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April 2002

The Aero-News Network Daily News Brief

ANN Exclusive:
Smart Plugs In The Market
It's a Small Start For One of the Most-Important New Products in Engine Technology
Featured over a year and a half ago in Aero-News ("SmartPlugs: A Better Idea?" 09-07-00, ANN), it's good to be able to say that SmartPlugs are available, at least for one popular engine. For now, the company has developed a stone-simple ignition system for Rotax 503 engines; a Continental O-200 is being tested; and many other applications are in the works.
The SmartPlug was invented by Mark Cherry, because, he told us at Sun 'n Fun, he "was intrigued by the simplicity of the [little .049-powered] Cox Dune Buggy's ignition system," when he was ten years old. He asked his Dad why the family car's ignition system had to have so many parts, in contrast. To make a long story (really) short, Mark couldn't get a satisfactory answer; so he got four patents, and the result is the Smart Plug.
How do they work?
SmartPlugs are like glow plugs, in that the compression itself generates enough heat to ignite the mixture.
SmartPlugs work in diesel, gasoline, natural gas, and alcohol-burning engines, though, making their future certain, across the spectrum of internal combustion.
The SmartPlug itself has a rod inside a pre-combustion chamber. The length and diameter of that rod are matched to the chamber, based principally on the fuel's characteristics and the engine's mechanical compression ratio.
The actual pressure inside the precombustion chamber, coupled with the amount of fresh (unburned) mixture available to the rod, is what starts the controlled ignition. This ignition system does away with such early 20th-Century devices as mechanical advance distributors, and can even do away with late-20th-Century devices such as ignition computers, knock sensors, and so on.
The result is a very lightweight, essentially tamper-proof, non-electric (except for starting) ignition system, that will continue providing ignition, even if the entire electrical system falls out of the airplane. Once the engine is up to running speeds and temps, no battery, no magneto, no computer, no spark plugs -- not even any "spark plug wires" -- none of that is required. To shut off the engine, turn off the fuel.
How about for my _____?
While Mark was explaining how this works, it was hard to keep others from coming by and starting over with the same questions: "How much?" (the basic kit, for a 503, is $200; options, such as a battery ($50), and amp gauge pack ($50) can bring that to, um, $300) "When can I get a system?" (The 503 system is available now; allow 6 weeks delivery: they're made by an outside contractor). "When can I get a system for my _____?" Mark says he's planning to have, by this Fall, a 447 kit and a 582 system available. The STCs for the O-200, as well as for the Lyc O-360, are in the works. "As the market justifies it, we'll make more models available," says Mark.
For 503 owners, it's easy to use one side of your regular electronic ignition, and let the SmartPlug provide more-complete ignition, and provide a sure-fire (!) backup.
Where are the plugs for my Harley?
Mark says, "The aviation market is unique, in that the customers are generally well-educated in the critical systems. The aircraft market is one where reliable ignition is paramount; and a sophisticated (as opposed to merely 'complicated') ignition is important for reliability and performance. We can add reliability, and add performance -- without the complexity."
He is working on additional programs, though. The DoD's "one-fuel" requirement has been a major driver. Mark says, "We're also converting the Honda generators to run on jet fuel for the Army." Additionally, "We're converting vehicles to run on dilute ethanol -- it may become a viable alternative to fuel cells." Did I mention that SmartPlugs can fire just about anything that burns?
Automotive applications are clearly the largest potential market, and Mark drives his personal Olds Quad Four to work, using Smart Plugs. "...but the EPA can actually be more troublesome than the FAA," he reminded me.
Mr. Cherry is currently arranging financing to go big-time, approaching what the SEC calls, "accredited investors." [If you have to ask, you're not one... --ed.]
FMI: www.smartplugs.com


 

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