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Underwater Thermoelectric Generator P14254

Underwater Thermoelectric Generator P14254. Agenda. Background Problem Statement Customer Requirements Engineering Requirements House of Quality System Analysis Functional Decomposition Concept & Architecture Development Engineering Analysis Risk Assessment Test Plan Project Plan.

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Underwater Thermoelectric Generator P14254

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  1. Underwater Thermoelectric GeneratorP14254 Rochester Institute of Technology

  2. Agenda • Background • Problem Statement • Customer Requirements • Engineering Requirements • House of Quality • System Analysis • Functional Decomposition • Concept & Architecture Development • Engineering Analysis • Risk Assessment • Test Plan • Project Plan Rochester Institute of Technology

  3. Discussion Points • Heat Sinking • Materials • External vs. System Electronics Power Source Rochester Institute of Technology

  4. Background Rochester Institute of Technology

  5. Background Information Boeing’s UUV, Echo Ranger • Developed in 2001 for seafloor mapping for oil/gas industry • Currently testing the idea for potential military applications • ISR • Harbor security • Current run time • ~28 hours Rochester Institute of Technology

  6. Background Information • Boeing wants to extend the mission time of their submarine • They are interested in thermoelectrics • Our Task:Prepare a proof-of-concept underwater thermoelectric generator that charges a battery. Rochester Institute of Technology

  7. Project Updates Since last time... Was undecided Was undecided Was Li-Poly We will not put much emphasis on specific heat source • Battery voltage:12V • Battery capacity: 750mAhr • Battery type: Li-ion • Emphasis on thermoelectric and total system efficiency Rochester Institute of Technology

  8. Customer Requirements • Continuously generate power • Operate efficiently • Charge a battery • Operate underwater • Heat source provides a constant source of heat • System can withstand interior enclosure temperature • Utilize passive safety features Rochester Institute of Technology

  9. Engineering Requirements • Power Output:20W • Heat Source Power Input:500W • Upper Ambient Operating Temperature:30°C • Thermal Overload Protection: 10% of max T • Operates Without User Input: 0 interactions • Heat Source Temperature: Ideally 300°C Rochester Institute of Technology

  10. House of Quality Rochester Institute of Technology

  11. System Analysis Rochester Institute of Technology

  12. Functional Decomposition Rochester Institute of Technology

  13. Mechanical System Level View Rochester Institute of Technology

  14. Thermal System Level View Red arrows are lost heat. Main heat path: Source  TEG  Sink  Water Rochester Institute of Technology

  15. Electrical System Level 0 Rochester Institute of Technology

  16. Electrical System Level 1 Rochester Institute of Technology

  17. Instrumentation System Level View v v Rochester Institute of Technology

  18. Morphological Chart *Ideas in red have proven to be not feasible Rochester Institute of Technology

  19. Rochester Institute of Technology

  20. Pugh Conclusions • Shapes: The simple rectangular prism won. • No External Control: We are going to have a microcontroller anyway • Enclosure Material: Thermoelectric side will need non-corrosive metal, electronics side can be plastic. Rochester Institute of Technology

  21. Engineering Analysis • Battery Capacity • Leakage • Heat Sinking • TEM efficiency Rochester Institute of Technology

  22. Batteries Li-Ion instead of Li-Poly • Li-Ion are more readily available and cost less than Li-Poly.Li-Poly’s higher energy density does not outweigh its cost, and it’s shape characteristics are not an added benefit to the project. Rochester Institute of Technology

  23. Batteries Battery Voltage: 12 V Battery Capacity: (20 W*95% efficiency )/12V = 1.58A 1.58A*0.5 hr charge time = 754mAhr Rochester Institute of Technology

  24. Leakage • At 2 feet test depth: • P=ρgh • P = 999 kg/m^3 * 9.81m/s^2 * 0.61m • P = 6 kPa or 0.87 psi • Test Spec IP68 met by a number of cheap enclosures by Integra Enclosures Rochester Institute of Technology

  25. Thermal Circuit Analysis Rochester Institute of Technology

  26. Thermoelectrics • 20% heat loss • 95% efficient charging system • Constant Thermoelectric Properties • Heat Sink is flat, isothermal vertical plate. Rochester Institute of Technology

  27. Heat Sink Rochester Institute of Technology

  28. Budget • Thermoelectrics – $40/ea • Enclosure – $200 • Electronics (Including cabling, microcontroller, and battery) – $250 • Testing – $100 Rough Total - ~$550 + 40n Rochester Institute of Technology

  29. Thermoelectrics • Power strongly dependent on Heat Sink. Rochester Institute of Technology

  30. Dumbbell Enclosure • If heat sink has 0.5K/W or greater resistance, the “cold” side will be very hot • We need to protect our electronics from damage • Dumbbell shape best mitigates risk to electronics Rochester Institute of Technology

  31. Risk Assessment Rochester Institute of Technology

  32. Test Plan • Test waterproofing without heat • Test thermoelectric, sensors, charging and max power point circuits • Test waterproofing with heat Rochester Institute of Technology

  33. Test Plan • Test heat sink • Integrate and test full system. 1: Heat Sink 2: Thermoelectric Array 3: Heat Source 4: Instrumentation 5: Microcontroller & Charging circuit 6: Battery Rochester Institute of Technology

  34. Project Plan • We only have 2 weeks • This is how we do it • 5 days --- integrate --- 5 days • Update EDGE & Risk Assesment Rochester Institute of Technology

  35. Issues on the Horizon • Thermoelectric clamping (300kPa min - recommend 1.2MPa) • External vs system powered electronics (sensors, microcontrollers, etc) • Heat sinking Rochester Institute of Technology

  36. Clamping Configurations Rochester Institute of Technology

  37. Questions Rochester Institute of Technology

  38. Problem Statement • Current State • Boeing’s current UUV, the Echo Ranger has a maximum mission time of 28 hours. Boeing would like to significantly extend this mission time. • Desired State • Boeing would like to utilize a thermoelectric system to significantly extend mission time of their UUVs. • Project Goals • Demonstrate proof of concept of thermoelectric system • Use a temperature differential to charge a battery • Achieve maximum thermoelectric efficiency over a range of temperatures • Establish a UUV-based research partnership between Boeing and RIT • Constraints • System must operate underwater • System must utilize a thermoelectric device • System must operate autonomously Rochester Institute of Technology

  39. Customer Requirements Rochester Institute of Technology

  40. Engineering Requirements Rochester Institute of Technology

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