Top Banner
Thermoelectric Waste Heat Recovery Program for Passenger Vehicles”, 2012 Vehicle Technologies Program Annual Merit Review PI: Douglas T. Crane Presenter: John W. LaGrandeur Amerigon May 18, 2012 This presentation does not contain any proprietary, confidential or otherwise restricted information Project ID # ACE080 1 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012
16

Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Nov 02, 2019

Download

Documents

dariahiddleston
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

“Thermoelectric Waste Heat Recovery Program for Passenger Vehicles”, 2012 Vehicle Technologies Program Annual Merit Review

PI: Douglas T. Crane Presenter: John W. LaGrandeur

Amerigon May 18, 2012

This presentation does not contain any proprietary, confidential or otherwise restricted information

Project ID # ACE080

1 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 2: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

BSST Program Overview

Timeline

Program Start Date: Oct ‘04

Program End date: Sept ‘11

Percent Complete: 100%

2 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Barriers Economic manufacture of TE engines and TEG subsystem

Vehicle system integration for optimum usage of TE power

Vehicle TEG system on-cost

Budget

Total Project spend: $ 11,874,538

DOE Share: $ 7,156,109

Contractor Share: $ 4,718,429 (39.7%)

FY2011 $ - Funding Received:

Partners

Project Lead: BSST

OEM Partners: BMW & Ford

Tier 1 Partners: Faurecia, Visteon

University/Fed’l Lab Caltech, JPL, NREL Partners: Virginia Polytechnic

Targets

FE Improvement: 10%

Page 3: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Phase 5 Objectives

Improve cylindrical TEG prototype manufacture with improved tooling and subassembly component manufacture

Integrate TEGs into BMW and Ford vehicles for road testing

Address series production manufacturability/ usability issues with the cylindrical TEG

3 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 4: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

BSST 2011 Program Milestones

4 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Date Milestone Actual

May 7 Complete TEG build and test at BSST

Completed

June 11 Complete engine/TEG dyno testing at NREL

Completed

August 15 Deliver TEGs for BMW and Ford Vehicle installations

Completed

October 15 Substantially complete TEG system evaluation in BMW and Ford vehicles

Completed

Page 5: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Approach: Improve TEG prototype manufacture

5 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

The liquid cooling tube alignment along the length of the gas HEX (through many, collinear TE engines) was difficult to align

Proposed solutions: Carefully control the gas HEX OD and utilize tooling to precisely locate successive TE engines in the direction of flow

Page 6: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Approach: Integrate TEGs into BMW and Ford vehicles for road testing

TEG atmospheric control (maintenance of O2 depleted atmosphere) was a

high priority

Solution: Install gas ports in outer shell (hermetic enclosure) with pressure sensor to check and refill Argon gas as required

6 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 7: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Approach: Address manufacturability/usability issues with the cylindrical TEG

The Phase 5 TEG provides a proof of concept for stack-arranged TE engines in a cylindrical form factor.

The current design has an inappropriate power form (high current, low voltage) and will be difficult to manufacture due to the complex liquid cooling circuit, number of parts and large hermetically enclosed volume.

The next generation TEG will retain a cylindrical form factor and stack-designed TE engines but be comprised of a number of smaller cartridges.

7 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 8: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Accomplishment: Improve TEG prototype manufacture

8 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Two Phase 5 Cylindrical TEGs were built using improved tooling and subassembly components

The TEGs were tested on the bench at Amerigon-Irwindale and in a peak performance test produced over 700 watts as a result of improving interfaces, thermal and electrical.

The hot side TE material temperature reached ~ 500C and the TEG has exhibited stable performance for > 6 months.

Page 9: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Accomplishment: Integrate TEGs into BMW and Ford vehicles for road testing

9 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

TEGs were installed in the BMW X6 and Ford Lincoln MKT.

The Ford installation is pictured at right.

• Powertrain coolant was circulated through the TEGs

• A resistive load was used to consumeTEG power

TEG Integration on Lincoln MKT

Page 10: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Accomplishment: Road test TEGs in BMW and Ford vehicles

Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 10

The BMW X6 was put into service in July 2011.

TEG power measured in the X6 is shown at right.

Page 11: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Accomplishment: Road test TEGs in BMW and Ford vehicles

11 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

The Ford Lincoln MKTwas put into service in August 2011.

TEG power measured in the MKT for a 65 mph cruise condition is shown at right.

0

50

100

150

200

250

300

350

400

450

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)

0

9

18

27

36

45

54

63

72

81

90

Veh

icle

Spe

ed (m

ph)

TEG Power

Exh. Temp. into TEG

Vehicle Speed

Bypass Opened Bypass Closed

Page 12: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Accomplishment: Dynamometer test the TEG with BMW’s 6 cylinder engine

12 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

The TEG was tested over steady state and drive cycle conditions at a designated NREL Lab

In preparation for the follow-on TEG program testing over US06 was performed.

0

50

100

150

200

250

300

0 200 400 600 800 1000 1200 1400

powe

r (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

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

Page 13: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Collaborations

OEM leadership has been provided by BMW from program inception and Ford since Phase 3.

Tier 1 support in the design-in of the cylindrical TEG for BMW and Ford vehicles was provided by Faurecia.

TE Material characterization was provided by Caltech and ZT Plus.

13 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 14: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Future Work A follow-on TEG program for passenger

vehicles began in October 2011. Objectives include: • 5% FE gain over the US06 drive cycle

• Economic feasibility assessment for 100K/annum TEG system manufacture

Amerigon partners include BMW and Ford, Caltech and NREL.

14 Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 15: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

Summary Relevance

• Exhaust gas waste heat conversion to electric power reduces fuel consumption and is aligned with the increasing electrification of vehicles.

Approach/Strategy for Deployment

• An approach focused on optimizing vehicle level system performance while reducing the amount of TE material used to facilitate commercialization has been followed.

Technical Accomplishments and Progress

• Two prototype cylindrical TEGs were manufactured and have provided stabile performance since July, 2011. The TEGs operate with TE material temperatures reaching ~ 500C and have produced over 700 watts of electrical power. Carefully controlled testing under NREL’s cognizance was performed on an engine dynamometer, and in bench testing at Amerigon the TEG computer performance model validated to within 5% to 10%.

Collaborations and Coordination with Other Institutions

• Faurecia, a Tier 1 global leader in exhaust systems, has joined BMW, Ford and BSST and is leading the TEG subsystem integration into the exhaust system. In parallel, Amerigon/BSST, through a self funded collaboration with OSU and Northwestern, has developed a pilot production facility ,ZT Plus ,for the manufacture of advanced TE material.

Proposed Future Work/Proposed Future Activities

• A follow on program has begun and Amerigon has made significant modifications to the TEG design to ready it for commercialization in the latter half of this decade.

15

Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012

Page 16: Thermoelectric Waste Heat Recovery Program for Passenger ... · Thermoelectric Waste Heat Recovery Program for Passenger Vehicles, 18 May, 2012 . The liquid cooling tube alignment

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