Performance Prediction and Optimization of Single-Piston Free Piston Expander-Linear Generator Based on Machine Learning and Genetic Algorithm

This paper proposed a single-piston free piston expander-linear generator (SFPE-LG) prototype applied to organic Rankine cycle systems. Two valve timing control strategies, namely, time control strategy (TCS) and position control strategy (PCS), were developed. Based on the experimental data, a back propagation neural network (BPNN) prediction model was established. The effects of structural parameters such as neural network layers, transfer function, training function, hidden layer nodes, and learning rate on the prediction accuracy of this BPNN model were discussed. The training and prediction accuracy of the BPNN model was verified using 5-fold cross-validation and Wilcoxon signed-rank test. Moreover, the BPNN model was integrated with a genetic algorithm to predict and optimize the maximum output power of the SFPE-LG. The results showed that the BPNN model used to predict the motion characteristics and output performance of the SFPE-LG exhibits strong learning ability and high prediction accuracy. Notably, the prediction accuracy of the BPNN model is significantly higher under the PCS compared to TCS. The effect of hidden layer nodes on mean square error (MSE) and correlation coefficient (R) is greater than that of the learning rate. When the number of hidden layer nodes exceeds 30, the BPNN model consistently achieves low MSE and high R. The optimization results showed that the SFPE-LG can obtain a maximum output power of 141.69 W under the TCS, when the working parameters are inlet pressure of 0.7 MPa, intake duration of 35 ms, load resistance of 67 Ω, and expansion duration of 104 ms, respectively.