BODHPS PROTOTYPE B

Testing and Documentation of improved prototype with a record

of power output.

General Test Goals

• This test will achieve the following 5 General Goals…

• 1) Provide documentation for publication to various Media channels for publicity and advertisement.

• 2) Provide further proof of Basic Requirements beyond proof of concept already achieved.

• 3) Test improvements made to Prototype A.• 4) Identify which application’s requirements could be met

by using the Prototype’s design; ie, same engine, etc.• 5) Identify improvements needed for production.

Specific Test Goals

• This test will achieve the following 3 Specific Goals to accomplish the General Goals…

• 1) Produce a Video Recording of test items, hardware, software, and operation.

• 2) Produce a Digital Database record of all measurements and calculations.

• 3) Add to previous test documentation.

Test Layout

Monitor Program in PC with Database

Engine Control Program in ECM

USB

Engine BODHPSAlternatorPower Load Resistors

ControlEngine Power Sensor Steam Power Sensor

Orifice Plate Flow Meter

Volt and Amp Meter

Basic Requirements to meet

• BODHPS is designed to recover otherwise wasted energy from the exhaust of any Internal Combustion Engine as Steam. The 3 main requirements are…

• 1) Do not affect the performance of the ICE.• 2) Produce “Live” Steam.• 3) Increase overall efficiency of the System.

Test Specific Details• Some items are not part of BODHPS but are used for testing:• The Monitor Program and the Engine Control Module are not required for BODHPS operation in any of the actual product applications.

They have been developed to provide tools for testing and improvement of the original prototype. Optimization of timing and engineering details are aided by these tools. The following detailed description is useful for understand the testing of BODHPS.

• The Engine Control Module• An Engine Control Module (ECM) is attached to the Internal Combustion Engine (ICE) to measure and control various processes relevant

to BODHPS testing. The measurements are engine RPM, air temperature, steam temperature, steam pressure, DC Voltage, and DC Current. The controls are throttle position, water injection, and alternator activation. Thermocouples are used to measure temperature. A High Wattage/Low OHM in-line resistor is used to measure current to the test Load. A Pressure Transducer measures Steam Pressure. Throttle position is controlled by a Servo Motor. The ECM gathers data and communicates that data via USB to the Monitor program running on an isolated PC.

• The Monitor Program• The Monitor Program (MP) provides a user interface for control settings and viewing of parameters needed for testing and improvement

of the main device. Also, the Monitor Program calculates the essential information about the output of the System. It calculates Break Horse Power (BHP) of the engine, and Boiler Horse Power (BoHP) of the steam. It then scales the BoHP to give the equivalent BHP of the steam. The MP also records are settings, measurements, and calculations along with a Time Stamp in a MS Access Database for future analysis.

• The Equations• Measurement of the Current to the load is calculated from the Voltage drop across the in-line resistor. Current = Voltage / Resistance.

Voltage on the Load is measured directly. Wattage on the Load is calculated as WATTS = Current x Voltage. BHP of the ICE is calculated as BHP = WATTS / 745.5.

• Measurement of the power of the steam produced is done as a function of the flow rate through and Orifice Plate Meter. A restrictor plate with a whole is placed in the steam flow. A pressure transducer measures the steam pressure before the plate. The steam exhausts to the atmosphere with a know pressure of 1A. An Orifice Plate Flow Calculator (http://www.flowmeterdirectory.com/index.html) was used to produce an MS Excel Spread Sheet of Various Steam pressures with specific whole diameters exhausting into the atmosphere. It shows the equation for BHP of Steam to be nearly linear as BHP = (0.245434328974359 + ((P1 - P2) x 0.065155671) + ((T- 212) x (-0.00127989))) x 60/34.5 for a .25” orifice.

• The Calculator and Spread Sheet, as well as test documents can be provided on request via e-mail to rwio@hotmail.com.

Test Results• The engine drives an alternator providing DC power to the load resisters. I calculate the engine produced 0.505

Crank Horse Power.• I measure Steam Pressure in the 0.5 in. dia. pipe before a 0.1875 in. Orifice allows the Steam to escape to the

atmosphere at 14.695432 PSI. The Orifice Plate Calculator is used to find the Flow Rate per hour. I calculate the Boiler Horse Power then the Brake Horse Power equivalent of 5.9 HP from Steam.

• May 26, 2010

• Engine Horse Power: Ave. Volts x Ave. Current = Watts / 745.5 = HP • 13.83 x 27.24 = 376.67 = 0.51•

• Steam Horse Power: Ave. Pressure Flow rate lb/min x 60 = lb/hr/34.5 = BoHP x 13.15 = HP• 1.78 = 0.26 =15.71 = 0.46 x = 5.99