SIX STROKE ENGINES

1. INTRODUCTION
The term six stroke engine describes two different approaches in
the internal combustionengine, developed since the 1990s, to improve its
efficiency and reduce emissions.In the first approach, the engine captures
the waste heat from the four stroke Otto cycle orDiesel 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. Aswell as extracting power, the additional stroke
cools the engine and removes the need for acooling 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 eachinjection 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 eachcylinder 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 Headengine, invented by Australian
farmer Malcolm Beare, and the German Charge pump, invented
by Helmut Kottmann.

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2. SYMBOLS USED

1. TFC:- Total fuel consumption in Kg/Hr

2. SFC:- Specific fuel consumption in Kg/Kwhr

3. BP :- Brake power in Kw

4. TDC :- Top dead center

5. BDC :- Bottom dead center

6. IVO :- Inlet valve opening

7. IVC :- Inlet valve closing

8. EVO :- Exhaust valve opening

9. EVC :- Exhaust valve closing

10. N :- Engine speed at final drive shaft to the wheel in rpm

11. P :- Load in Kg

12. T :- Time for 10 cc fuel consumption

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3. HISTORY OF SIX STROKE ENGINES
As mentioned earlier there are two approaches to study about six stroke
engines, i.e., first and second. There are four types of engine comes under
the first category of six stroke engines and two types of engine come under
the second category.
First Category:-
The engines coming under this category are

GRIFFIN SIX STROKE ENGINE:- Griffin engine was the first six
stroke engine developed in the world. It is developed by the engineer
Samuel Griffin in 1883. In 1886 Scottish steam locomotive makers
found a future in Griffin’s engine and they licensed the Griffin patents
also marketed the engine under the name ‘Kilmarnock’. They used
this engine mainly for electric power generation. Only two known
examples of a Griffin six-stroke engines survive today. One is in the
Anson Engine museum. The other was built in 1885 and for some years
was in the Birmingham Museum of Science and Technology, but in
2007 it returned to Bath and the Museum of Bath at Work

BAJULAZ SIX STROKE ENGINE:-

The Bajulaz Six Stroke Engine was invented in 1989 by the Bajulaz S A
company, based in Geneva, Switzerland. The Bajulaz six stroke engine is
similar to a regular combustion engine in design. There was however
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; 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 is then released into the cylinder
to work the power or expansion stroke. Meanwhile a second chamber
which blankets the combustion chamber has its air content heated to a high
degree by heat passing through the cylinder wall. This heated and
pressurized air is then used to power an additional stroke of the piston.
The advantages of the engine include reduction in fuel consumption by
40%, multi-fuelusage capability, and a dramatic reduction in pollution

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CROWER SIX STROKE ENGINE:-

This engine is invented by Bruce crower of California in USA in the
year 2004. Bruce Crower is actually a race car mechanic with his own
workshop. In his six-stroke engine, power is obtained in the third and
sixth strokes. First four strokes of this engine are similar to a normal four
stroke engine and power is delivered in the third stroke. Just prior to the
fifth stroke, water is injected directly into the heated cylinder via the
converted diesel engine's fuel injector pump. The injected water absorbs
the heat produced in the cylinder and converts into superheated steam,
which causes the water to expand to 1600 times its volume and forces
the piston down for an additional stroke i.e. the second power stroke. The
phase change from liquid to steam removes the excess heat of the engine.
As a substantial portion of engine heat now leaves the cylinder in the form
of steam, no cooling system radiator is required. Energy that is dissipated
in conventional arrangements by the radiation cooling system has been
converted into additional power strokes. In Crower's prototype, the water
for the steam cycle is consumed at a rate approximately equal to that of the
fuel, but in production models, the steam will be recaptured in a condenser
for re-use.

Second category:-
The engines coming under this category are
1. BEARE HEAD SIX STROKE ENGINE:-
Malcolm Beare 47 year old Australian wheat farmer is the inventor of this
six stroke engine. Actually the name six stroke engines was introduced by
Malcolm Beare. Beare created an innovative hybrid engine, combining
two-strokes in the top end with a four-stroke above the middle portion. So
by adding this four plus two equals six, he derived the name six stroke
engines. Below the cylinder head gasket, everything is conventional, in his
design. So one main advantage is that the Beare concept can be
transplanted to existing engines without any redesigning or retooling the
bottom end and cylinder. But the cylinder head and its poppet valves get
thrown away in this design. To replace the camshaft and valves, Beare
used a short-stroke upper crankshaft complete with piston, which is driven at half
engine speed through the chain drive from the engine. This piston moves against the
main piston in the cylinder and if the bottom piston comes four times upwards, upper
piston will come downwards twice.

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CHARGE PUMP ENGINE:-
In this engine, similar in design to the Beare head, a ‘piston charger’
replaces the valve system. The piston charger charges the main cylinder
and simultaneously regulates the inlet and the outlet aperture leading to no
loss of air and fuel in the exhaust. In the main cylinder, combustion takes
place every turn as in a two-stroke engine and lubrication as in a four-
stroke engine. Fuel injection can take place in the piston charger, in the gas
transfer channel or in the combustion chamber. It is also possible to charge
two working cylinders with one piston charger. The combination of
compact design for the combustion chamber together with no loss of air
and fuel is claimed to give the engine more torque, more power and better
fuel consumption. The benefit of less moving parts and design is claimed
to lead to lower manufacturing costs. Good for hybrid technology and
stationary engines. The engine is claimed to be suited to alternative fuels
since there is no corrosion or deposits left on valves. The six strokes are:
aspiration, precompression, gas transfer, compression, ignition and
ejection.

4. VELOZETA’S SIX STROKE ENGINE

Mechanical Engineering students of the college of Engineering in

Trivandrum, in the year 2006 made this six stroke engine as a part of their
B.Tech project. After the completion of the course they formed the
company Velozeta with the help of state and central government.They
have got the patent of this engine also. In Velozeta’s six stroke engine, a
four-stroke Honda engine was experimentally altered to build the six
stroke engine.The first four strokes of this engine are just like a
conventional four stroke engine. The additional two strokes are for better
scavenging and cooling of the engine which is provided by a secondary air
induction system.

4.1 THEORY:-
There is only a slight difference between Crower’s six stroke engine and
Velozeta’s six stroke engine. In the Crower’s six stroke engine and this
engine, the first four stokes are the same as a conventional four stroke
engine. In Crowers engine during the fifth stroke water is injected into the
cylinder and converted to steam which is used for expansion and the sixth
stroke eliminates the expanded vapors through the exhaust manifold. But
here the difference is that in the fifth stroke, instead of water, air from an
air filter is sucked into the cylinder through a secondary air line provided at

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the exhaust manifold. In the sixth stroke, a mixture of this air and unburned
gases are pushed out through the exhaust valve.

4.2 ENGINE PARTS MODIFIED:-

Cam shaft / Crank shaft Sprockets:-

In the six stroke engine the crankshaft has 1080 degrees of rotation for 360
degree rotation of the camshaft per cycle. Hence their corresponding
sprockets are having teeth in the ratio 3:1.In the original four stroke engine
the teeth of the sprockets of the crankshaft and the camshaft were in 2:1
ratio. The 34 teeth sprocket of the four stroke engine camshaft was
replaced by a 42 teeth sprocket in the six stroke engine. The camshaft
sprockets were also replaced from 17 teeth to 14 teeth to convert the four
stroke engine into six stroke engine.

2) Cam lobes

In the six stroke engine the 360 degrees of the cam has been divided into
60 degrees among the six strokes. The valve provided at the exhaust has to
be kept open during the fourth, fifth and the sixth stroke. The cam has been
made double lobed in order to avoid the hitting of the exhaust valve with
the piston head. The profiles of the exhaust and the inlet cams have been
shown in the figure 1.

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3) Valve Timing
The valve timing of the four stroke Honda engine has been changed. The
inlet valve opening (IVO) is 0° at TDC, same as that of the four stroke
Honda activa engine. Inlet valve Closes (IVC) at 25° after BDC, same as
that of the four stroke engine. Exhaust valve opens (EVO) 0° at BDC,
which in the original engine was 25° before BDC. Velozeta reduced this
25° advanced opening of exhaust valve to extract maximum work per
cycle. Exhaust valve closes 10 degree before TDC in order to prevent the
loss of air fuel mixture through the exhaust valve. Two reed valves have
been provided for the proper working of the engine.

4) Secondary Air Induction System

The secondary air induction system, supplies the air which is used during the fifth and
sixth stroke. During the fifth stroke air from the air filter ( f i g 24) is sucked into the
cylinder through the secondary air induction line. The reed valve ( f ig 22) opens to
permit the air flow. During the sixth stroke, the air is removed through the exhaust
manifold (fig 13). The reed valve (fig 23) opens and the reed valve (fig 22) closes
during this stroke. The inlet valve remains closed during these strokes
.
4.3 WORKING OF VELOZETA SIX STROKE ENGINE:-

The detailed working of the six stroke engine has been explained by using
figures 2-7, which give explanations regarding the each stroke. A detailed
label of the engine parts has been given in page (4). The working of the
engine is as follows. Also the detailed label of engine parts in the figures is
given allow.

Detailed Label of Engine Parts :-

1. Rings
2. Inlet Manifold
3. Cylinder Head
4. Cam shaft
5. Cam Lob No.1
6. Inlet valve
7. Sprocket 42T
8. Rocker Arm
8.1. Inlet Rocker arm
8.2. Exhaust Rocker arm
9. Head Cover
10. Cam Lob no.3
11. Exhaust valve
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12. Cam Lob No.2
13. Exhaust Manifold
14. Spark plug
15. Cylinder
16. Piston
17. Connecting rod
18. Timing Chain
19. Sprocket 14T
20. Crank
21. Secondary air induction unit
22. Reed valve (One way valve)
23. Reed valve (One way valve in Exhaust manifold)
24. Air filter
25. 42T sprocket holder
26. Bearing

First stroke ( Figure2 ) :-

During the first stroke the inlet valve (6) opens and air-fuel mixture from
carburetor is sucked into the cylinder through the inlet manifold (2).

Figure 2: First Stroke

Second stroke ( Figure 3 ) :-
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During the second stroke, piston moves from BDC to TDC, both the inlet
valve (6) and exhaust valve (11) are closed and the air-fuel mixture is
compressed. The compression ratio of the modified engine is same as that
of the original four stroke Honda engine 9:1.

Figure 3: Second Stroke

Third stroke ( Figure 4 ) :-

During the third stroke, power is obtained from the engine by igniting the
compressed air- fuel mixture using a spark plug (14). Both valves remain
closed. Piston movesfrom TDC to BDC.Figure4: Third Stroke

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Figure4: Third Stroke

Fourth stroke ( Figure 5 ) :-
During the fourth stroke, the exhaust valve (11) and the reed valve (23)
opens to remove the burned gases from the engine cylinder. Piston moves
from BDC to TDC.

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Figure 5: Fourth Stroke

Fifth stroke ( Figure 6 ) : -
During the fifth stroke, the exhaust valve (11) remains open and the reed
valve (23) closes. Fresh air from the air filter (24) enters the cylinder
through the secondary air induction line (21) provided at the exhaust
manifold (13). The reed valve (22) opens.Figure 6: Fifth Stroke 14

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Figure 6: Fifth Stroke

Sixth stroke ( Figure 7 ) :-
During the sixth stroke, the exhaust valve (11) remains open. The air
sucked into the cylinder during the fifth stroke is removed to the
atmosphere through the exhaust manifold (13). The reed valve (23) opens
and the reed valve (22) closes.

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4.4 Performance test results:-
Two tests i.e., Engine load test and Pollution, test was conducted on the six
stroke engine and on the same four stroke engine from which the six stroke
was developed.
Experimental Procedure:-
The same engine was altered as four stroke and six stroke to perform the
experiments. Load test and pollution test were conducted. The load test
was conducted using brake drum dynamometer. The final drive shaft from
the engine to the wheel was used for loading during the experiment. The
engines were tested for 320rpm a n d 6 4 0 r pm under the same loading
conditions. The time for consumption of 10cc of the fuel was noted during
the experiment. The % vol. of CO in exhaust gas during idling was tested
to check the pollution level of the engines. The results of load test and
pollution test have been tabulated in table (1) and table (2) respectively.

4.4.1 Load test results:-

N P T4 T6 TFC4 TFC6 TFC

(rpm) (kg) (S) (S) (kg/hr) (kg/hr) Redn%

320 0 88 95 0.302 0.280 7.36

320 4 83 92 0.321 0.289 9.81

320 8 78 90 0.341 0.296 13.32

320 10.5 75 84 0.355 0.317 10.72

320 13.5 71 78 0.375 0.341 8.98

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4.4.2Pollution Test Results:-

4.5 GRAPHS:-

Graph-1: Bp Vs TFC & SFC at 320rpm

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Graph-2: Bp Vs TFC & SFC at 640 rpm

4.6 ADVANTAGES OF SIX STROKE OVER FOUR

STROKE ENGINES:

The six stroke is thermodynamically more efficient because the change

in volume of the power stroke is greater than the intake stroke, the compression
stroke and the Six stroke engine is fundamentally superior to the four stroke
because the head is no longer parasitic but is a net contributor to – and an
integral part of – the power generation within exhaust stroke. The compression
ratios can be increased because of the absent of hot spots and the rate of change
in volume during the critical combustion period is less than in a Four stroke. The
absence of valves within the combustion chamber allows considerable design
freedom.

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Main advantages of the six-stroke engine:

Reduction in fuel consumption by at least 40%:

An operating efficiency of approximately 50%, hence the large

reduction in specific consumption. the Operating efficiency of current petrol
engine is of the order of 30%. The specific power of the six-stroke engine will
not be less than that of a four-stroke petrol engine, the increase in thermal
efficiency compensating for the issue due to the two additional strokes.

Two expansions (work) in six strokes:

Since the work cycles occur on two strokes (3600 out of 10800 ) or 8% more than
in a four-stroke engine (1800 out of 720 ), the torque is much more even. This
lead to very smooth operation at low speed without any significant effects on
consumption and the emission of pollutants, the combustion not being affected
by the engine speed. These advantages are very important in improving the
performance of car in town traffic.

Dramatic reduction in pollution:

Chemical, noise and thermal pollution are reduced, on the one hand, in
proportion to the reduction in specific consumption, and on the other, through
the engine’s own characteristics which will help to considerably lower HC, CO
and NOx emissions.

Multifuel:
Multifuel par excellence, it can use the most varied fuels, of any origin
(fossil or vegetable), from diesel to L.P.G. or animal grease. The difference in
inflammability or antiknock rating does not present any problem in combustion.
It’s light, standard petrol engine construction, and the low compression ratio2n
of the combustion chamber; do not exclude the use of diesel fuel. Methanol-
petrol mixture is also recommended.

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5. CONCLUSION

There is, at this day, no wonder solution for the replacement of the
internal combustion engine. Only improvements of the current technology can
help it progress within reasonable time and financial limits. The six-stroke
engine fits perfectly into this view. It’s adoption by the automobile industry
would have a tremendous impact on the environment and world economy,
assuming up to 40% reduction in fuel consumption and 60% to 90% in polluting
emissions, depending on the type of the fuel being used.

An allied with the so-responsive pickup and a wide spread of usable

power, makes the bike ridiculously easy to ride. You hardly need to use the
gearbox, just park it in top gear and ride. Even backing off the throttle in the
middle of a turn doesn’t require hooking down a gear — just crack it open when
you’re ready and feel the front wheel start to aviate on you. And hands-on
assessment of the six-stroke leads to some inescapable conclusions. The industry
trend away from cheaper two-stroke power in favor of costlier but cleaner four-
stroke engines in both Europe, Japan and South East Asia makes a concept like
the Beare six-stroke, which offers the best of both worlds, project a strong case
towards volume manufacture.

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REFERENCES

1. www.sixstroke.com

2. Excerpts from Beare technology.

3. High speed internal combustion engines by John B. Heywood.

4. http://www.jack-brabham-engines.com/

5. http://wikipedia.com

6. www.SeminarsTopics.com

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