SONEX Two-Stroke Heavy Fuel Engine (HFE) Technology

The U.S. Department of Defense (DoD) now requires engines used in unmanned aerial vehicles (UAVs) and other military applications for which gasoline storage and use are undesirable, to operate on less volatile, kerosene-based heavy fuels (JP-5, JP-8 and D-2 diesel) to reduce the hazard associated with gasoline.  In the case of two-stroke spark-ignited (SI) engines, Sonex has established a viable heavy fuel engine (HFE) technology baseline by applying its patented Sonex Combustion System (SCS) combustion chamber design and proprietary starting system to the conversion of single and multi-cylinder, lightweight, gasoline engines for use in military (and commercial) applications such as UAVs to start reliably, even in cold temperatures.

The SCS heavy fuel conversion maintains the gasoline engine’s stock carburetion or fuel injection system, intake and exhaust systems, spark ignition system, and compression ratio.  SCS HFEs^TM running on heavy fuels JP-5, JP-8 and D-2 diesel (with lubricant additive for all fuels) retain the ignition precision of the SI process and knock-free combustion.  No modifications are made to the moving parts, including the piston.  Compared to operation on gasoline, SCS HFEs achieve equal to or reduced fuel consumption (18%-28% less at cruise rpm) and produce no visible smoke.

In SI two-stroke engines, the SCS enables the combustion of heavy fuels through design modification of the cylinder heads to achieve a chemically/thermally enhanced combustion process while still relying on the spark to initiate combustion.  The SCS embodies a unique cylinder head with combustion chamber insert housing the proprietary SCS technology and a glow plug starting system.  SCS design features in the cylinder head provide control of fuel vaporization late in the compression stroke such that a portion of the heavy fuel is then vaporized near the spark plug.  As the combustion event progresses it causes the fuel to fully vaporize and combust.

For two-stroke gasoline engines that have the cylinder head and cylinder in a single casting, the stock cylinder head portion is removed by machining and the remaining cylinder casting is decked.  The SCS head assembly and cylinder are reattached to the crankcase by bolts.  The following figure shows an example of a disassembled SCS two-stroke HFE cylinder head assembly.

Disassembled SCS Two-Stoke HFE Components, from left to right:

Combustion chamber insert containing SCS design embodiments,

Cylinder head, including glow plug heater, and

Cylinder body with stock head removed

As described below, extensive prototype HFE development for a small (1 - 2 horsepower) gasoline engine for Insitu, Inc. has moved to the pre-production phase.  Other Sonex HFE designs in various stages of development are available for immediate application to commercially available SI gasoline engines.  For engine models not previously converted, Sonex will undertake development to achieve an optimized design.  The gasoline performance of an engine to be converted is thoroughly assessed using a baseline procedure to document thrust, fuel consumption, cooling and overall engine durability. The deliverable prototype HFE is achieved by applying the SCS engine design modifications in a two-step, best efforts process based on (1) a feasibility demonstration and (2) optimization of a prototype through design trade-off iterations to match the baselined gasoline power and improve fuel efficiency of the engine.

Business relationship with Insitu

Since 2005 the Company has worked on an application of the SCS HFE^TM technology with Insitu, Inc. of Bingen, Washington (website: www.insitu.com), a pioneer developer of long-range, unmanned, autonomous aircraft for military and commercial activities.  Insitu has developed the long endurance, low cost ScanEagle® UAV in partnership with The Boeing Company.  (ScanEagle® is a registered trademark of The Boeing Company.)  ScanEagle is being used to provide services for the U.S. Marine Corps, U.S. Navy, U.S. Air Force and Australian Defence Forces.  ScanEagle has logged more than 80,000 hours of flight time since it was first deployed with the Marines in 2004 and with the Navy in 2005, including more than 1,000 shipboard launch-recovery cycles from Navy ships.

Using computer aided design and rapid prototyping of castings, machined components and plastic fabrication, Sonex developed a prototype combustion system to convert the 3W-28i, two-stroke, SI gasoline engine used in the ScanEagle to heavy fuel operation.  A significant accomplishment has been the ability to reliably start the SCS HFE at cold temperatures.

In November 2006 Sonex signed an exclusive license agreement with Insitu for the SCS HFE^TM technology applicable to UAVs with HFEs that are twenty horsepower or less.   Insitu plans to be the first to market with an HFE in the Small Tactical Unmanned Aerial System class vehicle in 2008.  Sonex is free to license its HFE technology for use in UAVs using engines exceeding 20 hp, or on any size HFE for non-UAV use such as in all-terrain vehicles, pumps, outboard engines, small watercraft, and generator sets.

In January 2007 Insitu announced that it set an endurance flight mark for the ScanEagle by running its engine modified with HFE technology licensed from Sonex, along with other enhancements developed by Insitu engineers, on JP-5 heavy fuel for 28 hours and 44 minutes.  The previous longest flight on a ScanEagle was 22 hours and 10 minutes using gasoline.  The endurance flight on JP-5 was conducted in temperatures ranging from -6^o C to -16^o C with no observed problems.  At cruise power levels, the ScanEagle using the SCS HFE^TM consumed up to 28% less fuel than with the stock gasoline engine.

In April 2008 Insitu announced that it had flown HFE equipped ScanEagles in Iraq in a demonstration conducted in cooperation with the U.S. Navy in a real-world environment.  The announcement stated that the HFE was developed by Insitu in partnership with Boeing and Sonex.  As reported on its website, Insitu plans to be the first to market with an HFE in the Small Tactical Unmanned Aerial System class vehicle in 2008.  Insitu also announced the introduction of its new, larger UAV known as the Integrator^TM.  In an interview published in the August 20, 2007 print edition of Defense News, also available on Insitu’s website, Insitu President and CEO Steven Sliwa stated that the Integrator will start out with a gasoline engine and then move to heavy fuel using the SCS HFE technology.

The relationship with Insitu has been highlighted by a mutual understanding of each company’s expectations and engineering cultures, with the HFE development program having been based on milestones of collaborative efforts to accomplish qualified, flight worthy engines.  That program is now in the flight testing and pre-production phase, with market introduction scheduled for this year.  The Insitu relationship has achieved major advancements by Sonex that are transferable to the next HFE program.

Sonex is seeking partners to fully develop other applications of the SCS HFE technology. Based on the successful ongoing relationship of Insitu and Sonex, potential partners can appreciate the level of commitment required to achieve a reliable HFE.  Additional licensing opportunities are available.