Novel, shape optimised, TEG subsystem design

This research report presents a new, innovative design and manufacturing solution to recover thermal waste heat energy, from the combustion process of the engine, without affecting the process. Our research focuses on the exhaust port of the engine cylinder, were the waste heat energy and engine coolant are available to operate the thermoelectric generator (TEG) units. A new, one-piece TEG unit, is designed and computational fluid dynamics (CFD) analyzed, to evaluate and validate effective thermal waste heat transfer into the unit subsystem, at the temperatures ranging over 800°C. Additional simulations, on the internal combustion engine (ICE) cylinder head provided data of the flow temperature distribution when directly coming from the heat source. Using TEG units' test data, from our experiments, and data generated from our Matlab-Simulink model, we were able to validate and predict performances of the new TEG subsystem design. Our solution ensures the best surfaces matching, between the oval shaped TEG subsystem and the engine hot surface. Following that, it offers optimal energy recovery.