In this paper is presented an analytic, theoretical and numerical study of the Viscous Rotary Engine Power System (VREPS). In addition, a proposed process flow for the fabrication of the VREPS using DRIE of silicon is described. The design premise of the VREPS is to derive mechanical power from the surface viscous shearing forces developed by a pressure driven flow present between a rotating disk or annulus and a stationary housing. The resulting motion of the rotating disk or annulus is converted into electrical power by using an external permanent magnet, embedded nickel-iron magnetic circuits, and an external switched magnetic pole electric generator similar to the design proposed by M. Senesky for the UC Berkeley micro-Wankel Engine [1]. This paper will examine the power output, isentropic efficiency, and operating characteristics of the disk and annular viscous turbines using the lubrication approximation and the Creeping Flow Equations (Stokes Flow). The viscous turbine is optimized for maximum isentropic efficiency using MATLAB numerical optimization routines. Finally, a unique triple-wafer micro-fabrication process for VREPS is presented. The proposed design consists of a 250 μm thick, 3.4 mm OD / 2.4 mm ID annular rotor with embedded magnetic poles and four 10 μm driving channels on each side of the rotor. Electrical power is generated with a switched magnetic pole generator, external permanent magnet, and integrated magnetic circuits. Calculations with water predict an output power of 825 mW at an isentropic efficiency of 25% using a pressure drop of 5 MPa cross the device.

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