Y. D. Deng

Optimization of Fin Distribution to Improve the Temperature Uniformity of a Heat Exchanger in a Thermoelectric Generator

Thermoelectric generators (TEGs) are currently a topic of interest for energy recovery in vehicles. By applying TEGs to the outside surface of the exhaust tailpipe, a small amount of electrical power can be generated because of the temperature difference between the hot exhaust gases and the automobile coolant. The amount of power is anticipated to be a few hundred watts based on the expected temperature difference and the properties of the thermoelectric materials used in TEGs. It is well know that, for thermoelectric exhaust energy recovery, the temperature uniformity of the heat exchangers has a strong influence on the electric power generation. In the current research, the temperature uniformity of a heat exchanger was improved by optimizing the fin distribution to maximize the electric power generated for a given vehicle TEG. A computational fluid dynamics (CFD) model of the heat exchanger was constructed to assess the influence of different fin distributions on the temperature uniformity and the pressure drop in the exhaust system. For the fin distributions, four factors were considered: the length of, spacing between, angle of, and thickness of the fins. Based on these four factors, a design of experiments study using the orthogonal experimental method was conducted to analyze the sensitivity to the design variables and build a database to set up a surrogate model using the Kriging response surface method. A multi-island genetic algorithm was used to optimize the fin distribution based on this surrogate model. To validate the accuracy of the CFD model, a generic heat exchanger module was manufactured and a related testbed constructed, then the temperature distribution on the surface of the exchanger was measured to compare with the results obtained by CFD.

Research on the Compatibility of the Cooling Unitin an Automotive Exhaust-based Thermoelectric Generatorand Engine Cooling System

The temperature difference between the hot and cold sides of thermoelectric modules is a key factor affecting the conversion efficiency of an automotive exhaust-based thermoelectric generator (TEG). In the work discussed in this paper the compatibility of TEG cooling unit and engine cooling system was studied on the basis of the heat transfer characteristics of the TEG. A new engine-cooling system in which a TEG cooling unit was inserted was simulated at high power and high vehicle speed, and at high power and low vehicle speed, to obtain temperatures and flow rates of critical inlets and outlets. The results show that coolant temperature exceeds its boiling point at high power and low vehicle speed, so the new system cannot meet cooling requirements under these conditions. Measures for improvement to optimize the cooling system are proposed, and provide a basis for future research.

A 42-V Electrical and Hybrid Driving System Basedon a Vehicular Waste-Heat Thermoelectric Generator

A 42-V powernet has been recognized as the next generation of vehicle electrical systems, and the waste-heat thermoelectric generator is becoming the future of vehicular energy conservation and emission reduction technologies. In this paper, effective utilization of vehicular waste-heat energy is proposed by introducing an electrical and hybrid driving system, which is an assemblage of a waste-heat thermoelectric generator, a 42-V powernet, and an integrated starter and generator (ISG). A vehicle model and the submodels for the new system have been built on the ADVISOR platform based on MATLAB/Simulink, and the dynamic performance of the vehicle model tested using the Economic Commission for Europe–Europe Urban Dynamometer Cycle driving cycle. The simulation results indicate that application of a 42-V waste-heat thermoelectric vehicle could be an integrated approach for fuel economy improvement and emission reduction, compared with a conventional internal combustion engine vehicle and an ISG-type 42-V vehicle.

Simulation and Optimization of the Heat Exchanger for Automotive Exhaust-Based Thermoelectric Generators

In order to enhance the exhaust waste heat recovery efficiency of the automotive exhaust-based thermoelectric generator (TEG) system, a three-segment heat exchanger with folded-shaped internal structure for the TEG system is investigated in this study. As the major effect factors of the performance for the TEG system, surface temperature, and thermal uniformity of the heat exchanger are analyzed in this research, pressure drop along the heat exchanger is also considered. Based on computational fluid dynamics simulations and temperature distribution, the pressure drop along the heat exchanger is obtained. By considering variable length and thickness of folded plates in each segment of the heat exchanger, response surface methodology and optimization by a multi-objective genetic algorithm is applied for surface temperature, thermal uniformity, and pressure drop for the folded-shaped heat exchanger. An optimum design based on the optimization is proposed to improve the overall performance of the TEG system. The performance of the optimized heat exchanger in different engine conditions is discussed.

Experimental Investigation of Exhaust Thermoelectric System and Application for Vehicle

In this case study, an energy harvesting system using a thermoelectric power generator (TEG) has been constructed. Experimental investigation of the hot and cold sides of the thermoelectric modules (TMs) in this system has been undertaken to assess the feasibility for automotive applications. Two test benches have been developed to analyze the TM performance and the TEG system characteristics, especially the temperature difference, open-circuit voltage, and maximum power output of the TM and TEG system. As the performance of a TM is most influenced by the applied pressure and the temperature difference, a thermostatic heater, thermostatic water tank, and clamping devices are used in our experimental apparatus, increasing the output power of the TEG system. Based on the test bench, a new system called the “four-TEGs” system was designed and assembled into a prototype vehicle called “Warrior,” and the characteristics of the system such as the maximum power output have been studied in road tests. The results show great potential for application of this technology in future vehicles.

Control Strategy for a 42-V Waste-Heat Thermoelectric Vehicle

A 42-V waste-heat thermoelectric vehicle is employed as a potential application of thermoelectric generators for fuel economy improvement and emissions reduction. The 42-V waste-heat thermoelectric vehicle currently in development employs an assemblage driving system consisting of a waste-heat thermoelectric generator, a 42-V powernet, and an integrated starter and generator (ISG). The waste-heat thermoelectric generator also functions as a power supply. To optimize the utilization of the waste-heat energy generated by the thermoelectric generator, an electric assist control strategy and a torque split control strategy are proposed herein. Through the development of relevant systems and strategies, including the thermoelectric generator and an electric bus system, two vehicle models are established and compared using the ADVISOR platform based on MATLAB/Simulink. The calculation results show improved fuel economy and emissions performance resulting from the integration of the torque split control strategy into the 42-V waste-heat thermoelectric vehicle.

Multi-Objective Optimization Design for Cooling Unit of Automotive Exhaust-Based Thermoelectric Generators

In order to improve the performance of cooling units for automotive thermoelectric generators, a study is carried out to optimize the cold side and the fin distributions arranged on its inner faces. Based on the experimental measurements and numerical simulations, a response surface model of different internal structures is built to analyze the heat transfer and pressure drop characteristics of fluid flow in the cooling unit. For the fin distributions, five independent variables including height, length, thickness, space and distance from walls are considered. An experimental study design incorporating the central composite design method is used to assess the influence of fin distributions on the temperature field and the pressure drop in the cooling units. The archive-based micro genetic algorithm (AMGA) is used for multi-objective optimization to analyze the sensitivity of the design variables and to build a database from which to construct the surrogate model. Finally, improvement measures are proposed for optimization of the cooling system and guidelines are provided for future research.

Optimization of Cooling Unit Design for Automotive Exhaust-Based Thermoelectric Generators

Integrating a thermoelectric cooler (TEC) into the engine cooling system has various advantages including reducing additional mechanical parts, and saving energy and space for automotive applications. Based on performance parameters of the engine and thermoelectric modules, three different TEC configurations called plate-shape, stripe-shape, and diamond-shape are constructed with development of simulations of the different TECs and the performance of the circulating coolant. Based on these simulations, the velocity, pressure, and temperature fields of the coolant are obtained for further research. Besides, the temperature of the TEC and the output power of the thermoelectric generator (TEG) are acquired experimentally. Comparing the working performance of the different TECs, the simulation and experimental results show that the TEG using the diamond-shaped TEC achieves a relatively ideal performance. Finally, some measures are proposed to improve the cooling system, providing guidelines for future research.

Fluid Analysis and Improved Structure of an ATEG Heat Exchanger Based on Computational Fluid Dynamics

In this study, a numerical model has been employed to analyze the internal flow field distribution in a heat exchanger applied for an automotive thermoelectric generator based on computational fluid dynamics. The model simulates the influence of factors relevant to the heat exchanger, including the automotive waste heat mass flow velocity, temperature, internal fins, and back pressure. The result is in good agreement with experimental test data. Sensitivity analysis of the inlet parameters shows that increase of the exhaust velocity, compared with the inlet temperature, makes little contribution (0.1 versus 0.19) to the heat transfer but results in a detrimental back pressure increase (0.69 versus 0.21). A configuration equipped with internal fins is proved to offer better thermal performance compared with that without fins. Finally, based on an attempt to improve the internal flow field, a more rational structure is obtained, offering a more homogeneous temperature distribution, higher average heat transfer coefficient, and lower back pressure.

Optimization of Heat Exchangers with Dimpled Surfaces to Improve the Performance in Thermoelectric Generators Using a Kriging Model

Thermoelectric generators (TEGs) have become a topic of interest for vehicle exhaust energy recovery. Electrical power generation is deeply influenced by temperature differences, temperature uniformity and topological structures of TEGs. When the dimpled surfaces are adopted in heat exchangers, the heat transfer rates can be augmented with a minimal pressure drop. However, the temperature distribution shows a large gradient along the flow direction which has adverse effects on the power generation. In the current study, the heat exchanger performance was studied in a computational fluid dynamics (CFD) model. The dimple depth, dimple print diameter, and channel height were chosen as design variables. The objective function was defined as a combination of average temperature, temperature uniformity and pressure loss. The optimal Latin hypercube method was used to determine the experiment points as a method of design of the experiment in order to analyze the sensitivity of the design variables. A Kriging surrogate model was built and verified according to the database resulting from the CFD simulation. A multi-island genetic algorithm was used to optimize the structure in the heat exchanger based on the surrogate model. The results showed that the average temperature of the heat exchanger was most sensitive to the dimple depth. The pressure loss and temperature uniformity were most sensitive to the parameter of channel rear height, h2. With an optimal design of channel structure, the temperature uniformity can be greatly improved compared with the initial exchanger, and the additional pressure loss also increased.