Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
1
Thermoelectric HVAC and Thermal Comfort Enablers for
Light-Duty Vehicle Applications
Clay W. Maranville Ford Motor Company
May 17, 2013 Project ID # ACE047
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
2
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.
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
3
• 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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
4
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
5
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
6
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)
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
7
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
8
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
Page 12
Technical Approach
This presentation does not contain any proprietary, confidential, or otherwise restricted information
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
Page 13
Technical Accomplishments - Results
This presentation does not contain any proprietary, confidential, or otherwise restricted information
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
Page 14
Technical Accomplishments – Design & Build
This presentation does not contain any proprietary, confidential, or otherwise restricted information
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
.01
C32.001
D
S
GQ4AOTF42S60L R42
2.00K
R61
4.99K
D
S
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
15
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.
16
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
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 ∆=
17
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
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)
18
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
(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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
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
This presentation does not contain any proprietary, confidential, or otherwise restricted information
19
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
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
This presentation does not contain any proprietary, confidential, or otherwise restricted information
System Bill-of-Materials developed to study cost / weight / mfg. complexity
20
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
21
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
22
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
23
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
This presentation does not contain any proprietary, confidential, or otherwise restricted information
24
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
25
Technical Back-up Slides
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
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
4.0
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
Research & Advanced Engineering
2013 DOE Vehicle Technologies Annual Merit Review
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
Top Related