ADI Thermals Formidable Array of Capabilities
New Product Development
ADIs team has demonstrated their expertise in innovative alternative energy engineering with a unique combination of ground breaking new products. Each of these products is well integrated into a market strategy that will dominate the alternative energy field. With over 50 years experience in new product development they have an innate well practiced synergy of creative style.
Innovative, Cost Efficient Design
Through engineering innovation, ADI Thermal achieves an order of magnitude product improvement over the existing market. Its patented Dual Shell Stirling Engine achieves a ground breaking 25% improvement in efficiency over industry standard in the distributed generation market. The compact design boasts almost double the energy density at a fraction of the cost. It's unique combination of high fuel efficiency, quiet operation, and low maintenance make it the ideal product to advance Distributed Power Generation into a position of dominance in the new power market.
If necessity is the mother of invention, then Science is its genetic code, defining its limits and shaping its destiny. ADI Thermals talent for innovation rests upon its strong foundations in the sciences; In particular, those of chemistry, solar optics, materials, structures, thermodyanamics, and aero/astro-dynamics.
The speed at which ideas become reality is reflected in the impressive rapid prototyping capability of the company. Using CAD software Pro-E, the physical requirements of the hardware are quickly transformed into electronic part representations with comprehensive accurate dimensions and guaranteed perfect fit in assembly. These part definitions are used to create cutting routines on CNC Mills and Lathes; cutting parts from metal blanks. These custom parts are then assembled and scheduled for testing. CNC machining of parts gives direct feedback on the complexity of the design and time to manufacture which is very important for low cost engineering.
Given the high operating temperatures of efficient engines, incorporating modern alloy technology into our designs gives us a competitive edge. ADI Thermal uses cutting edge alloys from Rolled Alloys and Haynes International and has the capability to perform most of its critical assembly techniques in house (reducing process delays). Capabilities include welding, vacuum braze, and diffusion bonding. Electron beam welding and sacrificial casting is currently contracted with companies such as Electron Beam Welding of Buena Vista, CA and Precision Cast Molding of Portland, OR.
Extreme Pressure Vessels, Hermetic Seals
ADI Thermals keystone technology: the ultra high efficiency Dual Shell Stirling engine, relies on hermetic seals to contain its working gases (hydrogen, helium) at high pressure. Furthermore, for one of the reactants (Hydrogen); containment can be difficult, especially at high temperatures. This is because, as temperature increases, stainless steel alloys can become porous to hydrogen gas . ADI has garnered substantial experience in both hydrogen and helium containment through its extensive Stirling engine development program. This problem is controlled by means of it's proprietary technologies.
ADI Thermals Dual Shell Stirling engine uses PID loop control technology to keep it's components in sync. Using feedback loops from strategically placed instrumentation, the fuel and air feeding the burner is carefully controlled to maintain a constant temperature in the heater head. Engine RPM can be throttled quickly by spoiling compression using valves. The PID control loop uses these controls to respond to variable output demand.
ADI Thermals Stirling engine technology is based on the science of heat transfer. It relies upon sophisticated high temperature heat exchangers to cyclically heat and cool it working gas, creating pressure fluctuations that drive the crank using pistons. Heat is transformed into work, and careful attention must be paid to see that no heat is wasted. This task is further complicated by the high temperatures required for high efficiency and the necessity of compact design for low cost. ADI Thermal has mastered how to effectively manage this heat using its patented Dual Shell design, as well as heat exchangers, heat pipes, and modern insulation.
Before a product is fit to market, it must be run through a thorough and exhaustive set of tests to prove performance, structural integrity, endurance and failure modes. During its engine development program, ADI Thermal refined its already expansive expertise in test instrumentation, high speed data collection, and high volume data reduction.