The Legacy engine is a completely new design, transitional diesel engine, replacing the reciprocating engine with a rotary engine. The Legacy engine offers significant advances over conventional internal combustion engines in 1) power to weight ratio
2) multiple fuel acceptance
3) fuel economy
and 4) environmental compliance. These advances are achieved through a combination of innovative design geometry, rotary motion, aspiration simplicity, and manufacturing/part simplicity. The key technical challenge to the Legacy engine's commercialization, and the focus of this project, was the development of a viable roton tip seal. The PST concept for the roton tip seal was developed into a manufacturable design. The design was evaluated using a custom designed and fabricated seal test fixture and further refined. This design was incorporated into the GEN2.5A prototype and tested for achievable compression pressure. The Decision Point at the end of Phase 1 of the project (described below) was to further optimize the existing tip seal design. Enhancements to the tip seal design were incorporated into the GEN2.5B prototype and tested and evaluated using the iterative research strategy described below. Compression pressures adequate for compression ignition of diesel fuel were achieved, although not consistently in all combustion volumes. The variation in compression pressures was characterized versus design features. As the roton tip seal performance was improved, results pointed toward inadequate performance of the housing side seals. Enhancement of the housing side seal system was accomplished using a custom designed side seal test fixture. The design enhancements developed with the test fixture were also incorporated into the GEN2.5B prototype and tested and evaluated using the iterative research strategy described below. Finally, to simplify the requirements for the roton tip seals and to enhance the introduction and combustion of fuel, a flush-mount fuel injector was designed, manufactured and demonstrated in the GEN2.5B prototype.