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PBJ Xaustors -Exhaust Waste Energy Recovery

Client: Frank Albrecht – Future Truck. PBJ Xaustors -Exhaust Waste Energy Recovery. Peter Jorg James Stewart Robert Wiegers Jeremy Boles – Graduate Mentor. Presentation Overview. Background Concepts Testing Product Realization Recommendations. Background.

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PBJ Xaustors -Exhaust Waste Energy Recovery

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Presentation Transcript

  1. Client: Frank Albrecht – Future Truck PBJ Xaustors-Exhaust Waste Energy Recovery Peter Jorg James Stewart Robert Wiegers Jeremy Boles – Graduate Mentor

  2. Presentation Overview • Background • Concepts • Testing • Product Realization • Recommendations

  3. Background • The Future Truck Competition aims to “address important environmental and energy-related issues posed by the growing demand for sport utility vehicles.” • In a typical vehicle, the exhaust gas contains one of the largest portions of wasted energy, approximately 34% of available energy from the fuel. The motivation of the project is to capture some of this energy stream.

  4. Problem Formulation • Objectives: • Energy recovery will be greater than 180W • Compatibility and integration with other Future Truck subsystems will be realized • Constraints: • Additional system weight will be no more than 50 lbf • Ground clearance and crush zone competition requirements will not be violated • Effectiveness of catalytic converters will not be negatively impacted • Overall vehicle score will be positively impacted (i.e. fuel economy points exceed weight penalty)

  5. Concept Selection • Thermophotovoltaics • Enable usage of high temp (over 1,000ºF) waste heat • Projected high cost • Little availability to date • Modified turbo system • Off the shelf parts • Low Cost • High back pressure • Adsorption cooling • Potential for elimination of harmful refrigerants • Makes direct use of thermal energy • Cooling unit must be rather large

  6. Concept Selection (Cont’d) • Thermoelectrics • Commercially available • Low thermal efficiency, approximately 5% • No moving parts, solid state device • Compact size and low mass • Load matching circuit necessary

  7. Vehicle Testing • Attachment of the thermocouples to the exhaust pipes • Data Acquisition unit in cab of truck

  8. Vehicle Testing Results -Future Truck Optimal thermal conditions 450° – 500°F

  9. Solution Concept – Engine->Exhaust->TE chips->Battery IC Engine 41% Mechanical Output 25% Peripheral Systems 34% Power to Exhaust Exhaust System TE TE TE Unrecovered Power HX HX HX 0.75% Exhaust Power Converted to Electrical Power Power to Vehicle Subsystems Vehicle Battery Load Matching Circuit

  10. Thermoelectric Testing -bench Field point modules collecting data Fan emulating airflow from driving Heat sink and air ducting Thermocouples taking measurements Computer analyzing data Heat distribution plate DMM measuring current Heat source

  11. Lab View Controls Power vs. temp difference graph Sampling Number File path Temp readings Resistance input Voltage, power readouts Temperature difference graph

  12. Generator Testing Results Power output W Temperature Difference ºF

  13. Theoretical Output

  14. Thermoelectric Testing -engine James Test engine Exhaust system DMM measuring voltage output Exhaust coupler Thermal bypass valves

  15. Thermal Bypass

  16. Product Realization

  17. Exhaust SystemComparison • Last Year • Two catalytic converters • Split pipe between cats • Longer overall distance • Many bends • Extraneous sources of head loss • This Year • One catalytic converter • Larger (2.5”) pipe, consolidated after cat • Shorter overall distance • Fewer bends • Valves

  18. Budget

  19. Impact to Future Truck • Static Events • Design report, innovation • Judges’ interest • Dynamic Events • Reduced alternator load – improved gas mileage • Reduced head loss (?) – better engine performance • Weight issue – added vehicle weight increases engine load by ~25 W at 60 mph • Implementation of phase change material in cat – leg up in “cold” start emissions run

  20. Continuing Work • Load Matching Circuit • Underestimated aftermarket availability • EE recommendations • Forced Air Cooling • Original implementation scheme • Change in plans • Parasitic fan

  21. Recommendations • Thermoelectrics • Currently only have 7 operational chips • Load circuit implementation necessary • Current equipment levels – overall impact uncertain • Next Step • Expansion of generator to two heat sinks • Cost = $1200 • Roughly doubled output for comparable weight

  22. And now a moment of Zen Any Questions?

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