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1、InternationalJournalofAutomotiveTechnologyVol.9No.2pp.155?160(2008)DOI10.1007s12239?008?0020?yCopyright?2008KSAE1229?91382008039?05155THERMALDESIGNOFAUTOMOBILEEXHAUSTBASEDTHERMOELECTRICGENERATS:OBJECTIVESCHALLENGESK.M.SA

2、QR1)M.K.MANSOUR1)M.N.MUSA2)1)DepartmentofThermoFluidsFacultyofMechanicalEngineeringUniversitiTeknologiMalaysiaMalaysia2)ResearchManagementCenterUniversitiTeknologiMalaysia81310SkudaiJohBahruMalaysia(Received15June2007Rev

3、ised1December2007)ABSTRACT?Thepotentialfthermoelectricpowergeneration(viawasteheatrecoveryonboardautomobiles)todisplacealternatsprovideadditionalgingtoavehiclebatterypackhasincreasedwithrecentadvancesinthermoelectricmate

4、rialprocessing.Ingasolinefueledvehicles(GFVs)about40%offuelenergyiswastedinexhaustheatwhileasmalleramountofenergy(30%)isejectedthroughtheenginecoolant.Therefeexhaustbasedthermoelectricgenerats(ETEG)havebeenafocusfGFVappl

5、icationssincethelate1980s.TheconversionefficiencyofmodernthermoelectricmaterialshasincreasedmethanthreefoldinthelasttwodecadeshoweverdisputesastothethermaldesignofETEGsystemshaskepttheiroverallefficiencyatlimitedinsuffic

6、ientvalues.TherearemanychallengesinthethermaldesignofETEGsystemssuchasincreasingtheefficiencyoftheheatexchangers(hotboxcoldplate)maintainingasufficienttemperaturedifferenceacrossthethermoelectricmodulesduringdifferentope

7、ratingconditionsreducingthermallossesthroughthesystemasawhole.ThispaperfocusesonareviewofthemainaspectsofthermaldesignofETEGsystemsthroughvariousinvestigationsperfmedoverthepasttwentyyears.Thispaperisganizedasfollows:fir

8、sttheconstructionofatypicalETEGisdescribed.TheheatbalanceefficiencyofETEGarethendiscussed.ThenthethirdsectionofthispaperemphasizesthemainobjectiveschallengesfdesigningefficientETEGsystems.FinallyareviewofETEGresearchacti

9、vitiesoverthelasttwentyyearsispresentedtofocusonmethodsusedbytheresearchcommunitytoaddresssuchchallenges.KEYWDS:ThermoelectricpowergenerationAutomotivewasteheatrecoveryEnergymanagement1.INTRODUCTIONAnyautomobileETEGtypic

10、allyconsistsoffourcomponents:ahotboxthermoelectricmodulescoldplateassemblyelements.Thehotboxisthecomponentwhereexhaustheatistobeextractedthecoldplateisresponsiblefdissipatingheatafteritpassesthroughthethermoelectricmodul

11、estheassemblyelementsareresponsiblefapplyingsufficientcompressionfcetothesethermoelectricmodulesaswellasassemblingallothercomponentsinthedesiredcombination(Vzquezetal.2002).AthermoelectricmodulecontainsalargenumberofNtyp

12、ePtypesemiconductsarrangedincoupleswhichcanconvertheatdirectlyintoelectricpower(RoweBhari1983).Throughoutthispapertheabbreviation“TEMsisusedtorepresentthermoelectricmodules.Thermalinsulationisanotherimptantcomponentofany

13、ETEGisusedtodecreasethethermallossesacrossthehotboxalsothermalinterfacematerial(i.e.thermalgrease)mustbeappliedbetweenthehotcoldsurfacestheTEMstoovercomethethermalcontactresistancebetweenthetwosurfacestheTEMs.Thetypicalc

14、onstructionflowdirectionofwkingfluidsareillustratedinFigure1.2.ETEGHEATBALANCEEFFICIENCYIninternalcombustionenginesapproximately40%ofthefuelenergyiswastedinexhaustgas30%isdissipatedinCrespondingauth.email:khaledsaqr@Figu

15、re1.TypicalconstructionofETEG.TEMsareassembledbetweenthehotboxtwocoldplatesusingassemblyelements(compressionspringsbolts).THERMALDESIGNOFAUTOMOBILEEXHAUSTBASEDTHERMOELECTRICGENERATS157Intheradiatbasedcoldplate(Figure3(a)

16、)thecoolantpumppipingusuallyrequireresizingtocompensateftheadditionalcoolingload.HeatsinkcoldplatescanbeefficientiftheETEGistooperateatlowtemperaturegradientsthistechniquetakesadvantageofthemovementofthevehicletocreatetu

17、rbulenceintheairflowoverthecoldplate.4.REVIEWOFETEGRESEARCHThefirstETEGfautomobileapplicationswasbuiltin1963(Neild1963)butthemostimptantresearchinthisareahasbeenperfmedoverthelasttwentyyears.InthissectionthreeexamplesofE

18、TEGresearcharediscussedtoexplainhowtheresearchcommunityhasaddresseddifferentthermaldesignchallengestohighlightthemostimptantdevelopmentsinETEGtechnology.4.1.1KWETEGHiZInc.presentedanETEGfinstallationondieseltrucksin1992(

19、Bassetal.1992).Atotalnumberof72HZ13moduleswereusedtoproducepowerinthisETEG.Eachofthesemodulescontained49couplesofhotpressedbismuthtelluridebasedmaterials.Themodulesizewas5.3cmsquareby0.5cmthick82ginweight.Thehotcoldsided

20、esigntemperatureswere230oC30oCrespectively(HiZInc.1996).ThetotallengthoftheETEGwas48.26cmwithatotaldiameterof22.86cmatotalweightof13.6kg.Ahexagonalcrosssectionhotboxwasusedwithaluminumradiatbasedcoldplatesusedasaheatdiss

21、ipater.Thehotboxwasfabricatedbyweldingflatsteelplatestogethertofmahexagonalshapethesesteelplateshadatotalnumberof90internallongitudinalfinstoenhancetheheattransferfromtheexhaustgasestothemodules.TheTEMswereheldagainstthe

22、hotboxunderacompressiveunifmloadof14kgcm2.ThiscompressiveloadingwasappliedusingBellevillespringstoensureminimumthermalcontactresistancebetweenTEMsheatexchangersurfaces(seeFigure4).Thegeneratwasdesignedtoproduce1KWofelect

23、ricitybutwhentheexperimentaltestswereperfmedona14LCumminsNTC325enginetheETEGproducedonly400Wwhichwaslessthanhalfofthegoal.Itwasconcludedfromthetemperatureprofilemeasurementsthatthereductioningeneratedpowerwascausedbyabou

24、ndarylayerprobleminthegassidewheretheexhaustgasvelocitydecreasesaccdingtotheenlargementintheflowcrosssection(Bassetal.1995).Indertoresolvethisproblemthenumberoffinswasreducedfrom90to32finswhilethelengthofeachfinwasFigure

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