Thermoelectric HVAC and Thermal Comfort ... - Energy.gov€¦ · This presentation does not contain...

Research & Advanced Engineering

2013 DOE Vehicle Technologies Annual Merit Review

This presentation does not contain any proprietary, confidential, or otherwise restricted information

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Thermoelectric HVAC and Thermal Comfort Enablers for

Light-Duty Vehicle Applications

Clay W. Maranville Ford Motor Company

May 17, 2013 Project ID # ACE047




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Disclaimer

This report was prepared as an account of work sponsored by the California Energy Commission and pursuant to an agreement with the United States Department of Energy (DOE). Neither the DOE, nor the California Energy Commission, nor any of their employees, contractors, or subcontractors, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the DOE, or the California Energy Commission. The views and opinions of authors expressed herein do not necessarily state or reflect those of the DOE or the California Energy Commission, or any of their employees, or any agency thereof, or the State of California. This report has not been approved or disapproved by the California Energy Commission, nor has the California Energy Commission passed upon the accuracy or adequacy of the information in this report.




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• Start: Oct. 2009 • End: Aug. 2013 • Percent complete - 88%

• Barriers – Cost – Scale-up to a practical thermoelectric device – Thermoelectric device / system packaging – Component / system durability

• Targets

– By 2015, reduce by > 30% the fuel use to maintain occupant comfort with TE HVAC systems.

– Develop TE HVAC modules to augment MAC system – Integrate TE HVAC into vehicle. Verify performance and

efficiency benefits. – Validate efficiency improvements with next-gen TE.

• Total project funding: $8.48M – DOE share: $4.24M++ ++ Includes direct funding to NREL

– Contractor share: $4.24M • DOE funding received in FY12:

– $421,832 (Oct-11 to Sep-12) • DOE funding projection for FY13:

– $488,482 (Oct-12 to Sep-13) • DOE funding to-date: $2.89M** ** Does not include direct funding to NREL

Timeline

Budget

Barriers#

• Interactions/ collaborations: – Visteon, Gentherm, NREL, Ohio State University

• Project lead: Ford Motor Company

Partners

Overview

# Barriers & targets listed are from the VT multi-year program plan: http://www1.eere.energy.gov/vehiclesandfuels/pdfs/program/vt_mypp_2011-2015.pdf




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Relevance / Objectives

Project Goal: Identify and demonstrate technical and commercial approaches

necessary to accelerate deployment of zonal TE HVAC systems in light-duty vehicles

Program Objectives: • Develop a TE HVAC system to optimize occupant comfort and reduce

fuel consumption • Reduce energy required from AC compressor by 1/3 • TE devices achieve COPcooling > 1.3 and COPheating > 2.3 • Demonstrate the technical feasibility of a TE HVAC system for light-

duty vehicles • Develop a commercialization pathway for a TE HVAC system • Integrate, test, and deliver a 5-passenger TE HVAC demonstration

vehicle




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Technical Approach: Overall Program

• Develop test protocols and metrics that reflect real-world HVAC system usage

• Use a combination of CAE, thermal comfort models, and subject testing to determine optimal heating and cooling node locations

• Develop advanced thermoelectric materials and device designs that enable high-efficiency systems

• Design, integrate, and validate performance of the concept architecture and device hardware in a demonstration vehicle




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Relevance / Accomplishments FY2012 (Oct ‘11 to Sep ‘12) Objectives / Accomplishments: • Initiated TE component fabrication and bench testing • Completed evaluation of advanced TE heating/cooling materials • Completed advanced TE materials feasibility assessment • Fabrication of all major prototype components underway • Initiated system and component cost analysis • Initiated ancillary loads trade-study • Continued thermal comfort modeling toolset development • Finalized Bill-of-Material components for prototype vehicle integration

FY2013 (Oct’12 to Sep ‘13) Objectives: • Completed TE component fabrication and bench testing • Fabrication of all major prototype components completed • Completed system and component cost analysis • Installed TE HVAC system components, DAQ, and system controls into demonstration vehicle • Complete ancillary loads study (March) and comfort model development (Aug) • Develop system operation calibration strategy for vehicle tests (May) • Complete TE HVAC commercialization assessment (May) • Develop advanced TE HVAC commercial & technical roadmap (May) • Conduct objective and subjective vehicle-level tests of TE HVAC system (June - Aug) • Conduct thermal comfort model / zonal system modeling assessment correlation (Aug) • Demonstrate completed demonstration vehicle to DOE & CEC (Sep - Oct)




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Critical-Path Milestones: FY12, FY13

Month/Year Milestone Status Nov- 11 Thermal comfort modeling toolset functionality assessed for spot-comfort Complete Sep-11 TE HVAC assembly specification development completed Complete

Dec-11 Empirical buck-modeling validation studies completed Complete CAE and comfort models completed on final system architecture

Mar-12 Proof-of-principle TE unit, bench study, and model comparisons completed Complete Jun-12 Detailed CAD and packaging studies completed on TE HVAC Complete Sep-12 Updated results from advanced TE materials research Complete Sep-12 Design complete for vehicle-intent Electrical Power/Control, Air Handling, Liquid, and Central HVAC Complete Dec-12 Bench testing completed on vehicle-intent TE device hardware Complete Nov-12 System cost analysis completed Complete

Jan-13 Integrated TE device system bench validation testing completed Complete All component fabrication completed

Mar-13 Final integration of vehicle with TE HVAC system completed Delay to Apr-13

Mar-13 Ancillary load analysis study completed On-track

May-13 Commercialization study completed On-track

May-13 Advanced TE materials and devices R&D completed On-track

Aug-13

TE HVAC climate system performance and energy consumption testing completed On-track TE HVAC objective thermal comfort testing completed

TE HVAC subjective thermal comfort testing completed

Aug-13 Final FE model validated against test results On-track

Aug-13 Comfort model validated against baseline and modified vehicle test results On-track

Sep-13 Vehicle demonstrated to DOE On-track




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Go / No-Go Decision Points

Month/ Year End of Phase Go / No-Go Decision Status

Phase 3

Nov – 12 Vehicle-intent TE based subsystems meet bench-level performance and durability tests Met

Nov – 12 Cost analyses shows a potential business case for a TE HVAC system in the specified timeframe Met

Phase 4

Aug – 12 TE HVAC system meets comfort performance criteria specified in program objectives

Aug – 12 TE HVAC system improves fuel economy compared with baseline vehicle

Aug – 12 Cost study and commercialization analysis show TE HVAC commercial pathway for 2012-2015

Aug – 12 Measured COP meets program objectives

Reduce Thermal Loads

Efficient Delivery Zonal Concept

Efficient Equipment TE HVAC

System Level Solution

System Level Approach Required to Minimize Energy Use

9 National Renewable Energy Laboratory Innovation for Our Energy Future

National Renewable Energy Laboratory Innovation for Our Energy Future

Thermal manikin helps to validate virtual manikin Segment temperature,

sensation, comfort

Thermal manikin compared to trained climate control observer Temperature, sensation, comfort

CAE tool guides design Zonal climate control

Design impacts performance Design for comfort

and energy efficiency

Reduced thermal load

Technical Accomplishment: Integrated Modeling Approach Validated by Early Testing

National Renewable Energy Laboratory Innovation for Our Energy Future

Comfort Model Validation • Validate zonal system with CAE,

manikin and subject data

Ancillary Load Reduction Impact Determining the comfort/energy/cost impacts of: • Glazing – IR reflective or absorptive • IP – low mass, IR reflective • Body insulation • Parked car ventilation • Heated seats and other surfaces

Technical Accomplishment: Vehicle System Trade Studies to Optimize Design

Technical Approach


The approach to develop a zonal climate system has been broken into 4 phases: Phase 1 Developed test conditions, measures of success and test methodology Benchmarked testing of conventional HVAC configurations. Evaluated perceived comfort for multple configurations of a zonal climate system

Phase 2 Utilize CAE/CFD tools , including comfort models, for rapid evaluation of potential

system architectures and confirmation of selected architecture before building & testing Conduct subjective tesing for perceived comfort in vehicle buck to confirm CAE/CFD Develop design requirements for TED and base system

Phase 4 Integrate zonal climate system components into vehicle & validate system performance

Phase 3 Design components and subsytems to meet requirements from Phase 2 (CAE/CFD) Fabricate components and subsystems Validate component and subsystem performance – bench testing

Technical Accomplishments - Results


Measured Flow rate overall 2.4GPM Flow rate to overhead system 1.2GPM

Airflow System Results

Liquid System Results

Measured Flow Rates Front Heat Exchanger Heat Rejection

Technical Accomplishments – Design & Build


Airflow System

DESIGN BUILD

Liquid System

Power System HV-

HV-

HV-

A

HV-

LV (+)

HV-

B

LV (-)

HV+

LV (+)

HV+

HV-

HV-

+12V

Primary Current Sense (+)

Primary Current Sense (-)

Current Feedback

Voltage Feedback

36 x #20

36 x #20

8T - 465/40 Litz

8T - 140/40 Litz

8T - 465/40 Litz

8T - 140/40 Litz

T3

E55/28/21

10

11

41

2

13

14

8

7

6

9

5

C40.1

D

S

GQ3AOTF42S60L

R382.00K

R512.00K

D18

STPS60SM200CW

C381.0 uf d

C50.001, 1600V

+ C35120 uf d, 400V

HS3

EA-T220-64E

HS1

EA-T220-64E

R541K

D

S

GQ6AOTF42S60L

H12

HS2

EA-T220-64E

D20

STPS60SM200CW

+

-

U9BLM2904N

5

67

84

C331.0 uf d

R452.00K

+ C36680 uf d, 63V

R592.00K

R62

102

R3180.6

+

-

U9ALM2904N

3

21

84

J3

350759-4

12

C39

.1

R53100

R7051, 5W

R50

.01

R7151, 5W

D11

HS4

EA-T220-64E

D14SD103B (X4)

R40

13.7K

+ C27120 uf d, 400V

D13

T2CS4200V

3 2

14

177 uH

L11

2

3

4

5

6

D12

R48

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C32.001

D

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GQ4AOTF42S60L R42

2.00K

R61

4.99K

D

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GQ5AOTF42S60L

R39

49.9

R58

49.9

R44

49.9

R52

49.9

Output Voltage Sense

SiHF30N60E

(Y)SiHF30N60E

V60200PGW

V60200PGW

55867-A2

Panasonic TSUP

Output Current Sense

SiHF30N60E

Panasonic FC Series

Panasonic TSUP

(Y)

SiHF30N60E

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This presentation does not contain any proprietary, confidential, or otherwise restricted information.

TE DEVICE DEVELOPMENT APPROACH

Thermoelectric Device Development

• Refine and optimize the Phase 2 device design for improved performance, durability, mass reduction and condensate management.

• Perform a detailed cost study of the device and identify target cost reduction actions to improve economical viability.

• Modify and improve manufacturing methods for improved throughput and quality.

Advanced Thermoelectric Material Development • Investigate the physical properties of porous materials and

evaluate the performance of a single couple to validate the device level ZT. Coordinate with ZT::Plus to confirm performance measurements.

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ADV. MATERIAL RESEARCH-OSU Individual TE property (κ,S,σ) testing of porous

material samples shows an improvement in the ZT for both P-type & N-type samples.

ZTdevice Tests on the OSU material do not confirm the 3 parameter ZT values. – Attempts with different contact technologies to verify the

performance of the new material were conducted unsuccessfully. Thermocouples

p-leg n-leg

Cu electrode/ heat sink

Cu electrode/ heat sink

Peltier couple tests

TSzT κσ2=

max2 2 TZTc ∆=

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DESIGN AND BUILD OF DEVICE Phase 3 Improvements: • Air fin mass reduced 27%

resulting in a equal reduction in thermal response time.

• Several durability improvements resulting in a 5X increase in the total number of thermal cycles to failure.

• Assembly processes improved build time and repeatability.

Phase 3 Devices (4 Units)

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(48°C Inlet Air, 48°C Inlet Coolant, Cooling Mode) (5°C Inlet Air, 5°C Inlet Coolant, Heating Mode)

TEST AND MODELING CORRELATION • Thermoelectric device – Program COP Targets:

– Cooling Mode: COP of 1.3 with a ∆T.air of 17.5°C at 360W – Heating Mode: COP of 2.3 with a ∆T.air of 13.6°C at 211W

• Model matches ∆T within 1˚C & COP within 0.14

∆T.air = 17.5°C COP = 1.3 P.in = 360W

∆T.air = 13.6°C COP = 2.3 P.in = 210W



Technical Approach: TE HVAC System Cost Study

Methodology – Baseline assumptions and detailed cost analysis

• Assume HEV to enable all-electric TE systems

– Zonal HVAC Feature Set: • 20k, 100k unit volumes cost basis • Hi-Series, Low-Series

– Zonal subsystem cost analysis:

• Variable Cost, ED&T, Tooling, Mfg – Central HVAC – TE devices and seat climate – Overhead aux system – Balance of zonal TE system – Other modified systems


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Technical Accomplishment: Cost Study for Zonal System

Luxury HEV • Rows 1 & 2 advanced CCS • Front row TE system • Heated surfaces • Zonal HVAC • Zonal HVAC controls

Mainstream HEV • Row 1 advanced CCS • Front row TE system • Zonal HVAC • Zonal HVAC controls


System Bill-of-Materials developed to study cost / weight / mfg. complexity

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Collaborations and Project Coordination

• Ford Motor Company: – Prime Contractor – Vehicle OEM – Systems Integrator

• Halla Visteon Climate Control: – Climate System Tier-1 Hardware and Controls – Power Electronics for TE systems – Zonal HVAC Integrator

• NREL: – Occupant Comfort Modeling / Testing – Ancillary Loads analysis

• Gentherm: – Advanced Thermoelectric Device and Module Development – Climate-Controlled Seat Module and Integration – Production Thermoelectric Materials Scale-Up and Manufacturing

• Ohio State University: – Advanced Thermoelectric Materials Research (Task completed September 2012)

Broad industry, government, academia

collaboration with expertise in all aspect

of the project




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Remaining Critical-Path Activities for FY13 and FY14

FY13 (4Q12 – 3Q13) • Complete installation of TE HVAC system and analysis

equipment into test vehicle • Wind tunnel and field testing performance of TE HVAC system • Assess measured occupant thermal comfort and HVAC system

energy consumption vs modeling prediction • Commercialization assessment of TE HVAC system • Vehicle demonstration for DOE & CEC

FY14 (4Q13) • Prepare final report




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Summary • Relevance:

– Climate control systems are a large auxiliary load on the powertrain and energy optimization can result in overall vehicle fuel economy improvement

• Approach: – Project focus is on developing methods to optimize climate system efficiency

while maintaining occupant comfort at current levels using new technology, architecture, and controls approaches

• Technical Accomplishments: – On target to meet Phase 4 milestones and end-of-project deliverables – System architecture design study completed, advanced TE materials research

results encouraging, TED liquid-to-air device results on-track, thermal comfort modeling predictions validated by test results

• Collaborations: – Cross-functional team working well together. Good mix of skills and resources to

address the technical tasks in this project. • Future Directions:

– Continue to progress towards a vehicle demonstration of the technology




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Acknowledgements

• We acknowledge the US Department of Energy and the California Energy Commission for their funding support of this innovative program

• A special thank you to John Fairbanks (DOE-EERE), Rhetta DeMesa (CEC), and Carl Maronde (NETL) for their leadership

• Thanks to the teams at Ford, Visteon, NREL, Gentherm, and Ohio State University for their work on the program



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Technical Back-up Slides



Comfort Model Correlation Study Summary

0

0.5

1

1.5

2

2.5

3

3.5

4

0.0 10.0 20.0 30.0 40.0 50.0 60.0

Sensation - 43C cool down RadTherm V10.1(using new physiology model)

Driver Sensation

Passenger Sensation

Driver Subject

Passenger Subject

0

0.5

1

1.5

2

2.5

3

3.5

4

0.0 10.0 20.0 30.0 40.0 50.0 60.0

Sensation - 43C cool down RadTherm V10.1(using old physiology model)

Driver Sensation Passenger Sensation Driver Subject Passenger Subject

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0 10 20 30 40 50 60

Sensation - 43C cool down RadTherm V10.1 (using new physiology and Met rate of 1.2)

Driver Subject

Passenger Subject

Driver Sensation Met 1.2

Passenger Sensation Met 1.2

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

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0 10 20 30 40 50 60

Sensation - 43C cool down RadTherm V10.1(using new physiology, Met rate 1.0, lib htc)

Driver Subject

Passenger Subject

Driver Sensation Met 1.0

Passenger Sensation Met 1.0

Driver Sensation Met 1.0 Lib htc

Passenger Sensation Met 1.0 Lib htc



Detailed Phase 4 Timeline

Dec March May July Sept

System Installation

Calibration

WT Testing

Vehicle Sys. Model Validation

Vehicle Delivery

Jan Nov

Instrumentation

MS 4.3.10

Ancillary Loads Study MS 3.4.5

Advanced TE Materials & Devices Study MS 4.2.1

TE HVAC Commercialization Study MS 4.4.1

MS 4.3.11 / 4.3.12 / 4.3.13

MS 4.1.1

Comfort Model Validation MS 4.1.2

Data Analysis

Final Report

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