state of the art prototype vehicle with a thermoelectric ... · state of the art prototype vehicle...
TRANSCRIPT
STATE OF THE ART PROTOTYPE VEHICLE WITH A THERMOELECTRIC GENERATOR.
Dr. Boris Mazar, March 21st 2012
TE APPLICATION WORKSHOP, BALTIMORE.
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BMW X6 TEG PROTOTYPE VEHICLE. THE EVOLUTION OF THE THERMOELECTRIC GENERATOR.
TE Application Workshop, March 21st, 2012
Leve
l of
mat
urit
y an
d el
ectr
ic p
ower
out
put
200W
300W
>600W
Timeline
2003 2006 2008 2011
80W
Numerous prototypes have been built, cumulating in the 600W X6 demonstrator.
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BMW X6 TEG PROTOTYPE VEHICLE. THE PROJECT TEAM.
• Amerigon: Project leader and component design specialist.
• ZT Plus: TE material optimization and production.
• Faurecia: System integrator as TIER1 supplier.
• Ford/BMW: Vehicle integrators.
• NREL: Testing laboratory.
TE Application Workshop, March 21st, 2012
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BMW X6 TEG PROTOTYPE VEHICLE. BMW’S ROLE AND RESPONSIBILITY IN THE PROJECT.
combustion engine
friction model
vehicle parameters
exhaust line
cooling system
Vehicle simulation
TEG-Model (Amerigon)
Vehicle integration
exhaust line integration
data aquisition
cooling system integration
control strategy
visualization
TE Application Workshop, March 21st, 2012
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BMW X6 TEG PROTOTYPE VEHICLE. COOLING SYSTEM INTEGRATION.
Constraints and the key success factors:
• At extreme driving conditions the cooling capacity for the ICE must be guaranteed.
• The specific integration concept has a significant impact on the coolant temperature level for the
TEG (50-120°C).
• The heat rejected into the coolant can be used for an accelerated warm-up of the power train.
TE Application Workshop, March 21st, 2012
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BMW X6 TEG PROTOTYPE VEHICLE. EXHAUST LINE INTEGRATION.
TE Application Workshop, March 21st, 2012
Constraints and the key success factors:
• Under-floor package poses a challenging constraint for the TEG component design.
• Limitation of the exhaust backpressure plays a decisive role in maximizing the FE performance.
• The acoustic and mounting aspects were not considered within this project.
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BMW X6 TEG PROTOTYPE VEHICLE. ELECTRIC LOAD.
TE Application Workshop, March 21st, 2012
Constraints and the key success factors:
• Due to the thermal inertia the electric characteristics of the generated power is uncritical to the
stability of the power circuit within the vehicle.
• For an efficient integration, the voltage level of the TEG should be close to the value of the vehicle.
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BMW X6 TEG PROTOTYPE VEHICLE. INSTRUMENTATION.
TE Application Workshop, March 21st, 2012
Constraints and the key success factors:
• A comprehensive instrumentation is installed into the vehicle, measuring 48 local temperatures,
6 voltages, 3 currents, 2 pressure drops and 5 volume flow rates.
• Data logger allows to save the data during real driving and dynamometer conditions.
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BMW X6 TEG PROTOTYPE VEHICLE. SYSTEM PERFORMANCE FOR STEADY STATE CONDITIONS.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0
100
200
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400
500
600
700
50 60 70 80 90 100 110 120 130
0
1.4
1.2
1.0
0.8
0.6
0.4
0.2
Vehicle speed [kph]
Ele
ctri
c po
wer
[W
]
Impr
ovem
ent
in fu
el e
ffic
ienc
y [
%] Improvement in fuel efficiency
Electric power
TE Application Workshop, March 21st, 2012
0
700
600
500
400
300
200
100
50 60 70 80 90 100 110 120 130
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BMW X6 TEG PROTOTYPE VEHICLE. SYSTEM PERFORMANCE FOR DYNAMIC DRIVING.
TE Application Workshop, March 21st, 2012
Time [s]
Veh
icle
spe
ed [
kph]
Val
ve a
ngle
(0
=cl
osed
) [°
]
0
20
200
180
160
140
120
100
80
60
40
Ele
ctri
c po
wer
[W
]
0
500
450
400
350
300
250
200
150
100
50
0 500 1000 1500 2000
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BMW X6 TEG PROTOTYPE VEHICLE. SUMMARY.
• This robust technology is a promising method for waste heat recovery.
• A TEG with unique power levels was successfully built and integrated into a vehicle.
• The established simulation tool and the vehicle integration are the basis for an efficient
design process for future TEG components and concepts.
TE Application Workshop, March 21st, 2012
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BMW X6 TEG PROTOTYPE VEHICLE. OUTLOOK.
• High technical and commercial risks need to be overcome:
Scale-up of material production.
Assembly process.
System integration (exhaust backpressure, max. cooling power etc.).
System durability testing.
• The key for a successful market introduction lies in the reduction of costs:
The right choice for the TE material.
Lean assembly process.
High power levels at medium temperatures.
TE Application Workshop, March 21st, 2012
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BMW X6 TEG PROTOTYPE VEHICLE. ACKNOWLEDGMENT.
The financial support of the US Department of Energy as well as the coordination of
the scientific exchange is highly appreciated.
Thank you to the team for the constructive and successful cooperation.