thermoelectric generator performance for passenger...

Thermoelectric Generator

Performance for PassengerPerformance for Passenger Vehicles

Doug Crane and John LaGrandeur

March 20 20122March 20,, 201

Advanced Thermoelectric Solutions

Program Overview Amerigon recently completed a 7 year

TEG program with partners BMW and Ford. The $10M program phases are described below:

• Phase 1: System modeling and architecture evaluation

• Phase 2: Subsystem design, build and bench test

• Phase 3: System integration. Planar configuration TEG with primary HEX and secondary loop, power converter

• Phase 4: Cylindrical TEG built and tested on test bench at Amerigon

• Phase 5: Improved cylindrical TEG built, installed, and tested on BMW X6 and Lincoln MKT vehicles


Technology Summary

2005 2008 2009 2010 2011 2006 2007

Modeling

ADVISOR (NREL) BMW (GT Cool and Proprietary Models)

Ford (GT Power and Proprietary Models)

System Architecture

Secondary Loop

In-Line Flow Through

Gen 4

TEG Architecture

TE Engines


Stack Design TE Engine

Traditional TE module architecture consists of n & p type elements arranged in a planar array.

• Module size is constrained by thermally induced stress in the elements

A stack design has been developed which enables shorter n & p leg lengths (less TE material = lower cost) and improved design flexibility.

N Current

HEAT

HEAT

Amerigon Stack Design

P

HEAT

HEAT HEAT

Current

TRADITIONAL CONFIGURATION

P N

i

Cylindrical TEG

Bench Test Setup

Blower

Gas heaters

TEG under test

Test Conditions for Medium Temperature TEG

Test 1 2 3 4 5 6 7 8 9 10 11 12

Tfh,in (C) 390 390 390 425 425 425 510 510 510 620 620 620

Tfc,in (C) 20 20 20 20 20 20 20 20 20 20 20 20

vdot,h (g/s) 13.5 13.5 13.5 20.5 20.5 20.5 30.1 30.1 30.1 45 45 45

vdot,c (g/s) 170 250 330 170 250 330 170 250 330 170 250 330

max power output (W) 56.1 56.5 57.6 119 121 122 261 270 272 495 580 595

Test 13 14 15 16 17 18 19 20 21 22 23 24 25

Tfh,in (C) 390 390 390 425 425 425 510 510 510 620 620 620 620

Tfc,in (C) 40 40 40 40 40 40 40 40 40 40 40 40 20

vdot,h (g/s) 13.5 13.5 13.5 20.5 20.5 20.5 30.1 30.1 30.1 45 45 45 48

vdot,c (g/s) 170 250 330 170 250 330 170 250 330 170 250 330 330

max power output (W) 49.3 49.2 49.6 103 104 106 228 237 241 436 461 N/A 608

Note: Test 24 not completed due to the chiller overheating.


Cylindrical TEG Performance


Run Repeatability

The three runs were performed over a period

of two weeks (over 25 hours of testing) and

show good repeatability. There is a 9% decrease in electrical resistance from

run 1 to run 2 due to “settling in” of the device

interfaces

This reduction in electrical resistance caused a 5%

increase in peak power

0.00

0.50

1.00

1.50

2.00

2.50

0 200 400 600 800 1,000 1,200

volt

age

(V)

current (A)

Test 11hot inlet temperature = 620C, cold inlet temperature = 20C

hot mass flow = 45 g/s, cold mass flow = 250 g/s

1st run

2nd run

3rd run

Linear (1st run)

Linear (2nd run)

Linear (3rd run)

0

100

200

300

400

500

600

700

0 200 400 600 800 1,000 1,200

pow

er (W

)

current (A)

Test 11hot inlet temperature = 620C, cold inlet temperature = 20C

hot mass flow = 45 g/s, cold mass flow = 250 g/s

1st run

2nd run

3rd run

Poly. (1st run)

Poly. (2nd run)

Poly. (3rd run)

Power & Voltage Validation

0

100

200

300

400

500

600

700

0.00

0.50

1.00

1.50

2.00

2.50

0 200 400 600 800 1,000

pow

er (W

)

volt

age

(V)

current (A)

TEG Performance - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)

(hot mass flow = 45 g/s, cold mass flow = 250 g/s)(6/29/11)

measured voltage

simulated voltage

measured power

simulated power

Poly. (simulated power)

0

50

100

150

200

250

300

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

0 200 400 600

pow

er (W

)

volt

age

(V)

current (A)

TEG Performance - Test 19 (no first & last ring)(hot inlet temperature = 510C, cold inlet temperature = 40C)

(hot mass flow = 30.1 g/s, cold mass flow = 170 g/s)(6/29/11)

measured voltage

simulated voltage

measured power

simulated power

Poly. (simulated power)

11

Air Pressure Drop & Water Outlet Temperature Validation

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Test

1Te

st 2

Test

3Te

st 4

Test

5Te

st 6

Test

7Te

st 8

Test

9Te

st 1

0Te

st 1

1Te

st 1

2Te

st 1

3Te

st 1

4Te

st 1

5Te

st 1

6Te

st 1

7Te

st 1

8Te

st 1

9Te

st 2

0Te

st 2

1Te

st 2

2Te

st 2

3

pres

sure

dro

p (p

si)

TEG Model ValidationAir Side Pressure Drop

7/11/11

measured

simulated

0

10

20

30

40

50

60

70

Test

1Te

st 2

Test

3Te

st 4

Test

5Te

st 6

Test

7Te

st 8

Test

9Te

st 1

0Te

st 1

1Te

st 1

2Te

st 1

3Te

st 1

4Te

st 1

5Te

st 1

6Te

st 1

7Te

st 1

8Te

st 1

9Te

st 2

0Te

st 2

1Te

st 2

2Te

st 2

3

air o

utle

t tem

pera

ture

(C)

TEG Model ValidationWater Outlet Temperature

7/11/11

measured

simulated

12

Hot & Cold Shunt Temperature Validation

0

50

100

150

200

250

300

350

400

450

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

tem

pera

ture

(C)

hot shunt (ring)

TEG Model Validation - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)


measured

simulated

0

10

20

30

40

50

60

70

80

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

tem

pera

ture

(C)

cold shunt

TEG Model Validation - Test 11(hot inlet temperature = 620C, cold inlet temperature = 20C)


measured

simulated

Medium Temperature TEG Transient Model Validation

0

100

200

300

400

500

600

700

0 200 400 600 800

pow

er (W

)

time (s)

Medium Temperature TEG Transient Test(changing electrical load, Test 11)

measured

simulated

0

100

200

300

400

500

600

0 2000 4000 6000 8000

pow

er (W

)

time (s)

Medium Temperature TEG Transient Test(changing hot and cold temperatures and flows)

measured

simulated

US06 Simulated TEG Performance

0

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200

300

400

500

600

700

800

0

50

100

150

200

250

300

350

400

0 500 1000 1500te

mpe

ratu

re (C

)

pow

er (W

) & m

ass

flow

(g/s

)

time (s)

Simulated TEG Performance for US06 Drive Cycle(cold inlet temperature = 80C, cold flow = 250 g/s)

7/15/11

power output

gas mass flow

gas inlet temperature

Steady State Power Vs Coolant Flow/Temp

0

100

200

300

400

500

600

1300RPM,

50 Nm

1750RPM,

60 Nm

2000RPM,

65 Nm

2250RPM,

75 Nm

2500RPM,

80 Nm

2750RPM,

80 Nm

3000RPM,105Nm

pow

er (W

)

engine conditions

Measured Steady State TEG Performance on Dynomometer01/31/12

coolant flow = 10 lpm, coolant temp = 30°C






Repeatability: Steady State Power

0

50

100

150

200

250

300

350

400

450

500

1300RPM,

50 Nm

1750RPM,

60 Nm

2000RPM,

65 Nm

2250RPM,

75 Nm

2500RPM,

80 Nm

2750RPM,

80 Nm

3000RPM,105Nm

pow

er (W

)

engine conditions

Measured Steady State TEG Performance on Dynomometer01/31/12


coolant flow = 20 lpm, coolant temp = 55°C(repeat)

Engine Dynamometer US06 Drive Cycle Results

0

50

100

150

200

250

300

0 200 400 600 800 1000 1200 1400

pow

er (W

)

time (s)

US06 Driv Cycle Measured Dyno Resultscoolant temp = 80C and coolant flow = 20 lpm

2 cycles run back to back with 60s idle in betweenbasic bypass valve strategy employed

Engine Dynamometer US06 Drive Cycle Results

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400

pow

er (W

)

time (s)

US06 Drive Cycle Measured Dyno Resultscoolant flow = 20 lpm

2 cycles run back to back with 60s idle in between01/31/12

coolant temp = 80°C

coolant temp = 55°C

Note: Bypass valve closed for cycle

TE Mat’l Surface Temperatures (Hot) Vs US06

0

50

100

150

200

250

300

350

400

450

0 200 400 600 800 1000 1200 1400

hot s

hunt

tem

pera

ture

(°C)

time (s)

US06 Drive Cycle Measured Dyno Resultscoolant flow = 20 lpm & temp = 80°C


Cable 1

Cable 2

Cable 3

Cable 4

Cable 5

TE Mat’l Surface Temperatures (Cold) Vs US06

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400

cold

shu

nt te

mpe

ratu

re (°

C)

time (s)

US06 Drive Cycle Measured Dyno Resultscoolant flow = 20 lpm & temp = 80°C


Cable 6

Cable 7

Cable 8

Cable 9

Cable 10

Ford Lincoln MKT AWD


Vehicle Integration


Vehicle On-Road Test Results

Vehicle Speed 65mph

0

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500

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300Test Time (sec)

TEG

Pow

er (W

atts

), E

xhau

st T

empe

ratu

re (°

C)

TEG Power

Exh. Temp. into TEG

Exh. Temp. out of TEG

Bypass Opened Bypass Closed

BMW X6

BMW X6 Installation


Summary

TEGs have been built and bench tested with over 700W of power output achieved with air inlet temperatures up to 620C.

TEGs were installed in a BMW X6 and Lincoln MKT with at least 450W of power output achieved in road tests for both vehicles.

Repeatable performance has been achieved in bench and engine dynamometer testing. Repeatable performance still being achieved in over 6 months of vehicle testing.

Steady state model has been validated to within 10% error for a wide range of operating conditions and load resistances for power, voltage, temperatures, and pressure drops for TEGs with varying TE material

Transient model has been validated to within 10% error for a wide range of operating conditions and load resistances for TEGs with varying TE material

Validated transient model has been used to simulate automotive drive cycles such as the US06


Outlook and Further Work

Further work is required to address technical and economic risks for

TEG commercialization:

• Material and system costs

• Design robustness and performance

• FE Benefits Vs regulatory and customer drive-cycles

The partnership between BMW, Ford, and Amerigon will continue in a

follow-on DOE TEG program with the following key objectives:

• 5% FE gain for a passenger vehicle measured over the US06 drive cycle

• Economic feasibility defined for 100K/annum manufacturing volume


Acknowledgements US Department of Energy: John Fairbanks

DOE NETL: Carl Maronde

BMW: Boris Mazar, Andreas Eder and Carsten Spengler

Ford Motor Company: Clay Maranville, Dan Demitroff, and Quazi Hussain

Faurecia Exhaust Systems: Rita Fehle, Robin Willats, Boris Kienle, and Ed Kinnaird

Amerigon/BSST/ZT Plus: Steve Davis, Dmitri Kossakovski, Eric Poliquin, Vladimir Jovovic, Joe Dean & Lon Bell & the rest of the Amerigon Team

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