the injection of fuel begins an isochoric burn which has increased
thermal efficiency compared to a burn in the cylinder. The high pressure achieved is
then released into the cylinder to work the power stroke. Meanwhile a second
chamber which blankets the combustion chamber has had its air contents heated to
a high degree by heat passing through the walls from the burn. This heated and
pressurized air is then used to power another stroke of the piston in the cylinder. The
advantages of the engine include reduction in fuel consumption by at least 40%, two
expansion strokes (work) in six strokes, multi-fuel usage capability, and a dramatic
reduction in pollution. Bajulaz Six Stroke Engine was invented in 1989 by the Bajulaz
SA.

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SIX STROKE ENGINE 1504102

 Bajulaz six stroke engine features:-

 Reduction in fuel consumption by at least 40%

 Two expansions (work) in six strokes
 Multi fuel
 Dramatic reduction in pollution
 Liquefied Petroleum Gas
 Costs comparable to those of a four-stroke engine

CONSTRUCTION AND DESIGN OF SIX STROKE ENGINE

 The engine consists of 4 valves : intake valve(1) , heating chamber
valve(2),combustion chamber valve(3) and the exhaust valve(4) which control
the flow of the fluids in the cycle
 Engine consists of a combustion chamber for burning of fuel air mixture (6)
which is completely isolated from the cylinder and the burning of the fuel has
no direct effect on the piston as in the case of a 4 stroke ICE.
 An air heating chamber surrounds the combustion chamber which holds pure
air under high pressure. Heat passes from the combustion chamber to the air
heating chamber
 The wall of the combustion chamber allows transfer of heat to the air heating
chamber which heats the air under high pressure which is eventually used in
the 5th stroke.
 The burning of the fuel does not have any direct influence on the piston. The
energy released by the combustion passes through valve (3) which enters the
cylinder (5) and hence work is done on the piston (11)

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WORKING OF SIX STROKE ENGINE

The working of the 6 stroke ICE is very similar to the 4 stroke ICE.the first four strokes
remain the same with the addition of 2 more strokes discussed below:

 1st stroke:

Fig.: 1st stroke(suction stroke)

The inlet valve(1) is kept open. Due to cranking, the piston moves downward which
results in the formation of a pressure difference due to which pure air enters the
cylinder (5).The crankshaft completes rotates for half cycle.

 2nd stroke:

Fig : 2nd stroke (compression stroke)

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The inlet valve closes and the heating chamber valve (2) opens. The piston moves
upwards due to cranking forcing the pure air into heating chamber (7). The air at this
stage is converted to high pressure. The fuel is injected in the combustion chamber
and the fuel is ignited as shown the figure (initially compressed air is present in the
combustion chamber which results in the formation of fuel air mixture). Part of the
heat evolved will pass through the wall of the combustion chamber (8) and it heats
up the compressed air present in the air heating chamber. The crankshaft completes
another half cycle rotation in the 2nd stroke. At the end of 2 strokes the crankshaft
will rotate 1 complete cycle.

 3rd stroke (1st power stroke):

Fig:3rd stroke (1st power stroke)

The combustion chamber valve (3) opens and the gases of combustion enter the
cylinder (5). This pusher the piston downward and hence is known as the power
stroke. The crankshaft rotates for a half cycle. It should be noted that the air in the
heating chamber is continuously heated and this results in further increase of
pressure.

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 4th stroke (exhaust stroke):

Fig: 4th stroke (exhaust stroke)

The exhaust valve (4) opens. The piston moves upwards and the exhaust gases are
removed via this valve. The crankshaft rotates another half cycle. At this stage the
crankshaft completes 2 full cycles.In this stroke, less amount of heat energy is
expelled out when compared to the 4 stroke ICE as this heat has already been used
to heat the air at high pressure in the air heating chamber (7).

 5th stroke (2nd power stroke):

Fig : 5th stroke (2nd power stroke)

The heating chamber valve opens and the pure air now at high pressure and high
temperature enters the cylinder as shown in the figure which does work on the

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piston and hence it moves downwards resulting in the 2nd power stroke. The
crankshaft completes another half cycle.

 6th stroke:

Fig : 6th stroke

Finally the combustion chamber valve (3) opens the piston moves upwards forcing
the pure air into the combustion chamber which will be used as air for the fuel-air
mixture in the 3rd stroke or the first power stroke. The crankshaft will complete 3 full
cycles at the end of the 6th stroke. Hence fuel is injected once every in 3 cycles of the
crankshaft whereas in a 4 stroke ICE fuel is injected once in every 2 cycles.

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Graphical Representation
Following is the graphical representation of the six strokes in a cycle. The crankshaft
rotates a total of 1080o in 1 complete cycle. The six strokes are divided into 8 events
which are intern classified into 2 categories i.e. :

Static event : event occurs without the movement of piston

Dynamic event : event which occurs with the movement of piston

Fig : Graphical representation of six strokes

 External combustion cycle:

In this cycle there is no contact between the air and the heating source.

The events which take place are as follows:

(Refer graph)

E1. (Event 1) : Pure air intake in the cylinder (dynamic event).

E2. (Event 2) : Compression of pure air in the cylinder (dynamic event).

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E3. (Event 3) : Keeping pure air pressure in closed chamber where a maximum heat
exchange occurs with the combustion chamber walls, without direct action on the
crankshaft (static event).

E4. (Event 4) : Expansion of superheated air in the cylinder which does work on the
cylinder (dynamic event).

 Internal combustion cycle:

In this cycle direct contact takes place between the air and the heating source

The events which take place are as follows:

E5. (Event 5): Recompression of pure heated air in the combustion chamber
(dynamic event).

E6. (Event 6): Fuel injection and combustion in closed combustion chamber,without
direct action on the crankshaft (static event).

E7. (Event 7): Combustion gases expand in the cylinder and work is done on the
piston (dynamic event).

E8. (Event 8): Exhaust gases are removed (dynamic event).

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Graphical comparison of six stroke engine and four stroke

engine:

Graph 1:otto cycle

It is clear from the first graph that the work done by the 6 stroke engine is greater
than the 4 stroke engine. Graph 1 is in reference with a Petrol engine.

Graph 2:Dual cycle

Graph 2 refers to a diesel engine. The work done by six stroke engine is greater than
a 4 stroke engine for the same amount of fuel used.

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FACTORS CONTRIBUTING TO INCREASED THERMAL EFFICIENCY,

REDUCED FUEL CONSUMPTION AND POLLUTANT EMISSION :
1) The heat that is evacuated during the cooling of a conventional engine’s
cylinder head is recovered in the six-stroke engine by the air-heating chamber
surrounding the combustion chamber. As a result of this less heat is wasted which
increases the thermal efficiency.

2) After intake, air is compressed in the heating chamber and heated through 720o of
crankshaft angle, 360o of which in closed chamber (external combustion).

3) The transfer of heat from the very thin walls of the combustion chamber to
the air heating chambers lowers the temperature and pressure of the gases on
expansion and exhaust (internal combustion).

4) Better combustion and expansion of gases that take place over 540o of
crankshaft rotation, 360° of which is in closed combustion chamber, and 180° for
expansion.

5) The glowing combustion chamber allows the optimal burning of any fuel and
calcinate the residues.

6) Better filling of the cylinder on the intake due to the lower temperature of the
cylinder walls and the piston head.

7) Elimination of the exhaust gases crossing with fresh air on intake. In the six
stroke-engine, intake takes place on the first stroke and exhaust on the fourth stroke.

8) Large reduction in cooling power. The water pump and fan outputs are
reduced. Possibility to suppress the water cooler.

9) Less inertia due to the lightness of the moving parts.

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ADVANTAGES OF SIX STROKE ENGINE :

1) Reduction in fuel consumption by at least 40%:

2) Two expansions (work) in six strokes

3) Dramatic reduction in pollution:

4) Liquefied Petroleum Gas

5) Cost comparable to those of a four-stroke engine

DISADVANTAGES OF SIX STROKE ENGINE :

• Engine size increases due to many number of cylinders & additional components.

• Break power & indicated power per cycle per cylinder is comparatively lesser.

• Cost is high as compared to 4 stroke engine.

• Low Mechanical Efficiency due to large number of mechanical parts.

• The engine would be very bulky and will effect the overall performance, if installed
in a vehicle

APPLICATIONS OF SIX STROKE ENGINE :

• Motor boats

• Motor Pumps

• Generators

• Stationary Engines

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MODIFICATIONS IN SIX STROKE ENGINE

 CAMSHAFT MODIFICATIONS:

In the six stroke engine the 360 degree of the cam has been divided into 60 degree
among the six stroke. The exhaust cam has 2 lobes to open the exhaust valve at
fourth stroke (first exhaust stroke) and at the sixth stroke to push out the steam.

 CRANKSHAFT TO CAMSHAFT RATIO MODIFICATION:

In conventional four stroke engine, the gear at crankshaft must rotates 720. while
the camshaft rotates 360 to complete on cycle for six stroke engine, the gear at the
crankshaft must rotates 1080 to rotates the camshaft 360 and complete one cycle.
Hence their corresponding gear ratio 3:1

 CAM FOLLOWER MODIFICATION:

The bottom of shape of regular follower has the flat pattern, which is suitable with
the normal camshaft for four stroke engine. When reducing the Duration of valve
opening from 9000 to only 6000 the shape of the follower must be changed from flat
to roller or spherical shape. Mitsubishi single cylinder spark ignition was used to
apply these modifications on it.

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CONCLUSION:
The six stroke engine modification promises dramatic reduction of pollution and fuel
consumption of an internal combustion engine. Its adoption by the automobile
industry would have a tremendous impact on the environment and world economy,
assuming up to 40% reduction in the fuel consumption and 60% to 90% in polluting
emissions, depending on the type of fuel being used and the second piston replaces
the valve mechanism of a conventional engine and also it increases the compression
ratio.

REFERRENCES:
• www.quora.com

• www.wikipidea.org

• www.ijert.org

• Andrew De Jong, Marc Eberlein, John Mantel Tim, Opperwall Jim, VanLeeuwen
May 12, 2010 Calvin College ENGR 340

• vishal kumar tyagi, dev bhoomi institute of technology,dehradun, india. Study And
Analysis Of Six Stroke Engine.

• MR. BHATIA, A, “SIX STROKE ENGINE INTERNAL COMBUSTION ENGINE”, ICMEE,

KYOTO, 1- 3AUG. 2010

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