mopdf.com

Click to edit Master title styleSECRETThermoelectric Opportunitiesfor Light-Duty VehiclesClay MaranvillePrincipal Research ScientistFord Motor CompanyResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Click to editDisclaimerMaster title styleSECRETA portion of this presentation was prepared as an account of work sponsoredby the California Energy Commission and pursuant to an agreement with theUnited States Department of Energy (DOE). Neither the DOE, nor theCalifornia Energy Commission, nor any of their employees, contractors, orsubcontractors, makes any warranty, express or implied, or assumes any legalliability or responsibility for the accuracy, completeness, or usefulness of anyinformation, apparatus, product, or process disclosed, or represents that its usewould not infringe privately owned rights. Reference herein to any specificcommercial product, process, or service by trade name, trademark,manufacturer, or otherwise, does not necessarily constitute or imply itsendorsement, recommendation, or favoring by the DOE, or the CaliforniaEnergy Commission. The views and opinions of authors expressed herein donot necessarily state or reflect those of the DOE or the California EnergyCommission, or any of their employees, or any agency thereof, or the State ofCalifornia. This report has not been approved or disapproved by the CaliforniaEnergy Commission, nor has the California Energy Commission passed uponthe accuracy or adequacy of the information in this report.Research & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

AgendaClick to edit Mastertitle styleSECRET Ford’s Sustainability Strategy Regulatory and Societal Motivations for Energy Efficiency The Changing Landscape of Vehicle Technologies The Role of Waste Energy Recovery On-Vehicle Enabling Strategies for Thermoelectrics HVAC SummaryResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

AClickBroad ApproachSustainableTransportationto edittoMastertitlestyle SECRET Sustainable Governance:––– Economic Sustainability:–––– Ethical business practicesAddressing global public policy issues (Environmental & Safety Regulations)Incorporation of sustainable raw materials in product and manufacturingOperate profitably at current demand and changing model mixDevelop new products our customers want and valueFinance our plan and improve our balance sheetWork together effectively as one global teamEnvironmental Sustainability:–Climate Change / GHG Emissions / Fuel Economy – Each new or significantly refreshed vehicle will be best in class, or among the best in class, for fuel economyReduction in facility CO2 emissions of 30 percent by 2025 on a per-vehicle basisWater Use / Waste Disposal / Supply Chain Environmental SustainabilitySocietal Sustainability:––––Employees: Workplace Health & Safety, Working-TogetherCustomers & Communities: Fuel Economy, Safety, Connected Life, Volunteer CorpsDealers/SuppliersInvestors** Ford’s 2010/11 Sustainability Report is online lity-report-2010-11/defaultResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

SustainabilityStrategy– TechnologyClickto editMastertitle Migrationstyle200720112020Mid TermNear TermFull implementation ofknown technologyBegin migration toadvanced technologyNear TermMidMid Term. Significant number of vehicles withEcoBoost engines EcoBoost engines available in nearlyall vehicles. Electric power steering – beginglobal migration. Dual clutch and 6 speedtransmissions replace 4 & 5 speeds. Flex Fuel Vehicles Electric power steering - Highvolume Six speed transmissions - Highvolume2030Long TermContinue leverage of Hybridtechnologies and deployment ofalternative energy sourcesLong Term Percentage of Internal combustionengines dependent on renewablefuels Volume expansion of Hybridtechnologies Continued leverage of PHEV, BEV Weight reduction of 250 – 750 lbs Introduction of fuel cell vehicles Engine displacement reductionaligned with weight save Clean electric / hydrogen fuels. Increased unibody applications. Introduction of additional smallvehicles Additional Aero improvements. Add Hybrid applications. Battery management systems –begin global migration. Aero improvements. Stop/Start systems (micro hybrids)introduced. CNG/LPG Prep Engines availablewhere select markets demand Increased use of Hybrids Introduction of PHEV and BEVSECRET Continued weight reductionactions via advanced materials Introduction of new technologiesthat enable broad sustainabilityplan Vehicle capability to fully leverageavailable renewable fuels Diesel use as market demands Increased application of Stop/StartResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Hybrids,ClicHybrids,k to ePlug-Indit Master tanditleBEVsstyleResearch & Advanced EngineeringSECRET3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Regulatory & Societal Motivations to DevelopClickto editMastertitle styleEnergyEfficientVehicle Technology SECRETFuel economy trends driven by global factors:– US and California– EU CO2 Regulations– Global Oil Prices Fuel prices will continue to be put under pressure by increasingdemand from emerging markets Fuel economy targets in emerging markets are lagging developedcountries only by a few years By 2030, car ownership in China is expected to reach 230M units Safety & emissions regulations in emerging markets are laggingdeveloped countries only by a few years“We are committed to being a leader in fuel economy in every product segment in which wecompete. In keeping with our heritage as a company, we introduce new technology on a large scale.”- William Clay Ford Jr., June 2010* y-report-2010-11/defaultResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Competitionthe AlmightyDollarClickto editforMastertitlestyle Research & Advanced EngineeringSECRETPassive Safety (after the crash)Active Safety (avoiding the crash)Emissions (NOx, PM, CO, HC, etc.)Feature Content (you can never haveenough cup holders!)Fuel Economy Technology3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

TheChangingLandscapeof VehicleClickto editMastertitleTechnologiesstyle SECRET Multiple technologies are under consideration:– Improve regulated fuel economy / safety– Attract consumers through marketable features Winners determined by total competitiveness in areas of:–––––––Performance (W/kg, W/m3, W-hr/kg , W-hr/m3, W/ )Cost (enable cost avoidance, /mpg saved, etc.)Robustness / Quality (250K, 15 year durability)Ease of migration across fleet (B-car, Full-size truck, gas, diesel)Ease of integration (migration ability, partnerships with T1)Marketable feature (OEM revenue opportunity and differentiation)Secondary benefits (Improve driver seat comfort, reduce cabin noise)To be competitive in the auto industry ,technology must be mature and adaptable to a changing marketResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Technology Trends for Improving FEClick to edit Master title styleSECRETSource: NRC Report “Assessment of Fuel Economy Technologies for Light-Duty Vehicles”Cost will contribute significantly to technologies implemented for fuel economy improvementResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

ThetoRoleof WasteEnergytitleRecoveryClickeditMasterstyle Opportunities to Harvest Waste Energy–Heat Losses ––Engine ExhaustEngine FluidsBrakingElectronicsSolar LoadMechanical Losses PumpingVibrationsDriveline (crankshaft to wheels)Braking / SteeringAerodynamic losses SECRETFrontal areaCoefficient of dragOpportunities to Use Waste Energy––––––Offload electrical loadOffload mechanical loadProvide/transfer heat (coolant, oil, battery, )Store thermal energyStore electrical energy (battery, capacitor, )Store mechanical energy (spring, hydraulic, flywheel, )Research & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

Harvesting Engine Exhaust usingClickThermoelectricto edit Mastertitle stylePower GenerationSECRETThermoelectric Generator Installed Mid-BodyResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

ExhaustSystem PackagingClickTEGto&editMastertitle ex CouplingsResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

50090450814007235063Bypass Opened300Bypass Closed542504520036Vehicle Speed (mph)TEG Power (Watts), Exhaust Temperature ( C)TEGPerformancea 65mph titleFreewayCruise SECRETClickto edit forMasterstyleTEG Power15027Exh. Temp. into TEGVehicle 011001200Test Time (sec)Research & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

ChallengesAlternatorReplacementby a TEGSECRETClick toforeditMastertitle style TEG must be able to provide necessary power to the vehicle underextremely challenging conditions:– Provide 220 Amps @ 14 Volts (3kW) under worse-case electrical loadconditions– Vehicle Idle– City drive cycle (Start-Stop)– 50 C to -30 C ambient conditions– Full accessory loads, including current spikes– Reduce TOTAL fuel consumption, weight, and cost compared to analternator/battery system Ability to replace alternator in conventional vehicles is challenging Potential to supplement alternator is more attractive Significant potential for power generation in vehicles during highwaycruise EPA and EU off-cycle credits / EcoInnovation credits offer incentive toOEMs to adapt TEG designs for real-world operationResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD

AutomotiveHVAC SystemsClick toedit Mastertitle styleSECRETObjective: Provide occupant comfort over a broad range of ambient conditions HVAC functions include:– Occupant cooling (-40 C) and heating ( 50 C)– Dehumidifying, defogging, & defrostingConsiderations for a TED: Location, air flow rate, and temperature of localized air streams– Directly affect occupant comfort– Optimized for both heating and cooling modes Control strategy is critical to HVAC system performance and energy consumption– Best effective use of TED for zonal design may be to complement the main HVAC system Input power and voltage to TED– Limited available 12-volt power, even on HEVs Liquid-to-air or liquid-to-liquid devices– Improved efficiency but added mass and complexity Thermal mass of systemTotal system costsMotivation: HVAC is the largest single nonmotive consumer of power in a vehicleResearch & Advanced Engineering3rd Thermoelectrics Applications WorkshopMarch 21, 2012Baltimore, MD