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A novel free piston expander coupled with a linear generator (FPLG) prototype used in a small-scale organic Rankine cycle (ORC) system, is presented to recover the exhaust waste heat from vehicle engines. On the basis of continuous and stable operation of the FPLG, a large number of experiments were carried out under different operation conditions. The effects of intake pressure, operation frequency and external load resistance on the output performance of the FPLG as well as the motion rule of the piston are discussed. The results show that both peak power output and energy conversion efficiency can be improved by increasing the intake pressure appropriately. The energy conversion efficiency can reach up to 45.82% when the intake pressure is 0.26 MPa and operation frequency is 2.0 Hz. With the increase of the external load resistance, the peak power output of FPLG shows a trend of increasing first and then decreasing. And the maximum peak power output 47.5 W is obtained when the external load resistance is 20 Ω and operation frequency is 2.5 Hz. © 2018, Editorial Office of Journal of Xi'an Jiaotong University. All right reserved.
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