Integrated Thermoelectric Generator and Steam Cycle Drive Unit
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Solution Overview
Problem
The inefficiency of internal combustion engines in motor vehicles, where two-thirds of the heat energy released during combustion is wasted as lost heat, leading to suboptimal overall efficiency and increased fuel consumption.
Innovation Solution
A drive unit integrating a cyclic process device and a thermoelectric generator (TEG) to convert waste heat from the internal combustion engine into both mechanical and electrical energy, with the TEG being thermally coupled within the cyclic process device to maximize thermal energy utilization, utilizing a working medium that flows through the TEG to maintain a temperature difference for efficient energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a steam cycle process device or thermoelectric generator is used to utilize waste heat, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the steam cycle process device and thermoelectric generator into a single integrated waste heat utilization system. The thermoelectric generator is positioned to utilize temperature differences within the steam cycle device, allowing simultaneous mechanical work production (via steam cycle) and electrical energy generation (via thermoelectric effect) from the same waste heat source, thereby improving overall energy efficiency while sharing common structural components
Solution Approach 2:
The integrated system performs multiple functions: the steam cycle device generates mechanical work from waste heat, while the thermoelectric generator simultaneously produces electrical energy from temperature gradients within the same system. This multi-functionality allows comprehensive utilization of waste heat across different energy forms, addressing the energy efficiency improvement while consolidating rather than multiplying separate systems
2Use of energy by moving object
If the thermoelectric generator is integrated into the cycle device, then waste heat utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The thermoelectric generator is nested within the steam cycle process device structure, utilizing the temperature gradients already present in the cycle device. The TEG is positioned to draw thermal energy from hot components (such as exhaust gas pathways or heat exchangers) and reject heat to cooler components, effectively nesting an additional energy conversion function within the existing thermal system without requiring completely separate manufacturing processes
3Productivity
If the working medium flows through the TEG to maintain temperature difference, then energy conversion efficiency is improved, but heat loss from the cycle device increases
Solution Approach 1:
The patent converts what would otherwise be wasted thermal energy in the steam cycle device into useful electrical energy by positioning the thermoelectric generator to exploit temperature differences within the cycle. The 'heat loss' from the cycle device is reframed as a resource - the temperature gradient that would naturally dissipate is instead captured by the TEG to generate electricity, transforming a harmful energy loss into a beneficial energy conversion opportunity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the overall efficiency of the drive unit by effectively utilizing waste heat, reducing fuel consumption, and providing additional cooling capacity to the cyclic process device, while generating electrical power from the thermoelectric effect.
Implementation Method 1
a thermoelectric generator (TEG) configured to convert the thermal energy of the exhaust gas into electrical energy and which provides an electrical voltage when there is a temperature difference between its high-temperature side and its low-temperature side
Implementation Method 2
a first heat exchanger, where heat is transferred (directly or indirectly) from the exhaust gas to the working fluid, thereby increasing the temperature and/or pressure of the working fluid
Implementation Method 3
a second heat exchanger, where heat is transferred (directly or indirectly) from the working fluid to a cooling medium
Data Source
Figure 1
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AI summary
A drive unit (1) for a motor vehicle comprises: - an internal combustion engine, which has an internal combustion engine (2) and an exhaust system (4) through which exhaust gas (19) can be discharged from the internal combustion engine (2); - a cycle process device for converting heat energy from the exhaust gas (19) into mechanical work in a thermodynamic cycle, wherein a working medium (10) flows, with respect to its flow direction, - a first heat exchanger device (5), in which heat is transferred from the exhaust gas (19) to the working medium (10); - subsequently an expansion device (6), in which the working medium (10) expands and mechanical work is generated; and - subsequently a second heat exchanger device (8), in which heat is transferred from the working medium (10) to a cooling medium (11); - a thermoelectric generator (13).which provides an electrical voltage when there is a temperature difference between a high-temperature side (14) and a low-temperature side (15). The working medium (10) of the thermoelectric generator (13) can also be routed through the high-temperature side (14) and/or the low-temperature side (15) of the thermoelectric generator (13). This advantageously allows for thermal coupling between the thermoelectric generator and the thermoelectric generator (13), which has a positive effect on the overall efficiency of the waste heat recovery.