development of a 100-watt high temperature thermoelectric
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Development of a 100Development of a 100--Watt Watt High Temperature High Temperature
Thermoelectric Generator Thermoelectric Generator J. LaGrandeur, D. Crane, L. Bell
DEER Conference, Detroit, MIAugust 6, 2008
Development of a 100 watt High Temperature TE GeneratorDEER 2008
2
BSST OverviewBSST OverviewBSST is a subsidiary of Amerigon
and is located in Irwindale, CA (near Los Angeles)
BSST is developing advanced thermoelectric engines for heating, cooling and power generation
Sales & Technical SupportSales & Technical Support
Amerigon IncAmerigon Inc..Engineering, R&D CenterEngineering, R&D Center
Amerigon Inc. DetroitAmerigon Inc. DetroitWorld Headquarters World Headquarters Sales & Technical Support Sales & Technical Support
Amerigon Inc. Amerigon Inc. -- AsiaAsiaSales, Technical SupportSales, Technical Support
Amerigon Serves the Global Automotive Industry
Amerigon Serves the Global Automotive Industry
Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support GermanySales, Technical Support Germany
Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support EnglandSales, Technical Support England
Manufacturing Manufacturing ChinaChina
Amerigon Inc. Amerigon Inc. -- ChinaChinaSales, Technical SupportSales, Technical SupportManufacturing MexicoManufacturing Mexico
Sales & Technical SupportSales & Technical Support
Amerigon IncAmerigon Inc..Engineering, R&D CenterEngineering, R&D Center
Amerigon Inc. DetroitAmerigon Inc. DetroitWorld Headquarters World Headquarters Sales & Technical Support Sales & Technical Support
Amerigon Inc. Amerigon Inc. -- AsiaAsiaSales, Technical SupportSales, Technical Support
Amerigon Serves the Global Automotive Industry
Amerigon Serves the Global Automotive Industry
Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support GermanySales, Technical Support Germany
Amerigon Inc. Amerigon Inc. -- EuropeEuropeSales, Technical Support EnglandSales, Technical Support England
Manufacturing Manufacturing ChinaChina
Amerigon Inc. Amerigon Inc. -- ChinaChinaSales, Technical SupportSales, Technical SupportManufacturing MexicoManufacturing Mexico
2007 Escalade (ESV, EXT) Cadillac (XLR,DTS)
2006 Buick Lucerne
2006 Lincoln Zephyr Mercury Monterey
Lincoln LS
Lincoln Navigator Ford Expedition
* Four Seat Systems
Infiniti (Q45, M45)
Nissan Cima
Nissan Fuga
Hyundai Equus*
Lexus LS 430*
Toyota Celsior*
Toyota Century
2007 Range Rover
2007 Escalade (ESV, EXT)2007 Escalade (ESV, EXT) Cadillac (XLR,DTS)
2006 Buick Lucerne
2006 Lincoln Zephyr Mercury Monterey
Lincoln LS
Lincoln Navigator Ford Expedition
* Four Seat Systems
Infiniti (Q45, M45)
Nissan Cima
Nissan Fuga
Hyundai Equus*
Lexus LS 430*
Toyota Celsior*
Toyota Century
2007 Range Rover
Cadillac (XLR,DTS) Cadillac (XLR,DTS)
2006 Buick Lucerne2006 Buick Lucerne
2006 Lincoln Zephyr2006 Lincoln Zephyr Mercury MontereyMercury Monterey
Lincoln LSLincoln LS
Lincoln NavigatorLincoln Navigator Ford ExpeditionFord Expedition
* Four Seat Systems
Infiniti (Q45, M45)Infiniti (Q45, M45)
Nissan CimaNissan Cima
Nissan FugaNissan Fuga
Hyundai Equus*Hyundai Equus*
Lexus LS 430*Lexus LS 430*
Toyota Celsior*Toyota Celsior*
Toyota CenturyToyota Century
2007 Range Rover
Amerigon CCS Customers include most major OEMs
Development of a 100 watt High Temperature TE GeneratorDEER 2008
3
In Q4 2004 the US DOE Office of Vehicle Technologies started 4 Thermoelectric Waste Heat Recovery Programs
The Program objectives include:•
10% fuel efficiency improvement
•
Reduced emissions
•
A demonstrated path to commercialization and economic feasibility assessment
Development of a 100 watt High Temperature TE GeneratorDEER 2008
4
BSST Waste Heat Recovery BSST Waste Heat Recovery Program OverviewProgram Overview
The program is organized into 4 development phases:•
Phase 1
(Q3 04 thru Q2 05) A system architecture was created and bumper
to bumper model created using ADVISOR. Initial system FE savings were shown to reach 12%
•
Phase 2
(Q3 05 thru Q4 06) Key subsystems (Primary Exhaust Gas Heat Exchanger, Thermoelectric Generator Module TGM), Power Conversion Electronics) were built and tested. BMW converted the bumper to bumper model to a Gamma Technologies modeling platform
•
Phase 3
(Q1 07 thru Q3 08) Low and high temp TEGs are being built and tested with other key subsystems:
−
A BiTe TGM, has been built and tested demonstrating > 500 watts electrical power output.
−
A high temperature TEG will be built and tested in Q3 2008 (>100
watts)
−
The Waste Heat Recovery System will be operated on a test bench using a hot gas torch in Q3 2008
•
Phase 4
(Q4 2008 –
Q1 2009) A 500 watt high temperature TEG will be integrated and
tested with BMW’s in line 6 cylinder engine on an engine dynamometer at the Federal Laboratory in NREL Colorado
4
Development of a 100 watt High Temperature TE GeneratorDEER 2008
5
BSST TE EngineBSST TE EngineBSST stack design allows:
•
Optimum compressive loads for thermal and electrical interfaces
•
Tailored n and p type element geometries for highest efficiency
Development of a 100 watt High Temperature TE GeneratorDEER 2008
6
BiTe TEGBiTe TEG
n-type Bi2Te3n-type Bi2Te3
160 mm
TE Circuit (Bi2Te3 subassemblies)
160 mm160 mm
TE Circuit (Bi2Te3 subassemblies)
500W Generator (Delta T = 207°C)
0
100
200
300
400
500
600
0 5 10 15 20 25 30 35 40Current (Amps)
Pow
er (W
atts
)
0
10
20
30
40
50
60
Vol
tage
(V)
PowerV-I
5 Sept 2007
160 mm
Development of a 100 watt High Temperature TE GeneratorDEER 2008
7
Single plate(interfacial resistance = 2μΩcm2,
hot volume flow = 8 gpm (Xceltherm 600),cold volume flow = 8.85 lpm (water or glycol/water))
0102030405060708090
100110120130140150160170180
0 20 40 60 80 100 120 140 160 180 200 220 240 260
hot fluid inlet temperature (C)
pow
er (W
)
cold water inlet = 5C
cold water inlet = 15C
cold water inlet = 25C
cold glycol/water inlet = -5C
cold glycol/water inlet = 5C
cold glycol/water inlet = 15C
cold glycol/water inlet = 25C
cold water inlet = 4.68C, 8.85 lpm, hot oilflow = 4.3 gpmcold water inlet = 5.12C, 8.85 lpm, hot oilflow = 3.8gpmcold water inlet = 5.33C, 8.85 lpm, hot oilflow = 4.2 gpmcold water inlet = 6.60C, 8.85 lpm, hot oilflow = 7.5 gpmcold water inlet = 14.13C, 8.85 lpm, hot oilflow = 7.9 gpmcold water inlet = 24.51C, 8.85 lpm, hot oilflow = 8 gpmcold glycol/water inlet = -3.23C, 11.0 lpm,hot oil flow = 6.1 gpmcold glycol/water inlet = -6.02C, 10.9 lpm,hot oil flow = 6.0 gpmcold glycol/water inlet = -6.62C, 10.9 lpm,hot oil flow = 7.0 gpmcold glycol/water inlet = -5.68C, 10.9 lpm,hot oil flow = 6.9 gpmcold glycol/water inlet = -6.60C, 10.8 lpm,h t il fl 6 8
Peak Test Results Compared to SimulationsPeak Test Results Compared to Simulations Measured to simulated values vary by < 5%Measured to simulated values vary by < 5%
Development of a 100 watt High Temperature TE GeneratorDEER 2008
8
TEG Power ManagementTEG Power ManagementThe 100 watt BiTe TEG was tested with a prototype Power Control System (PCS) and resistive load.
The prototype PCS includes:•
Boost and buck converters with microprocessor control to provide a maximum voltage of 12.8 VDC (resistive load maximum operating voltage)
•
Serial data interface to report input and output voltage, current, power and converter efficiency
Three 50 watt automotive headlamps were used to test the PCS with the TEG.
Development of a 100 watt High Temperature TE GeneratorDEER 2008
9
PCS PerformancePCS Performance--
BiTe 100 Watt TEGBiTe 100 Watt TEGPower Control System (PCS) Performance
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0
TEG Power to the Converter
Con
vert
er P
ower
Out
93.0%
94.0%
95.0%
96.0%
97.0%
98.0%
99.0%
100.0%
Con
vert
er E
ffici
ency
Output Power Converter Efficiency
Development of a 100 watt High Temperature TE GeneratorDEER 2008
10
High Temperature TEG Design SummaryHigh Temperature TEG Design Summary
Hot side heat exchanger redesigned for 5000C exhaust gas (BiTe TEG used liquid heat exchangers with 2000C oil)
Three different TE subassemblies designed to match exhaust gas temperature gradient in the direction of flow to provide maximum TE material performance
TEG thermal and electrical interfaces modified to withstand high temperature environment
Development of a 100 watt High Temperature TE GeneratorDEER 2008
11
Prototype Exhaust Gas Heat Prototype Exhaust Gas Heat ExchangerExchanger
Stainless steel brazed construction with wavy fin
Diamond surface coating for electrical isolation
Development of a 100 watt High Temperature TE GeneratorDEER 2008
12
Prototype Cold Side Heat Prototype Cold Side Heat ExchangerExchanger
Lytron off the shelf aluminum cold plate
Surface finish: clear anodized for electrical isolation (blue die for anodize coating confirmation)
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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100 Watt High Temperature TEG100 Watt High Temperature TEG
Counter flow design
Three configurations of TE subassemblies designed to match the temperature gradient in the heat exchanger for maximum TE performance
TE Bank 1High Temp
TE Bank 2Medium Temp
TE Bank 3Low Temp
Gas flow Coolant flow
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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TE Subassembly Design and TE Subassembly Design and ConstructionConstruction
Hot and cold “T Shunts”
provide electrical and thermal connections to TE elements
T shunts and elements designed to match thermal flux to optimize
TE conversion efficiency
Proprietary Matlab Simulink computer tool simultaneously solves non linear equations to optimize performance and selected design parameters
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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TE Subassembly Design and TE Subassembly Design and ConstructionConstruction
TE subassemblies fabricated by BSST
High and medium temperature sections include Half Heusler and BiTe segmented elements
Low temperature TE subassemblies use BiTe only
TE Subassembly Thermal TE Subassembly Thermal Cycling ResultsCycling Results
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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Segmented Half-Heusler/Bi2Te3 Subassembly(heater = 470C, water bath = 70C, I = 9.0A)
0.00.10.20.30.40.50.60.70.80.91.01.11.21.31.41.5
0 10 20 30 40 50
cycles
pow
er (W
)
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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Segmented Half-Heusler/Bi2Te3 Subassembly(heater = 350C, water bath = 70C, I = 10.0A)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0 10 20 30 40 50 60 70 80 90 100 110
cycles
pow
er (W
)
Development of a 100 watt High Temperature TE GeneratorDEER 2008
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Bi2Te3 Generator Thermal Cycling1181 cycles, Th = 190C, water bath = 20C
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0 200 400 600 800 1000 1200 1400
cycles
pow
er (W
)
Development of a 100 watt High Temperature TE GeneratorDEER 2008
20
Summary and Further WorkSummary and Further Work
A low temperature TEG has been built and tested providing over 500 watts electric power at a ∆T of 2000C
Prototype TE subassemblies for a high temperature TEG have been designed, built and tested•
A 100 watt high temperature TEG will be completed in Q3 2008
•
A 500 watt high temperature TEG will be completed in Q4 2008 with Engine Dynamometer testing in Q1 2009
Testing of a low temperature TEG in a diesel engine vehicle is underway with results finalized in Q4 2008
Development of a 100 watt High Temperature TE GeneratorDEER 2008
21
AcknowledgementsAcknowledgements
John Fairbanks and the US DOE Office of Vehicle Technologies (OVT)
Aaron Yokum
and Carl Maronde of the DOE NETL
Andreas Eder and Boris Mazar of BMW
Steve Newton of Visteon
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