1. Project Review P07442: Thermoelectric Demonstration Test Bed
Sponsored by: Dr. Stevens
Mat Balduzzi (ME)
Neil Sharma (ME)
Chia Ching Tung (EE)
Adam Ledgerwood (ME)
Mike Pietrowski (EE)
Lee Comstock (ME)

2. P07442: Project Description
Test bed to test future thermoelectric power modules that could be used for vehicle exhaust heat recovery for electric power generation
Market: 1) Automotive Industry
2) Any waste heat application
High Level Customer Needs/Engineering Specifications
- Simulate Exhaust Temperatures………………… deg. C
- Simulate Exhaust Flow Rates…………………… kg/s
- Optimal Temperature Gradient of Modules……….230 deg. C, 30 deg. C
- Characterize Energy of the System……………….Energy Losses, In, Out
- Complete Data Acquisition System………………..LabView
- Design & Build a TEG Power Unit to Test………...Yes, Hi-Z 20 modules
Have class brainstorm why design reviews are important

3. P07442: Final Concept
Have class brainstorm why design reviews are important

4. P07442: Final Concept
Have class brainstorm why design reviews are important

5. P07442: Risk Assessment RISKS:
Safety concerns with high temperatures (600 deg. C)
Safety concerns with high voltage and amps (240V, 60 Amps)
Concerns with ventilation of exhaust temperatures ( deg. C)
Possible damage to heating element after 60s of no flow conditions
MITIGATIONS:
Insulation on exposed piping, shielding of heating system
Circuit breakers, RED emergency stop button
In-Line Radiators at exhaust outlet, possibility of exhaust to atmosphere
Relay switch to not allow power to heater without blower running
Have class brainstorm why design reviews are important

6. P07442: Product Development
Phase 0: Planning
Phase 1: Concept Development
Phase 2: System Level Design
Phase 3: Detailed Design
Phase 4: Testing and Refinement
MSD I
MSD II
Alpha Prototype 1 2 3 4
Current Phase of Development

7. P07442: Current State of Design
Meets all customer needs except:
- Total energy output.
Design meets engineering specifications for full system and subsystems.
On target to meet project budget of $12K.
Limitations:
- 12KW of electrical energy

8. P07442: MSD II Project Schedule Milestones
Finalize BOM and critical parts ordered – Week 1
Final Design Review – Week 2
Prototype Construction Completed – Week 5
Debugging Prototype and Integrating Labview – Week 6
Engineering Specification Testing Done – Week 7
Demonstration of Senior Design Project – Week 8
Finalize technical paper, website and poster – Week 9
Final Project Review – Week 10