3 kW Thermoelectric Generator for Natural Gas-Powered Heavy-Duty Vehicles – Holistic Development, Optimization and Validation

Abstract

Emissions from heavy-duty vehicles need to be reduced to decrease their impact on the climate and to meet future regulatory requirements. The use of a cost-optimized thermoelectric genera-tor based on total cost of ownership is proposed for this vehicle class with natural gas engines. A holistic model environment is presented that includes all vehicle interactions. Simultaneous op-timization of the heat exchanger and thermoelectric modules is required to enable high system efficiency. A generator design combining high electrical power (peak power of about 3,000 W) with low negative effects was selected as a result. Numerical CFD and segmented high-temperature thermoelectric modules are used. For the first time, the possibility of an eco-nomical use of the system in the amortization period of less than << 2 years is available, with a fuel reduction in a conventional vehicle topology of already up to 2.8%. A significant improve-ment in technology maturity was achieved and the power density of the system was significant-ly improved to 298 W/kg and 568 W/dm3 compared to the state of the art. A functional model successfully validated the simulation results with an average deviation of less than 6%. An elec-trical output power of up to 2,700 W was measured.