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In this paper, a test rig of free piston expander-linear generator (FPE-LG) for organic Rankine cycle (ORC) waste heat recovery system using compressed air is established. Based on the FPE-LG test rig, the experiments of external load resistance effect on the motion characteristics, output performance and energy conversion efficiency of the FPE-LG are conducted. The results show that the displacement and velocity of the free piston assembly increase with the external load resistance. As the external load resistance and intake pressure increase, the peak voltage output of the FPE-LG increases. The maximum peak voltage output is 44.4 V. The peak power output initially shows a non-linear increasing trend when growing the external load resistance and stabilizes in the end, the maximum peak power output of 110 W can be achieved. In addition, the energy conversion efficiency of the FPE-LG first increases and then decreases with intake pressure and external load resistance. The maximum energy conversion efficiency can reach up to 73.33%. © 2020, Solar Energy Periodical Office Co., Ltd. All right reserved.
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