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NASA USLI – PDR

This project explores the recovery of waste heat from aerospace engine exhaust using thermoelectric generators (TEGs). By leveraging rockets to simulate flight conditions, we aim to test and optimize TEG performance concerning recovered heat, thrust losses, and energy efficiency. Despite jet engines operating at only 35% efficiency, even minor improvements can yield significant benefits. Our setup features lightweight TEGs, detailed data acquisition systems, and precise testing protocols, facilitating efficient energy recovery to power onboard systems during extended flights.

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NASA USLI – PDR

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  1. NASA USLI – PDR VU Aerospace ClubRocket-based Studies of Thermoelectric Exhaust Heat Recovery in Aerospace Engines

  2. Project Overview • Recover waste heat from exhaust • Use thermo electric generators (TEG) • Initial Testing for: • Recovered Heat • Thrust Losses • Use rocket to simulate flight conditions of jet

  3. Application • Use thermoelectric generators to recover waste heat coming off of jet engines • Commercial jets run for hours at a time • Can recover energy to power on-board systems during flight • Small improvements = big benefits on large scale

  4. Motivation • Energy efficiency is important global topic • Typical jet engines run at 35% efficiency • Small increases in efficiency can pay large dividends • Test for net increase in efficiency • Rocket is cheapest means of testing theory while achieving in-flight operating conditions

  5. Payload Description • Thermoelectric Generators (TEGs) will recover waste heat in exhaust flow • Attach TEG assembly on aft end of rocket • Voltages read and stored on-board by data logger

  6. Thermoelectric Generator • Allows for direct conversion between thermal and electrical energy • Function through motion of excess electrons and the Seebeck Effect • Very reliable since no moving parts • Lightweight

  7. Payload Verification/Testing • Testing facility to measure power output as function of: • Geometry • Temperature difference • Flow rate • LabVIEW used to measure and record: • Temperatures • Voltages • Initial tests determine optimal electrical resistance

  8. Data Acquisition • Using SparkFunLogomatic V2 microSDDataloggers on board. • Each board has up to 10 channels. • Low cost and recording to SD makes accessing data simple.

  9. Data Acquisition Layout SD Cardash MCU Vout A/D Resistor bank TEG + - + - TEG

  10. Rocket Dimensions & Weight • Length: 125 in • Diameter: 6.3 in • Span Dia.: 26.3 in • CG: 89.9 in • Stability Margin: 1.86 • Launch Mass: 16.8 kg • Thrust-to-Weight: 3.69 • CP: 101.3 in Electronics Bay

  11. Rocket Materials • Dyna-wind body tube • Carbon Fiber Composite Fins for added stability • AV Bay located in coupler tubing • Break-away wiring will allow for data collection until recovery deployment

  12. Verification and Testing • Motor • Static testing • Thrust effects of payload • TEG location • Number of TEGs • Preliminary Flights • Safe take-off velocity • Full-scale flight

  13. Integration • Utilizing microSD to log data on-board • System small enough to make redundant collection viable • Breakaway connectors eliminate wiring concerns • Mounting options: • Fixed to airframe • Threaded on motor retainer

  14. Motor • Cesaroni Pro98 L610 • Long burn (8.1s) • Aeropack Retainer • Thrust to weight: • 5.4 (initial) • 3.7 (average)

  15. Recovery System • Dual deploy recovery system • Static firing to test deployment • 12-14’ main chute with 24-36” drogue chute • Fireball used to prevent zippering • Black powder charges • Redundant systems using PerfectfliteminiAlt/WD

  16. Rocket Safety • Static fires to characterize thrust • All components used to industry standards • Stability margin within safe range • Scaled and preliminary flights • All codes and laws followed during all team events

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