A chimney cap type ship exhaust gas waste heat self-power supply monitoring device

Abstract

This invention relates to the field of marine energy conservation, environmental protection, and IoT monitoring technology, and in particular to a chimney-cap type self-powered monitoring device for waste heat from ship exhaust gas. The device includes an installation and connection assembly, a heat capture assembly, a thermoelectric conversion assembly, a cold-end enhanced heat dissipation assembly, and an energy management and control assembly. Based on the gradient porosity design of the heat-absorbing core and the self-cleaning characteristics of the Giroid lattice structure, the heat exchange area of ​​the device is increased by 3.5 times, and the exhaust back pressure is always controlled within a safe range below 1.0 kPa, avoiding interference with the normal operation of the ship's engine. A passive enhanced heat dissipation shroud is installed to improve heat dissipation efficiency, solving the heat dissipation problem under low-speed / light wind conditions. The flange-removable and modular structure design reduces the deployment cost of the device on older ships and requires no intrusive modifications, making it suitable for the practical application needs of small and medium-sized older ships such as fishing boats, engineering vessels, and inland waterway transport vessels.

Description

Technical Field

[0001] This invention relates to the field of ship energy conservation, environmental protection and Internet of Things monitoring technology, and in particular to a chimney cap type ship exhaust waste heat self-powered monitoring device. Background Technology

[0002] With the implementation of the International Maritime Organization (IMO)’s “Strategy for Reducing Greenhouse Gas Emissions from Ships”, the shipping industry is facing stringent requirements for improving energy efficiency and monitoring greenhouse gas and pollutant emissions.

[0003] Among them, small and medium-sized old vessels (including fishing boats, engineering boats, and inland waterway transport vessels) are an important part of shipping and water operations. Their engines emit high-temperature exhaust gas directly, causing a large amount of waste heat and thermal pollution. Moreover, they are not equipped with online monitoring equipment for exhaust temperature, CO2, and particulate matter, and therefore cannot meet emission regulatory requirements.

[0004] For the monitoring system upgrade of the aforementioned ships, if traditional wired sensors are used, cabling through the cabin is required, which presents problems such as high construction difficulty, long cycle, and high upgrade cost (about 20,000 to 30,000 yuan per ship). On the other hand, if battery-powered wireless monitoring nodes are used, batteries need to be replaced frequently, resulting in high maintenance costs in the later stage. In addition, the waste batteries are prone to secondary environmental pollution. Neither of these options can meet the actual upgrade needs of old ships.

[0005] Thermoelectric generation (TEG) technology, based on the Seebeck effect in semiconductors, can directly convert heat energy into electrical energy. It has the advantages of no moving parts and no maintenance, making it an ideal technology for recovering waste heat from ship exhaust. The core of this technology is to construct an efficient heat source, thermoelectric generation, and cold source heat flow channel: heat exchange at the hot end mostly adopts traditional finned or porous medium heat exchangers. The Gyroid lattice structure based on triple period minimal surface (TPMS) has become an emerging direction for enhancing heat exchange due to its high specific surface area and continuous flow channel characteristics. Cooling at the cold end mainly adopts two methods: natural air cooling and forced air cooling. Due to fluctuations in ship operating conditions, the output voltage of thermoelectric generation is unstable, requiring a power management circuit to achieve energy regulation.

[0006] Although thermoelectric power generation technology has theoretical advantages, when directly applied to scenarios such as waste heat recovery from ship exhaust and power supply for monitoring, existing technologies still have the following technical shortcomings:

[0007] The contradiction between heat exchange efficiency and flow channel anti-clogging performance is prominent. To improve heat exchange efficiency, existing exhaust gas heat exchangers mostly adopt dense fins or porous structures with a single porosity. However, marine diesel engine exhaust contains a large amount of carbon soot particles and oil stains, and the micro-flow channels are prone to carbon accumulation and scaling, resulting in blockage. After blockage, not only does the heat exchange thermal resistance increase sharply and the power generation efficiency decrease, but it also causes the exhaust back pressure to exceed the 1.0 kPa safety warning line, affecting the normal operation of the engine and even damaging the main engine. If the flow channel aperture is simply enlarged to avoid blockage, it will result in insufficient heat exchange area and inability to effectively extract waste heat from the exhaust gas.

[0008] Cold-end heat dissipation solutions cannot balance efficiency and energy consumption. The efficiency of thermoelectric power generation depends on the temperature difference between the cold and hot ends. Existing forced air cooling solutions require electric fans, which consume a lot of electricity, significantly reducing the net output power of the system and even causing negative power output. Natural air cooling solutions rely on environmental convection. Under low wind speed conditions such as low-speed navigation, berthing, and downwind operation of ships, the cold end temperature rises rapidly, and the temperature difference between the cold and hot ends is insufficient, directly causing the power generation system to fail.

[0009] The energy management system cannot adapt to the fluctuations in the ship's operating conditions. Under conditions such as idling, cruising, and full load, the exhaust gas temperature (100℃~600℃) and flow rate of the ship's engine fluctuate drastically, resulting in significant changes in the internal resistance and output voltage of the thermoelectric generator. Traditional power management circuits lack maximum power point tracking (MPPT) function, have low energy extraction efficiency, and lack a hybrid energy storage mechanism. The monitoring nodes are immediately de-energized after the engine stops, making it impossible to achieve all-weather data sensing.

[0010] The existing waste heat recovery devices are mostly large, independent pieces of equipment that need to be connected in series to the exhaust pipes. Installation requires cutting the original pipes, welding flanges, and erecting supports, which is an intrusive modification. In addition, old ships have narrow spaces and their hull structures cannot be easily modified. This modification method is difficult to carry out and takes a long time, making it impossible to promote and apply it on a large scale. Summary of the Invention

[0011] In view of this, the technical problem to be solved by the present invention is how to design a self-powered wireless emission monitoring thermoelectric generator for old ship exhaust that combines efficient anti-blocking heat exchange, passive heat dissipation, adaptive operation under changing conditions, and non-intrusive installation.

[0012] To solve the aforementioned technical problem, a chimney cap-type ship exhaust waste heat self-powered monitoring device is provided, comprising:

[0013] The mounting connection assembly is a quick-release flange; the heat capture assembly includes a heat-absorbing core, a heat insulation chamber, a heat-conducting sleeve, and a heat-conducting substrate; the thermoelectric conversion assembly is a thermoelectric generator; the cold-end enhanced heat dissipation assembly includes heat dissipation fins and a flow guide; the energy management and control assembly includes a component placement chamber and a control board integrated in the placement chamber; and the top of the heat-conducting sleeve is formed with an exhaust port.

[0014] The heat-conducting sleeve is fixedly connected to the quick-release flange. The heat-absorbing core is interference-filled into the inner cavity of the heat-conducting sleeve. The heat-conducting substrate is set on the outer wall of the heat-conducting sleeve. The thermoelectric generator is set between the heat-conducting substrate and the heat dissipation fins. The flow guide is coaxially sleeved outside the heat dissipation fins. The component placement compartment is set on the top of the heat-conducting sleeve and located outside the exhaust port.

[0015] The components work together to achieve integrated functions such as waste heat capture, thermoelectric conversion, passive enhanced heat dissipation, fluctuation energy management, and wireless monitoring of exhaust parameters.

[0016] In a preferred embodiment, the heat-absorbing core adopts a triple-period minimal curved surface Giroid lattice structure integrally formed by metal 3D printing, and its porosity varies from bottom to top along the direction of exhaust gas flow.

[0017] In a preferred embodiment, the porosity of the exhaust gas inlet section of the heat-absorbing core is 80%, and the porosity of the exhaust gas outlet section transitions to 50%.

[0018] The heat-absorbing core and the heat-conducting sleeve are designed for pull-out assembly, and the heat-absorbing core can be pulled out axially after the quick-release flange is removed.

[0019] In a preferred embodiment, the heat-absorbing core and the heat-conducting sleeve are interference-fitted and assembled by a heat-shrinking process, and the heat insulation chamber is disposed between the heat-conducting sleeve and the lower outer shell of the flow guide shroud.

[0020] The thermally conductive substrate extends outward from the middle of the outer wall of the thermally conductive sleeve to form a ring structure, providing a bonding support surface for the thermoelectric generator.

[0021] In a preferred embodiment, the outer cylindrical surface of the heat-absorbing core is precision machined by CNC, and the surface roughness is controlled within Ra1.6.

[0022] In a preferred embodiment, thermoelectric generators are arranged in a ring array on the upper surface of a heat-conducting substrate, and the cold end face of the thermoelectric generators is in contact with the heat dissipation fin substrate.

[0023] A high thermal conductivity interface material is coated between the hot end face of the thermoelectric generator and the thermally conductive substrate, and between the cold end face and the heat dissipation fin substrate.

[0024] In a preferred embodiment, the heat dissipation fins extend radially outward;

[0025] The air deflector is designed as a spiral air deflector, which together with the heat dissipation fins forms a cooling airflow channel. The cross-sectional area of ​​the channel is a contracting structure along the airflow direction.

[0026] In a preferred embodiment, the height of a single tooth of the heat dissipation fin is 30 mm, and the cooling airflow channel narrows from 50 mm at the inlet to 25 mm at the throat.

[0027] The inner flow channel of the deflector is integrally formed with several sets of spiral guide vanes with an inclination angle of 30°.

[0028] In a preferred embodiment, the control board integrates an impedance matching unit, a hybrid energy storage unit, and a voltage regulator unit that are electrically connected in sequence, and also integrates a sensing and communication module.

[0029] The sensing and communication module includes a low-power microcontroller unit, a sensor interface, and a long-range wireless communication module;

[0030] The component storage compartment has a display screen mounting port on its side wall;

[0031] The impedance matching unit can track the maximum power point of the thermoelectric generator array under ship exhaust temperature fluctuations of 100℃~600℃.

[0032] In a preferred embodiment, the heat-conducting sleeve is made of high thermal conductivity 6061 aluminum alloy, and its inner cavity bottom is integrally formed with an annular limiting shoulder, which is adapted to the end of the heat-absorbing core outlet section to limit the insertion depth of the heat-absorbing core.

[0033] According to the present invention, based on the gradient porosity design of the heat-absorbing core and the self-cleaning characteristics of the Giroid lattice structure, the heat exchange area of ​​the device is increased by 3.5 times, and the exhaust back pressure is always controlled within a safe range of less than 1.0 kPa, so as to avoid affecting the normal operation of the ship's engine.

[0034] The passive enhanced heat dissipation shroud is set up to improve heat dissipation efficiency and solve the heat dissipation problem under low speed / light wind conditions of ships.

[0035] Impedance matching units are set up to improve energy extraction efficiency, and hybrid energy storage units enable maintenance-free power supply for the monitoring nodes throughout their entire life cycle.

[0036] The quick-release flange and modular structure design reduce the deployment cost of equipment on old ships and do not require intrusive modifications, making it suitable for the actual application needs of small and medium-sized old ships such as fishing boats, engineering boats, and inland waterway transport vessels. Attached Figure Description

[0037] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0038] Figure 1 An axial cross-sectional view of a monitoring device according to an embodiment of the invention.

[0039] Figure 2 This is a schematic diagram of the structure of a monitoring device according to an embodiment of the invention.

[0040] Figure 3 This is a top view of a monitoring device according to an embodiment of the invention.

[0041] Figure 4 Schematic diagram of the internal structure of a monitoring device according to an embodiment of the invention Figure 1 .

[0042] Figure 5 Schematic diagram of the internal structure of a monitoring device according to an embodiment of the invention Figure 2 .

[0043] Figure 6 Schematic diagram of the internal structure of a monitoring device according to an embodiment of the invention Figure 3 . Detailed Implementation

[0044] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0045] Please see Figures 1 to 6 As an embodiment of the present invention, a chimney cap type ship exhaust waste heat self-powered monitoring device is provided, which is suitable for the recovery of waste heat from ship engine exhaust and the self-powered online monitoring of ship exhaust temperature, CO2, smoke particulate matter, and is adapted to the non-destructive retrofit requirements of exhaust pipes of small and medium-sized old ships.

[0046] It includes a quick-release flange 100 (installation connection assembly), a heat-absorbing core 200, a heat insulation chamber 300, a heat-conducting sleeve 301, a heat-conducting substrate 302 (heat capture assembly), a thermoelectric generator 400 (thermoelectric conversion assembly TEG), heat dissipation fins 500, a component placement chamber 600, a flow guide 700 (cold end enhanced heat dissipation assembly), a display screen mounting port 701 (energy management and control assembly), and an exhaust port 800;

[0047] The components work together to achieve integrated functions such as waste heat capture, thermoelectric conversion, passive enhanced heat dissipation, fluctuation energy management, and wireless monitoring of exhaust parameters;

[0048] For ease of description, the device consists of an exhaust channel (hot end), a power generation layer, a heat dissipation layer (cold end), and a flow guide cover from the inside out. The top of the device is equipped with a component storage compartment 600 (electrical compartment), and the bottom of the device is equipped with a quick-release flange 100 that is compatible with different pipe diameters.

[0049] Regarding the installation connection components, the quick-release flange 100, which is used as a load-bearing connection component, is fixed with a heat-conducting sleeve 301.

[0050] The heat-conducting sleeve 301 is welded or bolted to the quick-release flange 100;

[0051] When in use, the quick-release flange 100 is used to fix the device to the end of the ship's exhaust pipe with bolts. There is no need to cut or weld the original exhaust pipe of the ship, which can achieve non-destructive and quick installation and disassembly of the device and the ship's exhaust pipe, reducing the difficulty and technical threshold of the renovation of old ships.

[0052] Regarding the heat capture component, it is located at the central axis of the device, serving as a flow channel for high-temperature exhaust gas. It transfers the heat energy of the exhaust gas to the thermoelectric conversion component, preventing carbon buildup and clogging, and controlling the exhaust back pressure within a safe range (<1.0 kPa). It includes...

[0053] The heat-absorbing core 200 is made of a triple-period minimal surface (TPMS) Gyroid structure formed by metal 3D printing (SLM) in one piece.

[0054] The Gyroid lattice structure is described by implicit equations:

[0055]

[0056] Among them, t controls the offset of the isosurface, which corresponds to the change in porosity. Combined with the scale coefficient, different sibling sizes a can be generated.

[0057] Specifically, the porosity of the heat absorption core 200 varies in a gradient along the direction of exhaust gas flow. The porosity of the exhaust gas inlet section is 80%, which, combined with the large pore size, can reduce the exhaust back pressure and accommodate large carbon particles in the exhaust gas, preventing inlet blockage. The porosity of the exhaust gas outlet section gradually transitions to 50%, and the pore size is reduced to enhance fluid turbulence and maximize the heat transfer specific surface area.

[0058] In one feasible implementation, the heat-absorbing core 200 is distributed in at least three sections along the axial direction, including an exhaust gas inlet section, an exhaust gas middle section, and an exhaust gas outlet section. Based on the implicit equation parameterization design of the Gyroid triple-periodic minimal surface, key parameters such as cell size, wall thickness, porosity, flow channel dimensions, and hydraulic diameter vary in a gradient matching manner along the exhaust gas flow direction to adapt to the anti-clogging, low flow resistance, and high-efficiency heat exchange requirements of different regions.

[0059] In the exhaust gas inlet section, the porosity ε is designed to be 80%, achieved by adjusting the isosurface offset parameter t in the Gyroid implicit equation, satisfying the formula:

[0060] (Where Vs is the volume of the solid material, and Vtot is the total volume within the segment)

[0061] The high porosity design is used to reduce fluid resistance, and together with other parameters, it keeps the exhaust back pressure below 1.0 kPa.

[0062] The cell size a is 6mm~8mm, determined by the scale factor s using the formula This parameter determines the heat exchange area and resistance level. The inlet section adopts a large cell size to reduce airflow resistance while providing basic heat exchange capacity.

[0063] The wall thickness δ is designed to be 0.3mm, and the molding process is controlled based on a formula:

[0064] (in, This is the isosurface offset. (For the gradient of the implicit equation)

[0065] The thin-walled, thick-walled design further enhances porosity while also taking into account the structural strength and thermal conductivity requirements.

[0066] Minimum flow channel size The minimum diameter of the flow channel is 4.0 mm, which is determined by the minimum value of the flow channel diameter function within the flow field region Ωf. This parameter determines the structure's anti-clogging ability. The maximum minimum flow channel size can accommodate large particulate carbon soot in the exhaust gas and avoid clogging of the inlet section flow channel.

[0067] The hydraulic diameter Dh is 4.5mm~5.0mm, determined by calculation using the formula:

[0068] (Where Ac is the effective cross-sectional area of ​​the flow channel, and Pw is the wetted perimeter of the flow channel)

[0069] This parameter effectively characterizes a non-circular flow channel as a circular flow channel, and the large hydraulic diameter further enhances the flow capacity and reduces the flow resistance at the inlet section.

[0070] In the middle section of the exhaust gas, this section serves as a transition zone, where the porosity ε smoothly transitions to 65%. This is achieved by continuously adjusting the isosurface offset parameter t of the Gyroid implicit equation along the flow path, taking into account both flow resistance control and heat transfer efficiency improvement.

[0071] The cell size a is reduced to 4mm~5mm, which is determined by the scale factor s using the formula It is determined that the cell size should be appropriately reduced to increase the heat transfer area per unit volume, while avoiding a sharp increase in flow resistance.

[0072] The wall thickness δ is increased to 0.4mm. Based on the aforementioned formula, the molding is controlled. The wall thickness is appropriately increased to improve the structural strength and thermal conductivity of the middle section and enhance the heat conduction capacity.

[0073] The minimum flow channel size dmin is 2.5mm~3.0mm, which is determined by the minimum value of the flow channel diameter function within the flow field region Ωf. While ensuring the flow capacity, the perturbation degree of the flow channel on the fluid is gradually increased, laying the foundation for efficient heat exchange in the outlet section.

[0074] The hydraulic diameter Dh is 3.0mm~3.5mm, which is determined by the aforementioned formula. By changing the hydraulic diameter in a gradient, the flow capacity of the channel is smoothly transitioned, avoiding sudden changes in flow resistance.

[0075] In the exhaust gas outlet section, the porosity ε is reduced to 50%, which is achieved by adjusting the isopleth offset parameter t in the Gyroid implicit equation. The low porosity design can increase the heat transfer area per unit volume and enhance the forced convection heat transfer between the exhaust gas and the heat absorption core.

[0076] The cell size a is further reduced to 2.5mm~3mm, which is determined by the scale factor s according to the aforementioned formula. The smaller cell size increases the heat transfer specific surface area and enhances the fluid disturbance effect.

[0077] The wall thickness δ is increased to 0.5mm. Based on the aforementioned formula, the molding is controlled. The thick wall design improves the structural strength and thermal conductivity of the outlet section, and enhances the heat conduction efficiency of the heat to the heat-conducting sleeve.

[0078] The minimum flow channel size dmin is 1.5mm~2.0mm, which is determined by the minimum value of the flow channel diameter function in the flow field region Ωf. A smaller minimum flow channel size can enhance fluid disturbance and intercept residual fine carbon soot in the exhaust gas, preventing impurities from entering the downstream pipeline.

[0079] The hydraulic diameter Dh is 1.8mm~2.2mm, which is determined by the aforementioned formula. A smaller hydraulic diameter enhances the turbulence of the fluid in the flow channel, improves the heat transfer coefficient, and maximizes the heat capture efficiency.

[0080] Based on the three-stage stepped parameter design, the heat absorption core 200 forms a flow resistance and heat exchange synergy structure with low resistance and anti-clogging in the inlet section, smooth transition in the middle section, and efficient heat exchange in the outlet section. It achieves the control target of exhaust back pressure <1.0kPa, and can prevent carbon buildup and blockage and efficiently capture heat energy. It adopts a pull-out fit design, and can be pulled out axially after removing the quick-release flange 100, which is convenient for cleaning or replacement and maintenance.

[0081] The heat-absorbing core 200 and the heat-conducting sleeve 301 are pull-out type, and the heat-absorbing core 200 can be pulled out axially after the quick-release flange 100 is removed.

[0082] In this embodiment, the outer cylindrical surface of the heat-absorbing core 200 is processed by CNC precision machining, and the surface roughness is controlled within Ra1.6. The heat-absorbing core 200 is set as a pull-out structure, which does not require disassembling the outer shell of the device. Only the quick-release flange 100 needs to be removed to pull out the heat-absorbing core 200 for cleaning or replacement, thus achieving convenient maintenance.

[0083] Specifically, in order to achieve axial positioning, assembly limitation and error prevention of the heat-absorbing core 200, the bottom of the inner cavity (base position) of the heat-conducting sleeve 301 is integrally formed with an annular limiting shoulder. The size of the limiting shoulder is adapted to the end of the outlet section of the heat-absorbing core 200 and forms an axial abutment fit with the lower end face of the heat-absorbing core 200 to limit the axial insertion depth of the heat-absorbing core 200 and prevent over-assembly.

[0084] The end structure of the inlet section of the heat absorption core 200 cannot effectively abut against the limiting shoulder, thus avoiding the heat absorption core being installed backwards and indirectly achieving a foolproof positioning effect. There is no need to set an additional positioning key, which simplifies the structure and ensures assembly consistency and the correctness of the flow channel direction.

[0085] The heat-conducting sleeve 301 is a cylinder (hot end temperature equalization sleeve) made of high thermal conductivity 6061 aluminum alloy. The high thermal conductivity of 6061 aluminum alloy ensures rapid heat conduction. The heat-absorbing core 200 is interference-filled in the inner cavity of the heat-conducting sleeve 301.

[0086] In one feasible implementation, the heat-absorbing core 200 and the heat-conducting sleeve 301 are assembled by H7 / r6 interference fit and heat fitting process. The heat-conducting sleeve 301 is heated and expanded before being assembled with the heat-absorbing core 200. After the heat-conducting sleeve 301 cools and shrinks naturally, a tight fit can be achieved, eliminating contact thermal resistance and ensuring that the heat absorbed by the heat-absorbing core 200 is quickly conducted radially to the outer wall of the heat-conducting sleeve 301.

[0087] Specifically, the outer wall of the heat-conducting sleeve 301 extends outward to form an annular heat-conducting substrate 302, which provides a bonding support surface for the thermoelectric conversion assembly. The top opening of the heat-conducting sleeve 301 forms an exhaust port 800 for the exhaust gas after heat exchange is completed.

[0088] The heat insulation chamber 300 is disposed between the heat-conducting sleeve 301 and the lower outer shell of the flow guide 700. It is used to isolate the high-temperature area of ​​the hot end from the cold end components and the external environment, block the heat radiation of the heat-conducting sleeve 301 from directly heating the cold end structure, and maintain the temperature difference characteristics between the hot and cold ends required for thermoelectric conversion.

[0089] Regarding the thermoelectric conversion component, it converts thermal energy into electrical energy based on the Seebeck effect of semiconductors, and is disposed between the hot end heat-conducting substrate 302 and the cold end heat dissipation fins 500, which includes a number of thermoelectric generators 400.

[0090] The thermoelectric generator 400 is arranged in a ring array and closely attached to the upper surface of the heat-conducting substrate 302 (hot end of thermoelectric generator 400), and the cold end of thermoelectric generator 400 is attached to the substrate of heat dissipation fin 500.

[0091] In this embodiment, a high thermal conductivity interface material (thermal grease or graphite sheet) is coated between the hot end face of the thermoelectric generator 400 and the thermally conductive substrate 302, and between the cold end face of the thermoelectric generator 400 and the heat dissipation fin 500 substrate. This material is used to fill the micro gaps in the contact surfaces, reduce contact thermal resistance, improve heat conduction efficiency, and ensure efficient conversion of thermal energy into electrical energy.

[0092] Regarding the cold-end enhanced heat dissipation component, based on external natural wind or ship navigation wind, it enhances cooling of the cold end of the thermoelectric generator 400 without additional power consumption, maintaining an effective temperature difference between the hot and cold ends. It is coaxially mounted outside the thermoelectric conversion component and includes...

[0093] The heat dissipation fins 500 are manufactured using a high-density aluminum profile inserting process. Their substrate is in close contact with the cold end face of the thermoelectric generator 400. The fins extend radially outward, with a single tooth height of 30mm, to provide sufficient heat dissipation area and quickly conduct heat from the cold end of the thermoelectric generator 400.

[0094] The air guide shroud 700 is installed outside the heat dissipation fins 500 and is configured as a spiral shroud, forming a cooling airflow channel together with the heat dissipation fins 500;

[0095] Specifically, the lower end of the fairing 700 is evenly provided with 6-8 air inlets, which are inclined downward at 45° and distributed circumferentially at equal angles along the circumference of the fairing 700 (the included angle between adjacent air inlets is 45°-60°), which can adapt to the ship's rolling (pitch ±15°, roll ±20°) and random wind direction changes during the ship's navigation.

[0096] That is, even if one side of the air inlet is blocked due to wind direction shift or ship tilt, the other circumferentially distributed air inlets can still take in air normally, thus avoiding the problem of cold end heat dissipation interruption caused by the failure of one side air intake.

[0097] The downward-sloping air inlet reduces the entry of rainwater, seawater droplets, and marine pollutants into the cooling channel, lowering the risk of dirt buildup and blockage in the heat dissipation fins, making it suitable for harsh working environments at sea.

[0098] Furthermore, the top of the flow guide 700 is coaxially aligned with the exhaust port 800, and the inner diameter of the air outlet at the top of the flow guide 700 is slightly larger than the outer diameter of the exhaust port 800, forming an annular flow guide gap.

[0099] When the high-temperature exhaust gas (100℃~600℃) from the ship engine is discharged from the exhaust port 800, it will form an upward high-temperature hot plume. This hot plume will generate a negative pressure suction effect at the top air outlet of the guide shroud 700, forming a secondary suction force. This works in synergy with the ship's sailing wind and natural wind to enhance the intake power of cooling air.

[0100] The 700 fairing has a spiral structure that tapers at the top and opens at the bottom, and also functions as a chimney. Even when the ship is sailing at low speed (wind speed < 2m / s) or in windless conditions, the chimney suction formed by the exhaust gas hot plume can still drive the cooling air to flow in the flow channel, ensuring the continuity of heat dissipation at the cold end and avoiding the decrease in temperature difference between the hot and cold ends and the decrease in thermoelectric conversion efficiency due to the lack of wind.

[0101] In a preferred embodiment, the cross-sectional area of ​​the flow channel between the inner wall of the shroud 700 and the outer edge of the heat dissipation fin 500 is set as a contraction structure along the air flow direction (from the air inlet to the air outlet), contracting from 50mm at the inlet to 25mm at the throat. Based on Bernoulli's principle, the external airflow is forcibly accelerated, destroying the laminar boundary layer on the surface of the heat dissipation fin 500 and enhancing convective heat transfer.

[0102] The throat position of the flow channel (the smallest cross-sectional area, 25mm) is designed at the axial midpoint of the heat dissipation fin 500 (i.e., 15mm away from the heat dissipation fin 500 substrate). The selection of this position is in conjunction with the height, spacing and number of heat dissipation fins 500.

[0103] Combined with the design of the 500 heat sink fins with a single tooth height of 30mm, the throat corresponds to the middle area of ​​the fins. This area is the core heat exchange area of ​​the 500 heat sink fins (heat is concentrated and the heat exchange area accounts for 60%).

[0104] The radial spacing of the heat dissipation fins 500 is set to 8-10mm, and the number is 24-32. The angle of the flow channel contraction at the throat position (12° with the axial angle) is matched with the radial extension angle of the fins, so that the accelerated cooling airflow sweeps evenly across the full height area of ​​each heat dissipation fin, avoiding the problem of uneven heat exchange caused by the airflow concentrating at the top or root of the fins.

[0105] The throat position is aligned with the middle of the heat dissipation fin 500, so that the airflow forms a stable turbulent state after acceleration, further destroying the laminar boundary layer on the fin surface and maximizing the heat transfer efficiency. The throat height is calculated based on the heat transfer characteristics, flow channel resistance and suction power of the heat dissipation fin, and is synergistically adapted with the structural parameters of the heat dissipation fin.

[0106] Furthermore, several sets of spiral guide vanes are integrally formed in the inner flow channel of the shroud 700, with a vane inclination angle of 30°. These guide vanes can force the cooling air to generate spiral flow, prolonging the residence path and time of the air on the surface of the heat dissipation fins 500, and further improving the heat exchange efficiency.

[0107] In the case of tailwind operation, the external airflow and the hot plume at the top of the 700 shroud are in the same direction. The contraction structure of the flow channel further accelerates the airflow. The spiral guide vanes guide the airflow to form a spiral flow, prolonging the contact time between the airflow and the heat dissipation fins. The circumferential air inlet assists in air intake, avoids airflow short-circuiting, and ensures heat dissipation efficiency.

[0108] In headwind conditions, the spiral structure of the 700 shroud and the inclined air inlet guide the headwind to change its direction, avoiding airflow turbulence caused by the airflow directly impacting the heat dissipation fins. The flow channel contraction structure and the heat plume suction effect compensate for the headwind resistance, ensuring that the cooling airflow passes through the flow channel stably and maintains effective heat exchange even if the headwind resistance is large.

[0109] In crosswind conditions, the evenly distributed air inlets in the circumference enable multi-directional air intake, avoiding uneven air intake caused by crosswinds on one side. The spiral guide vanes transform the lateral airflow into spiral flow, forcing the airflow to flow radially along the heat dissipation fins, ensuring that the airflow can sweep over all heat dissipation fins, avoiding local heat dissipation failure, and maintaining more than 80% of the rated heat dissipation efficiency in crosswind conditions, thus avoiding unstable cold end heat dissipation in crosswind conditions on ships.

[0110] Furthermore, the fairing 700 is made of high-temperature resistant modified glass fiber reinforced material to ensure structural rigidity and thermal insulation performance, prevent solar radiation or waste heat from heating the cold end, and avoid reducing the temperature difference between the hot and cold ends.

[0111] In this embodiment, the flow guide 700 is made of glass fiber reinforced modified polyethylene terephthalate-1,4-cyclohexanediethanol ester (PETG-GF) by 3D printing;

[0112] Regarding the energy management and control components, they are integrated into a component placement compartment 600 at the top of the device. The component placement compartment 600 is located around the exhaust port 800, avoiding the central high-temperature zone and utilizing the residual airflow from the cool air outlet for natural heat dissipation. A display screen mounting port 701 is provided on the side wall of the component placement compartment 600 for mounting a display component for exhaust gas monitoring data. The control board integrates a low-power microcontroller unit (MCU), sensor interfaces (temperature, pressure, and smoke sensors), and a long-range wireless communication module, which includes…

[0113] The maximum power point tracking impedance matching unit (MPPT) can track the maximum power point of the thermoelectric generator array 400 in real time under the fluctuation of ship exhaust temperature (100℃~600℃), thereby improving the energy extraction efficiency of exhaust waste heat.

[0114] The hybrid energy storage unit adopts a topology structure of supercapacitors and lithium batteries connected in parallel. The supercapacitors are used to buffer voltage pulses and achieve fast charging, while the lithium batteries are used for long-term energy storage, ensuring that the monitoring nodes can still maintain standby power supply after the ship's main engine stops.

[0115] The voltage regulation unit, including a low dropout regulator (LDO), can regulate the voltage output from the hybrid energy storage unit to provide stable power to the sensors, displays, and long-range wireless communication modules (LoRa) at the load end.

[0116] The sensing and communication module collects parameters such as temperature, pressure, and smoke opacity of ship exhaust through the sensor interface. After processing by the low-power microcontroller unit, the monitoring data is wirelessly transmitted to the receiving end by the long-distance wireless communication module, realizing real-time online monitoring of exhaust parameters.

[0117] In one feasible implementation, the low-power microcontroller unit uses an STM32L051C8T6 or ESP32-C3 industrial-grade chip, the low-dropout regulator uses an AMS1117-3.3 / TPS7A02 regulator, the impedance matching unit uses a CN3791 / BQ24650 dedicated chip, the supercapacitor uses a 2.7V 10F / 20F farad capacitor, the lithium battery uses a 3.7V 18650 industrial-grade lithium iron phosphate battery, the long-range wireless communication module uses an E22-400T20S / SX1278 industrial-grade module, the temperature sensor uses a PT100 / DS18B20, the pressure sensor uses an MPX5010, and the smoke sensor uses an MQ-2.

[0118] The selection of electrical components is not limited to the exemplary models mentioned above. Any electrical component that has ultra-low power consumption, industrial-grade temperature resistance and anti-interference, adaptability to self-powered power supply from waste heat of ship exhaust gas and variable operating condition fluctuation characteristics, and can achieve equivalent impedance matching, energy storage, voltage stabilization, sensing and communication functions, falls within the protection scope of this invention.

[0119] Normal usage status:

[0120] Based on the gradient porosity heat-absorbing core 200 structure, efficient capture and anti-clogging of waste heat from exhaust gas is achieved. A thermoelectric generator array 400 converts the temperature difference between the hot and cold ends into electrical energy. Passive enhanced heat dissipation maintains the effective temperature difference. Impedance matching and hybrid energy storage enable efficient management of fluctuating electrical energy, powering shipborne sensors and enabling wireless monitoring of exhaust gas parameters. The process includes the following steps:

[0121] S1. Exhaust gas flow and waste heat capture: The high-temperature exhaust gas (temperature range 100℃~600℃) discharged from the ship engine enters the inner cavity of the heat-conducting sleeve 301 through the quick-release flange 100. After the exhaust gas flows through the Giroyd lattice channel of the heat-absorbing core 200 along the axial direction, it is discharged from the device from the exhaust port 800 at the top.

[0122] S1a. During the flow of exhaust gas, its heat energy is efficiently captured by the heat-absorbing core 200. Because the heat-absorbing core 200 and the heat-conducting sleeve 301 are H7 / r6 interference fit and assembled by heat-shrinking process, there is no contact thermal resistance. The heat is quickly conducted radially to the outer wall of the heat-conducting sleeve 301 and further transferred to the annular heat-conducting substrate 302, and finally conducted to the hot end face of the thermoelectric generator 400.

[0123] S2. Enhanced heat dissipation and temperature difference maintenance at the cold end: External natural wind or ship navigation wind enters the cooling air channel from the air inlet below the shroud 700. After being forcibly accelerated by the Venturi contraction structure (inlet 50mm → throat 25mm), it forms a spiral flow under the guidance of the 30° spiral guide vanes. The airflow sweeps across the surface of the radially radiating heat dissipation fins 500, efficiently removing the heat from the cold end face of the thermoelectric generator 400.

[0124] S2a and the heat insulation chamber 300 can block the interference of hot end heat radiation to cold end, so that the hot and cold ends of the thermoelectric generator 400 maintain a stable and effective temperature difference, and meet the conditions for thermoelectric conversion.

[0125] S3. Thermoelectric conversion and energy management: The thermoelectric generator 400 generates electrical energy based on the Seebeck effect under the action of the temperature difference between the hot and cold ends. The electrical energy is first transmitted to the impedance matching unit, which tracks the maximum power point of the thermoelectric generator 400 array and completes impedance matching to improve energy extraction efficiency.

[0126] S3a. The matched electrical energy is stored in a hybrid energy storage unit consisting of a supercapacitor and a lithium battery connected in parallel. The supercapacitor buffers voltage pulses and enables fast charging, while the lithium battery stores energy for a long time.

[0127] S3b: The electrical energy output from the hybrid energy storage unit is regulated by the voltage regulator unit to provide a stable power supply for the display screen, temperature / pressure / smoke sensor and long-distance wireless communication module at the load end;

[0128] S4. Exhaust gas parameter monitoring and transmission: The sensor collects parameters such as temperature, pressure, and smoke opacity of the ship's exhaust gas through the interface. After the collected parameters are processed by the low-power microcontroller unit, they are wirelessly transmitted to the external receiver by the long-distance wireless communication module, realizing self-powered real-time online monitoring of the ship's exhaust gas status.

[0129] S4a. When the ship's main engine stops, the lithium battery in the hybrid energy storage unit continuously powers the monitoring nodes, enabling all-weather standby data sensing.

[0130] Compared with the prior art, the present invention has the following characteristics:

[0131] Based on the gradient porosity design of the heat-absorbing core 200 and the self-cleaning characteristics of the Giroyd lattice structure, the heat exchange area of ​​the device is increased by 3.5 times, and the exhaust back pressure is always controlled within a safe range of below 1.0 kPa to avoid affecting the normal operation of the ship's engine.

[0132] The passive enhanced heat dissipation shroud 700 is installed, which improves heat dissipation efficiency by 40% and solves the heat dissipation problem under low speed / light wind conditions on ships.

[0133] Impedance matching units improve energy extraction efficiency by 30%, and hybrid energy storage units enable maintenance-free power supply for monitoring nodes throughout their entire lifecycle.

[0134] The quick-release flange 100 and modular structure design reduce the deployment cost of equipment on old ships by 95% without requiring intrusive modifications, making it suitable for the actual application needs of small and medium-sized old ships such as fishing boats, engineering boats, and inland waterway transport vessels.

[0135] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. The scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A chimney cap-type ship exhaust waste heat self-powered monitoring device, characterized in that, This includes mounting and connection components, heat capture components, thermoelectric conversion components, cold-end enhanced heat dissipation components, and energy management and control components; The mounting connection assembly is a quick-release flange (100), the heat capture assembly includes a heat-absorbing core (200), a heat insulation chamber (300), a heat-conducting sleeve (301) and a heat-conducting substrate (302), the thermoelectric conversion assembly is a thermoelectric generator (400), the cold end enhanced heat dissipation assembly includes heat dissipation fins (500) and a flow guide (700), the energy management and control assembly includes a component placement chamber (600) and a control board integrated in the placement chamber (600), and the top of the heat-conducting sleeve (301) is formed with an exhaust port (800). The heat-conducting sleeve (301) is fixedly connected to the quick-release flange (100), the heat-absorbing core (200) is interference-filled in the inner cavity of the heat-conducting sleeve (301), the heat-conducting substrate (302) is disposed on the outer wall of the heat-conducting sleeve (301), the thermoelectric generator (400) is disposed between the heat-conducting substrate (302) and the heat dissipation fins (500), the flow guide (700) is coaxially disposed outside the heat dissipation fins (500), and the component placement compartment (600) is disposed on the top of the heat-conducting sleeve (301) and located around the exhaust port (800); The components work together to achieve integrated functions such as waste heat capture, thermoelectric conversion, passive enhanced heat dissipation, fluctuation energy management, and wireless monitoring of exhaust parameters.

2. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 1, characterized in that, The heat-absorbing core (200) adopts a triple-period minimal curved surface Giroid lattice structure integrally formed by metal 3D printing, and its porosity varies from bottom to top along the direction of exhaust gas flow.

3. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 2, characterized in that, The porosity of the exhaust gas inlet section of the heat-absorbing core (200) is 80%, and the porosity of the exhaust gas outlet section transitions to 50%. The heat-absorbing core (200) is pulled out in a pull-out manner with the heat-conducting sleeve (301). After the quick-release flange (100) is removed, the heat-absorbing core (200) can be pulled out axially.

4. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 1, characterized in that, The heat-absorbing core (200) is press-fitted with the heat-conducting sleeve (301) and assembled by a heat-shrinking process. The heat insulation chamber (300) is located between the heat-conducting sleeve (301) and the lower outer shell of the flow guide (700). The thermally conductive substrate (302) extends outward from the middle of the outer wall of the thermally conductive sleeve (301) to form an annular structure, providing a bonding support surface for the thermoelectric generator (400).

5. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 4, characterized in that, The outer cylindrical surface of the heat-absorbing core (200) is precision machined by CNC, and the surface roughness is controlled within Ra1.

6.

6. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 1, characterized in that, The thermoelectric generator (400) is arranged in a ring array on the upper surface of the heat-conducting substrate (302), and the cold end face of the thermoelectric generator (400) is in contact with the heat dissipation fin (500) substrate. The hot end face of the thermoelectric generator (400) is coated with a high thermal conductivity interface material between the hot end face and the thermally conductive substrate (302), and between the cold end face and the heat dissipation fin (500) substrate.

7. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 1, characterized in that, The heat dissipation fins (500) extend radially outward; The air guide shroud (700) is configured as a spiral air guide shroud (700), which together with the heat dissipation fins (500) forms a cooling air flow channel, and the cross-sectional area of ​​the flow channel is a contraction structure along the air flow direction.

8. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 7, characterized in that, The single tooth height of the heat dissipation fin (500) is 30mm, and the cooling airflow channel narrows from 50mm at the inlet to 25mm at the throat. The inner flow channel of the flow guide (700) is integrally formed with several sets of spiral flow guide blades with an inclination angle of 30°.

9. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 1, characterized in that, The control board integrates an impedance matching unit, a hybrid energy storage unit, and a voltage regulation unit that are electrically connected in sequence, and also integrates a sensing and communication module. The sensing and communication module includes a low-power microcontroller unit, a sensor interface, and a long-range wireless communication module. The component placement compartment (600) has a display screen mounting port (701) on its side wall. The impedance matching unit can track the maximum power point of the thermoelectric generator (400) array under the fluctuation of ship exhaust temperature from 100°C to 600°C.

10. The chimney cap type ship exhaust waste heat self-powered monitoring device as described in claim 3, characterized in that, The heat-conducting sleeve (301) is made of high thermal conductivity 6061 aluminum alloy. The bottom of its inner cavity is integrally formed with an annular limiting shoulder. The limiting shoulder is adapted to the end of the outlet section of the heat-absorbing core (200) to limit the insertion depth of the heat-absorbing core (200).

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