Wood Burning Generator
Contents
1. Figure 2 Wood Burning Generator under Construction Budget Analysis The budget as a whole is still within the required limits As construction has begun the amount of purchased parts has increased and a better idea of the final budget has emerged The thermosyphon cooling system and user interface remain over budget while the thermoelectric generator inverter and encasement remain under budget At this time the team still has 124 93 not directly budgeted for parts Table 1 shows an overview of the budget Table 1 Budget Overview Sub Function Original Current Thermosyphon 55 00 256 05 Thermoelectric Generator 215 00 205 36 User Interface 65 00 92 58 Inverter 60 00 47 22 Cooling System 70 00 107 97 Encasement 35 00 15 89 Contingency 350 00 124 93 Total 850 00 850 00 Both shipping charges and taxation lead to the most changes in the budget These expenses were either unknown or not included in the original budget but rather have been added as they were encountered Additionally small ticket items such as thread seal tape and hardware were not included originally and now are causing the expenses to increase The change in material for the encasement caused the encasement budget to lower by about 15 00 because of the cost difference between wood and steel As expected these minor increases and decrease have not affected the ability for the team to stay under budget A unique budgetary concern for the wood burn2. The generator will sit on the hearth and a device will be extended into the fire for heat collection There will be no permanent attachments such as bolts or screws to be affixed prior to use Harmful Gases The device should not compromise the existing effectiveness of the fireplace to route harmful gases carbon dioxide carbon monoxide nitrogen oxides and aldehydes out from the house Due to the large variety of sensors needed along with the associated costs this will be judged by visually observing if there is a change to the amount of smoke in the room when the device is in use compared to when it is not in use Nature of Fuel The device will work with a fire built with wood logs not wood chippings or sawdust The user will not be required to cut the logs to certain dimensions provided the logs will fit in the fireplace User Intervention The user will be responsible for maintaining the fire An indicator on the device will notify the user if the fire is not hot enough sufficient power is not being produced see Indicators and Controls The device should not require the user to burn more than 25 pounds of wood per hour Indicators and Controls The device will indicate visually e g LED to the user when enough electricity is being generated to run a device Additionally the user will be able to cut off power to the outlet by shutting off the device with a switch Electrical Safety The electrical system must be grounded
3. The graphs below represent graphically the results from the 3 round tests The legends indicate the voltage of the battery for each test The first graph Figure 17 shows negative voltages but that is only due to reversal of polarity of multimeter during tests The second graph Figure 18 illustrates the current flowing through the battery 3rd Round Tests T T D D RB RXS 0 B uit X BA lt ofA u ee lt c Q im im 3 QO gt Su Q rm co 10 15 Thermoelectric Generator Voltage V Figure 17 Results of 3 Round Tests 3rd Round Tests 10V miiv A 12V x 13V x 14V X xp AN CIN A as X Zener Diode Current A 10 15 Thermoelectric generator voltage V Figure 18 Results of 3 Round Tests 28 Figures 19 and 20 demonstrate a rough estimate of how the electrical components will be placed inside the encasement There will be some sort of aid to help keep the circuit board in place Once the hinged panel is in place the supports for the PCB will be designed Additionally the circuit board shown is not the professional board that will be used in the final prototybe but instead just the one etched in the project lab Figure 19 Electrical components inside encasement Figure 20 Electrical components inside encasement 29 Encasement Design and Progress The encasement will house all the internal components of the wood burning generator Insulation will be
4. Once construction began the tanks boiler holding tank and thermoelectric generator condenser took an extra five weeks to complete which further delayed completion The thermosyphon is currently complete except for the condensing tubes which will be added after additional testing is completed Unfortunately construction of the thermoelectric generator and cooling system had to wait for the thermoelectric generator condenser to be complete before their designs could be tested Additional thermosyphon testing will need to be completed before these components are permanently installed The design changes from the thermosyphon did not affect the design of the thermoelectric generator After the thermoelectric generator condensing chamber was completed the thermoelectric generators were temporarily attached to test their integration This test was successful and after further testing of the thermosyphon the generators will be permanently attached and their output will be tested The means of assembling the cooling system has been tested and will work However to allow further testing of the thermosyphon the cooling system has been removed temporarily along with the thermoelectric generators The only modification to the original design involves applying pressure downward onto the heat sinks This pressure will increase the thermal conductivity between the thermosyphon the thermoelectric generators and the cooling system All the parts for the cooling
5. 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0071 0 0352 0 0564 0 0842 0 1141 N A 12 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Negative numbers only represent that current is flowing through the battery due to polarity of multimeter during tests Battery Current 0 0091 0 0091 0 0091 0 0091 0 0091 0 0021 0 0103 0 0116 0 0118 0 0186 0 0324 0 0492 N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0071 0 0332 0 0591 0 0845 0 0980 N A LC Table 4 3rd round testing with 14V 5W 1N5351B Zener diode Battery voltage V gt TEG voltage Another test is shown and graphed in Appendix F 13 V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0123 0 0123 0 0123 0 0123 0 0123 0 0123 0 0073 0 0103 0 0116 0 0118 0 0159 0 0308 N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0090 0 0354 0 0562 0 0791 0 1103 N A 14 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0163 0 0180 0 0186 0 0190 0 0192 0 0193 0 0136 0 0101 0 0117 0 0120 0 0146 Zener Current 0 0041 0 0060 0 0073 0 0073 0 0073 0 0073 0 0083 0 0363 0 0543 0 0833 0 1082 Zener too hot Zener too hot Negative numbers only represent that current is flowing through the battery due to polarity of multimeter during tests 27
6. C without cooling Cooling Device 14 VDC 23 Amps User Interface 12 VDC 20 mA Battery 12 VDC 18 A Inverter 120 10 VAC A gt 1 5 Amps 60 05 Hz Unit Outlet Functional Description of Blocks Fireplace The user s fireplace will act as the combustion chamber and contain the wood burning fire The fire will be required to provide temperatures between 100 C and 500 C Input Wood Output Temperatures between 100 C and 500 C Thermosyphon The thermosyphon will collect heat from the fire in a boiler changing liquid water to water vapor which will then exit the fireplace and deliver temperatures ranging from 100 C to 180 C The vapor will condense in copper coils be stored in a holding tank and then return to the boiler Input Temperatures between 100 C and 500 C Output Temperatures between 100 C and 180 C Hot Side Heat Sink The hot side heat sink will transfer the heat from the thermosyphon to the hot side of 10 thermoelectric generators 40mm x 40mm each It will be maintained at temperatures between 100 C to 180 C Input Temperatures between 100 C and 180 C Output Temperatures between 100 C and 180 C Thermoelectric Generator The thermoelectric generator will use the temperature differential that exists between the hot side heat sink and the cold side heat sink to produce approximately 14 volts and 23 amps DC or 322 watts 10 individual thermoelectric generators prov
7. EncsementBulld DD SS Inverter un aS User Interface Buil ur PM 2 lntalTesig EEE ThermosyphonTesting EO rGTesig Jo 1 EE 03 CoolingDeviceTesting aaa EncsementTesting E A 0 0 0 Inverter Testing CC a User Interface Testing EE Projectstatus N System Integration ee System Testing nd Mods User s Manual A FalRpot AA Figure 3 Spring Gantt Chart showing the original schedule blue and the revised schedule yellow In the revised schedule some construction and testing will happen after spring break During the first week after returning from break additional testing will be performed on the thermosyphon to prepare it for completion as well as for attaching the thermoelectric generators and cooling system At this same time the encasement inverter and user interface will continue to be built The next week week of March 22 the thermosyphon will be completed and the thermoelectric generators and cooling system will be attached to the thermosyphon These three components along with the inverter and user interface will then be integrated into the encasement the same week The last week of construction week of March 29 will consist of testing the thermoelectric generators the cooling 10 system is included in this test and the electrical components At this point major construction and testing should
8. Model Number BCMMASSO9P10 Datasheet Unavailable Part Name Picture Wire Supplier Unknown Manufacturer Unknown Model Number Unknown Datasheet Unavailable 44 Appendix F Circuit diagrams and results J2 D2 Inverter Key Space 1N964B LM7812CT Fan BJT_NPN_VIRTUAL e LED 1500 Figure 24 Circuit 1 For the circuit above R4 and R5 are the only differences from the circuit on page 25 45 9y Battery voltage V gt 10 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Table 5 2nd round testing with 14V 5W 1N5351B Zener diode Battery Current 0 0040 0 0040 0 0040 0 0010 0 0102 0 0113 0 0119 0 0187 0 0293 N A N A N A N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0120 0 0361 N A N A N A N A 11 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0044 0 0044 0 0044 0 0045 0 0021 0 0103 0 0115 0 0118 0 0179 N A N A N A N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0103 0 0397 N A N A N A N A 12 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0091 0 0091 0 0091 0 0091 0 0091 0 0001 0 0100 0 0116 0 0118 0 0224 N A N A N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0128 0 0409 0 1136 N A N A N A LV Battery
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10. by a connection to an existing wall outlet s ground All internal wires should be able to handle the maximum amount of current in order to prevent electrical fires Wire that is at least an AWG gage 10 nonmetallic insulated wire will provide this safety General Safety Any exposed outside of the fireplace surface of the device should not exceed 43 degrees Celsius 110 F in order to prevent burning the user Project Overview Project Status With the beginning of the spring semester construction has officially begun on the wood burning generator prototype Work commenced on the thermosyphon and the electrical components immediately after returning from the Christmas break Delays in the thermosyphon caused work on the encasement cooling system and thermoelectric generator to begin later than planned but significant progress has been made in each component A robust budget has allowed the team to remain under the 850 constraint Figure 1 Wood Burning Generator Design Before work could begin on the thermosyphon a major design change was made prior to finalizing the design This change consisted of moving the pressure relief valve from before the thermoelectric condensing chamber to after it This will allow cooler steam to transfer heat to the thermoelectric generators rather than just steam that can eventually make it through the valve This change was minor in regards to construction but nonetheless delayed the start of building
11. changes in the thermosyphon design those changes do not affect the layout or functionality of the thermoelectric generator The thermoelectric generator has been laid out on the thermosyphon to check for any integration problems As soon as testing of the thermosyphon is complete the generator will be permanently attached All of the parts for the thermoelectric generator have been bought The original design of the thermoelectric generator calls for 10 individual thermoelectric generators to be arranged on a copper heat sink provided by the thermosyphon The cooling system attaches to the top of these generators increasing heat transfer across them which is converted to electricity The individual thermoelectric generators are bonded to the thermosyphon s copper heat sink and the cooling system s aluminum heat sinks by use of a thermal paste Figure 8 shows the interaction of the thermoelectric generator with the thermosyphon and the cooling system Figure 8 Thermoelectric Generator interaction with the thermosyphon and cooling system The individual thermoelectric generators are wired together in a configuration that produces the desired output voltage of greater than 12 9 volts Each generator produces approximately 7 volts and 4 6 amps When placed in series the voltage of a thermoelectric generator is cumulative and the current remains constant When in parallel the current is cumulative and the voltage remains constant Figure 9 shows the c
12. much that the budget was compromised With the aid of the faculty safety concerns can be addressed without making budgetary decisions that could lead to a dangerous prototype Optional features will ensure that the budget can remain below the 850 limit Schedule Analysis Despite a lot of work going into making the schedule the actual events of this semester have not resembled the original plan Taking time to finalize the design and delays in the thermosyphon construction have been the main causes of getting behind A revised schedule has been created which moves the completion of construction to three weeks later than originally planned The first week of the semester was spent finalizing the design which immediately put the team behind one week Once construction began week of January 18 delays in the thermosyphon pushed the schedule back four weeks Construction on the thermoelectric generator encasement and cooling device then began during the week of March 1 Work on the electrical components began one week after anticipated during the week of January 18 and will continue until its integration into the generator as a whole This schedule is illustrated in a Gantt chart Figure 3 yellow bars show updates to the schedule before spring break and the revised schedule after spring break Project Management Documentation Initial Build o HN Thermosyphon Build O3 CCOO TEG Build IL A AF Cooling Device Build A
13. used around the thermoelectric condensing chamber and around the holding tank to keep the electronics from overheating and the surface of the encasement from burning the user One major design change has been implemented concerning the material of the encasement Originaly the encasement was to be made out of 1 8 inch steel sheet However the weight of the thermosyphon boiler made out of 1 8 inch steel sheet made the team reconsider this choice To replace the steel sheet the encasement will be made out of 5 0 mm utility plywood The plywood will be painted on the inside and outside with a high heat paint to protect it Figure 21 Encasement Panels Left and Assembled Encasement Right Parts for the encasment have been cut out and assembled Brackets were made from scrap metal and were used to bolt the wooden panels together The two lower side panels are hinged to allow easy access to the holding tank for adjusting the water level and to the electronics for testing and maintenance Another major part of the encasement is the insulation that surrounds the thermoelectric condensing chamber and the holding tank These pieces of insulation have been cut out and tested for fit In testing it was found that the insulation does not perfectly seal off each section of the device from one another This could be fixed by either filling the gaps with a spray foam recutting the pieces to fit better or a combination of the two Ano
14. voltage V gt Table 6 2nd round testing with 14V 5W 1N5351B Zener diode 13 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0123 0 0123 0 0123 0 0123 0 0123 0 0123 0 0022 0 0099 0 0116 0 0121 N A N A N A Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0156 0 0475 0 1010 N A N A N A 14 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0178 0 0184 0 0186 0 0187 0 0188 0 0187 0 0187 0 0054 0 0097 0 0119 0 0212 Zener Current 0 0056 0 0061 0 0064 0 0064 0 0064 0 0064 0 0064 0 0117 0 0460 0 1110 0 1910 Zener too hot Zener too hot It is important to point out that the negative voltages from Tables 5 and 6 and in Figures 25 and 26 represent current that is flowing through the battery The legend for both graphs below indicates the different voltages of the battery 2nd Round Tests o lt c Q im im 3 Q gt im Q co 6 8 10 12 14 16 Thermoelectric Generator Voltage V Figure 25 Battery Current with battery voltages from 10V 14V 2nd Round Tests Zener diode current 10 Thermoelectric generator voltage Figure 26 Zener Diode Current with battery voltages from 10V 14V 48
15. 125 10 50 76 86 022 45 iNs34gB 11 1225 25 188 10 50 84 80 025 430 iNs3soB 13 100 25 10 10 10 99 70 025 365 115 anses3B 16 75 25 7 10 10 122 60 030 295 280 0 5 144 53 040 250 1N5357B 237 1N5358B 1N5359B 1N5360B wN5360 B 27 so so 120 10 os 206 41 oseo 176 1Ns3eoB 28 so 60 130 30 os 212 39 oeo 170 msasa 90 40 eo wo 10 os 2a 37 oo CD D D c lt D 7 D h O 53 o pt D ie o 2 a O C 5 D a X 0 I ELECTRICAL CHARACTERISTICS Ta 25 C Vr 1 2V MAX If 1 0 A FOR ALL TYPES TYPE Zener Test Maximum Zener Impedance Maximum Reverse Maximum Maximum Maximum Voltage Current Surge Voltage Regulator Current Regulation Current Note 1 Note 2 lt N amp y bl 45 720 58 0 75 760 10 os eso 17 200 545 75 5 69 z amp J O CO c Oh 3 00 S oo o a Co o N e NS O 4 I 18 18 els Im RO NN MN ND 1G 09 09 e M 1 100 12 e so 10 o5 760 15 250 475 mo 12 120 140 80 230 150 10 o5 06 12 250 30 1 50 80 330 so 10 o5 ia 11 300 316 153848 160 80 350 150 10 05 122 11 300 204 1Nsse5B 170 80 380 115 10 05 19 10 300 280 430 wo 10 o5 187 10 400 2
16. 5388B IM 5 0 W ZENER DIODE 3 3 VOLTS to 200 VOLTS Semiconductor Corp 5 TOLERANCE 145 Adams Avenue Hauppauge NY 11788 USA Tel 631 435 1110 Fax 631 435 1824 AXIAL LEAD EPOXY CASE Manufacturers of World Class Discrete Semiconductors B 0 The Central Semiconductor 1N5333B Series Silicon Zener Diode is a high quality voltage regulator for use in industrial commercial entertainment and computer applications ABSOLUTE MAXIMUM RATINGS SYMBOL UNIT Power Dissipation T 75 C PD 5 0 W Operating and Storage Temperature Ty TSTG 65 to 200 C Tolerance B Suffix 5 ELECTRICAL CHARACTERISTICS TA 25 C Vr 1 2V MAX Ir 1 0A FOR ALL TYPES TYPE Zener Test Maximum Zener Impedance Maximum Reverse Maximum Maximum Maximum Voltage Current Surge Voltage Regulator Current Regulation Note 1 ae UJ a zr zzrGtzt ZzkG zk mar r az M Q ma pa Volts A Volts mA 33 380 30 40 10 30 10 20 O85 140 B 36 350 320 dN5338B 51 240 15 40 10 10 10 144 039 930 dNsa33908 56 220 10 40 10 10 20 134 9025 865 1N53408 60 200 10 30 10 10 30 127 019 790 ansas28 68 175 10 20 10 10 52 115 01 70 1N534438 75 1175 15 20 10 10 57 107 015 630 HNsad5B 87 150 20 20 10 0 66 95 020 545 recess 91 iso 20 110 1 19 115 pr su obra iN5347B 10 1255 20
17. 64 1N5387B 190 50 450 350 10 o5 144 09 50 250 INSS88B 200 50 52 09 Note 1 Surge Current ir Maximum allowable peak non recurrent square wave current PW 8 3ms Note 2 Voltage Regulation AVz Vz Measurements are made at 10 and then at 50 of the Iz max value listed in the electrical characteristics table The test current time duration for each Vz measurement is 40 10 ms TA 25 C INCHES MILLIMETERS 0 145 MAX 3 68 MAX B O350MAX 8 89 Max 1 0 MIN 25 4 MIN D O043MAX 1 09MAX Appendix E Encasement Parts Reduced energy loss lower heating amp cooling bills High R value Unsurpassed durability Moisture resistant facers Lightweight easy to install Part Name Encasement Exterior Utility Plywood Supplier Lowe s Datasheet Unavailable Specifications Thickness 5 2mm Area 4x8 Feet Name Insulation Supplier Lowe s Manufacturer Dow Model Number 263063 Datasheet Unavailable Specifications See Below Insulation Type Polyisocyanurate Thickness Inches 0 5 Length Feet 8 0 Width Feet 4 0 R Value 3 0 Installation Instructions included Yes Weather Resistant Barrier Yes 43 Name Aluminum Scrap Metal Supplier Harding University Physical Resources Manufacturer Unknown Model Number Unknown Datasheet Unavailable Part Name Worm Clamp 4 Supplier Lowe s Home Improvement Manufacturer King Seal Fastener Technology
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19. SK 0235 OD 2 PLACES O I DD OD DICO SD OD X DU QU OO XD D XE CDC A OG oO DIS D 9909022722309 09 OO OGD OOO 0 0 0 QOO DUO DOG COTO D CHO OO LIO OIL ORE Length Width Height Weight of TR C W 40mm Fan P N in mm in mm in mm Ibs g pins Impingement Cooling 3 151502UBFA 1 50 38 1 1 50 38 1 0 20 5 1 0 0229 10 4 ea 3 29 3 151503UBFA 1 50 38 1 1 50 38 1 0 30 7 6 0 0275 12 5 121 1 80 3 151504UBFA 1 50 38 1 1 50 38 1 0 40 10 2 0 0320 14 5 A 1 49 3 151505UBFA 1 50 38 1 1 50 38 1 0 50 12 7 0 0365 16 6 121 1 17 3 151506UBFA 1 50 38 1 1 50 38 1 0 60 15 2 0 0411 18 6 VA 0 98 3 151507UBFA 1 50 38 1 1 50 38 1 0 70 17 8 0 0456 20 7 121 0 85 3 151508UBFA 1 50 38 1 1 50 38 1 0 80 20 3 0 0501 22 7 121 0 75 3 151511UBFA 1 50 38 1 1 50 38 1 1 10 27 9 0 0637 28 9 121 0 60 Please see Disclaimer at www coolinnovations com COOLINNOVATIONS www coolinnovations com e sales coolinnovations com e Tel 905 760 1992 e Fax 905 760 1994 ADVANCED HEAT SINKS qa3A dasds SLH9lM TIV SeJIM MV sleu 1y dA X e ee s s jleg 9 ALON 96 9 96 9 96 9 96 9 800 Gc 0 GC 0 6t C6 C6 87 Oc G _0SO gasor0ay 0c X Or X O SO XHSOTOQV 0c X Or X O 0SO XHSOFOQV 0c X Or X 0 0SO XINSOFOQV 0c X Or X O og ao og doAni nouln c 00S do Aniuno n 005 S0 ANLIND AN O VO CO LO LO O B A gt JE O eo oOIOIO
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21. Teflon Seats One valve does it all Teflon Packing lt M RATINGS APPROVED 150 psi WSP K in 400 psi WOG LANG ANSI NSF 61 8 AA 61 lt 5 CSA 4G 5G 125G gas ratings 2 2 UL listed for flammable liquids Y4 2 FM for fire protection 17 2 Conforms to MSS SP 110 Sew NS Qkin 2 Water grand Options T Handle Ball Brass Forged Brass chrome Plated DIMENSIONS Working Pressure P Is O IC IET a radioed o rere pue Tan 5 B Center of PorttoTop 1 1 19 2m 2 BETT CR CMH Center of Valve to End i 33 E Port Port Opening DE pc mac e e AL MEM EA a 75 1 Locking Handle Pressure Temperature Rating 100 200 300 400 500 Working Temperature F 1 2 EINEN DIA 572 E 2 Dav 3 5 2 3 3A 5 Ya Appendix B Thermoelectric Generator Parts Part Name Thermoelectric Generator Supplier Thermal Enterprises Manufacturer Thermal Enterprises Catalog Number HT1 12710 TEG Datasheet Unavailable Specifications 40mm x 40mm x 3 3mm Operates from 0 16 volts DC and 0 10 5 amps Operates from 60 deg C to 225 deg C Fitted with 6 inch Teflon insulated leads Perimeter sealed for moisture protection Part Name Thermal Grease Supplier Newegg com Manufacturer Arctic Silver Model Number Ceramique e e Datasheet Unavailable e b Specifications See Below E gt DR Fr o Model Brand Arctic Silver Model Cerami
22. Wood Burning Generator Mid Term Progress Report March 2 2010 Kevin Jensen Drew Messick Jeremy Verzosa Table of Contents Requirements Specification e eiie epe EPIS dais OIM mE PV IM mE MI oH RIS e MAN DCN 3 PFOJECLOVEN OW NETT 5 PFOJECESL AN SE ee T IC 6 Budget Analysis een dies II RR EU IM C DM DT 8 SEM CCUG AN AA A A ctn Enn Me ea 10 Block Dias at ee ee EE ME EM Ee LU CTI S a DUE 12 Functional Description of BIOCKS iei i veia vr Nee 13 System Progress and Accomplishments a un 15 Thermosyphon Design and Progress ccccssseccccssccccesececcesecccceussccecsesececsuecceseuscessunecesseeceeseesecetsugneses 16 Thermoelectric Generator Design and Progress 19 Cooling System Design and Progress nn ae 21 User Interface Inverter Design and Progress ssssssssscscccccccccccssseeeeeeeeeeeesseeceeecssseeeeesueueeeesseeeeeeeeees 23 Encasement Desien dnd PITOBEeSS cate 30 ABPENAICES c c E AS AA E ee me eee A E A A 32 Appendix A Thermosyphon Parts si eine 33 Appendix B Thermoelectric Generator Parts ccccccsssccccssseccceseecccceseccceeeseceseesececeecesseueceesauecetsugesees 35 Appendix C Cooling System Parts comes lla NT 36 Appendix D User Intertace Inverter Parse eek 39 Appendix E Encasement Parts Benannte 43 Appendix F Circuit diagrams and results occoconocicnonacnonennoronononaricnonariononanroncorocononariononanrorconoracononasos 45 Requirements Specification Background There is a large in
23. be completed At the beginning of the semester a goal was set to have approximately 8096 of the device completed by Spring Break To gauge how much has actually been accomplished each device was weighted based on the size and scope of an individual component compared to the device as a whole and on how much work will be required during construction A percentage of completion could then be given to each component and a total percent complete could be calculated Using this method the team found that approximately 7296 of the construction testing is complete Table 2 shows all of the estimated completion percentages along with their given weights This falls short of our original goal but given the setbacks encountered it is a satisfactory number Table 2 Percent Completion of Construction Component Percent of Total Device Percent Complete Thermosyphon 4096 8096 Thermoelectric Generator 1096 5096 Cooling System 1096 8096 Electrical Components 2096 6096 Encasement 2096 7596 Total 10096 7296 11 CT Fireplace 100 C lt T lt 500 C Block Diagram Encasement Boundary mn m a a a a a BB a a ME ME ME ME ME ME ME ME ME a ME ME ME ME ME ME ME ME a ME a LL Zu Sen ME ME LL o ME ME ME Lo ME ME ME LL ME Eo ME LL ME LL LL ME ME ME ME ME ME ME ME ME a ME ME ME ME ME ME ME ME ME ME ME ME HK a mm 100 C lt T lt 180 C Hot Side Heat Sink 100 C lt T lt 180 C Thermoelectric Generator Excess heat 180
24. d which was then stored in the holding tank This holding tank was connected to the boiler Both the boiler and the holding tank will have the same water level This ensures that the boiler will never become dry Figure 4 Original Thermosyphon Design Before construction even began one major change was made to the thermosyphon This consisted of putting the pressure relief valve after the thermoelectric condensing chamber rather than before it This change allows any steam to enter the thermoelectric generator condensing chamber rather than only steam that meets the 180 C criteria When steam in the chamber exceeds this temperature the pressure relief valve will open and eject the steam into the condensing tubes protecting the thermoelectric generators from overheating This should allow the device to work even when the fire is not producing enough heat to raise the steam temperature above 180 C This move naturally affected the physical design of the thermoelectric condensing chamber as well as the condensing tubes 16 n _ A RRA Figure 5 Original left and improved right pressure relief valve location The new thermoelectric condensing chamber is 1 125 x 8 125 x 3 25 inches 0 02858 x 0 2064 x 0 08255 m As before the top of the chamber is made of copper onto which the thermoelectric generators will be attached The pipe from the boiler attaches to the bottom as well as the pressure relief valve 150 psi For ad
25. de testing the fans to make sure they run off of the battery and testing the integration of the fans with the encasement Unless the fans are broken they should have no trouble running off of the battery The encasement integration test will ensure that the final installment of the cooling system into the encasement will go smoothly After the thermosyphon is complete the thermoelectric generators and the cooling system will be permanently attached and tested to ensure they work properly 22 User Interface Inverter Design and Progress The initial user interface breadboard was constructed with a 5 6 V 0 5 W Zener diode This caused a problem because the breakdown voltage was too low allowing too much current to flow through the Zener diode practically burning it out A 1N5351B 14V 5W Zener diode has been purchased and implemented into the circuit design and a place for it etched on a PCB Testing to determining how much current flows through the Zener diode as well as the battery is shown in Tables 3 and 4 on pages 26 and 27 respectively Table 3 is the test data for circuit 1 which is the original schematic Table 4 is the test data for circuit 2 which is the updated schematic The new circuit design is shown in Figure 16 on page 25 and the original design is shown in Figure 24 in Appendix F It is good to point out that both circuits force more current 100mA through the Zener diode when the TEG voltage is too high Another set of tests i
26. ded safety an additional pressure relief valve with a cracking pressure of 175 psi will also be attached to the bottom The 150 psi pressure relief valve is enclosed by another tank with three exits These three exits connect to the copper condensing tubes 3 8 inch tank flanges allow copper fittings to be directly attached to the pressure relief valve enclosure and to the holding tank The top two flanges each connect to copper T fittings that allow two condensing tubes to be connected to each The bottom flange prevents any liquid water from collecting in the pressure relief valve enclosure by connecting to another condensing tube that will go directly to the holding tank All five condensing tubes connect to a single 3 8 inch tank flange in the top of the holding tank f Figure 6 Improved Thermosyphon Design Left and Current Construction Right 17 Construction has so far been defined by the fabrication of the tanks The cutting and welding of metal has taken much longer than anticipated due to scheduling conflicts with someone qualified to do the welding However once the tanks were complete they were connected to one another quickly because this merely consisted of screwing pipes together UT x Y A o NN ae a Ag Es 4 e i 7 M t iih uM s P1 ev we 2 nf Im Pia 4 C P s A T be ad rw LEM Figure 7 Current Level of Construction for the Thermosyphon PR gt A major concern is the check valve between the h
27. e battery Input 12 7 V DC and 1 5 A 60 05 Hz User controlled switch Output LED indicator Unit Outlet The unit outlet is the standard household outlet NEMA type B that the user will plug their device into For safety reasons the neutral pin will be connected to the metal frame of the device Input 110 VAC 125 VAC greater than 1 5 Amps 60 05 Hz Output 110 VAC 125 VAC greater than 1 5 Amps 60 05 Hz 14 System Progress and Accomplishments Thermosyphon Design and Progress One of the main reasons that the team is behind schedule is due to the thermosyphon At the beginning of the semester some design changes were made which put off beginning construction for approximately one week To compound this problems found during construction scheduling conflicts with a professional welder as well as lack of available time in the Mechanical Engineering Lab have plagued the thermosyphon Almost all the parts for the thermosyphon have been purchased The original design of the thermosyphon consisted of three main parts connected by piping The boiler was located in the fireplace and allowed heat to be added to liquid water turning it into steam This vapor then traveled to the thermoelectric generator condensing chamber where some heat is extracted for conversion to electricity The remaining heat was then removed by routing the vapor through an extension of copper pipe exposed to air This condensed the vapor back into a liqui
28. erature the generator will begin to produce electricity and notify the user that they can plug in a device The user will then be able to plug in any electrical device which uses less than 150W of power to a standard NEMA Type B outlet Special Restrictions The generator must be considered safe with no parts exposed that could cut or burn the user Additionally the electrical aspects should present no risk of fire or shock The NEMA Type B outlet should be properly grounded Input The input of the device is a wood burning fire in an open hearth fireplace The heat from the fire will serve as the energy source for the electric generator Closed stoves and gas burning fireplaces will not be supported Output The generator s output connector will consist of a NEMA Type B electrical outlet The outlet will provide 125 VAC 15 and at least 1 5 A 10 at 60 Hz 0 5 For comparison most normal household electrical outlets in the United States provide approximately 125 volts and 15 amps at 60 Hz when connected to the power grid Technical Requirements The following requirements must be met 1 Size The device should be small and light enough to be carried by a single person The generator should be no greater than 0 6 x 0 6 x 0 46 meters 2x 2x 1 5 feet This does not include the device for collecting and transporting heat from the fire to the generator Weight The device should not weigh more than 22 7 kg 50 Ibs Installation
29. f the thermoelectric generator It consists of 10 finned heat sinks and two fans located directly above them Each heat sink is attached to the top of one thermoelectric generator with thermal paste The fans are attached to the inside of the top of the encasement and are powered by the battery circuitry This configuration is shown in Figure 11 TTT E The only modification to the original cooling system design involves applying additional pressure onto the heat sinks The pressure will be applied by flat metal straps two per pair of heat sinks which run in between the pins of the heat sinks Wires will be attached to the ends of each strap and connected underneath the thermoelectric condensing chamber using worm clamps that have been cut open The clamps will then be tightened to provide tension in the wires and thus add pressure to the heat sinks Figure 12 illustrates this Flat Metal Straps Heat Sink Tension Wire Thermoelectric Condensing Chamber Tighten Worm Clamp Here Figure 12 Cooling System Integration Test 21 Figure 13 Heat Sink Pressure Test To test whether this method would provide the necessary pressure a set of heat sinks was attached to the thermoelectric condensing chamber The setup worked even better than expected In fact the wires were so tight that the chamber could even be picked up by the heat sinks Figure 13 Additional tests that need to be performed inclu
30. iding 7 volts and 4 6 amps each assuming a temperature differential of 130 C two sets in series of five in parallel Input Temperature between 100 C and 180 C Output 14 Volts and 23 amps DC 322 watts Excess heat 180 C without cooling Cooling Device The cooling device will remove 2149 W or more of heat from the thermoelectric generators This will be achieved through forced convection by two fans over ten finned heat sinks Input Excess heat 180 C without cooling Output 2149W heat removed Battery The battery will be charged by excess DC voltage produced by the thermoelectric generator It will serve as a regulator as the output of the thermoelectric generator fluctuates Input 14 V and 23 ADC 322 W Output 12 7 V and 18 A DC 228 6 W 13 Inverter The inverter will convert the DC power from the thermoelectric generator or battery into AC power and step up the voltage Input 12 V and 18 A DC 216 W Output 120 10 VAC greater than 1 5 Amps 60 05 Hz User Interface This circuitry will control the flow of power to the outlet as well as indicate to the user when sufficient power is being supplied to the outlet When the user switch is in the on position power will be available and the user can plug in a device using 200 watts or less When it is in the off position no power will be supplied to the outlet Additionally a single indicator LED will light up when at least 12 volts is being supplied by th
31. ing generator lies with safety To ensure that the prototype is as safe as possible during operation the faculty has allocated additional funds to the project that will not count towards the final cost This safety oriented change includes the addition of another pressure relief valve that vents directly to the atmosphere This will allow the system s pressure to be relieved before it reaches a breaking point that could lead to possible injuries See Thermosyphon Design and Progress for details The additional pressure relief valve and associated tank flange add up to a cost of 22 83 One major component still remains to buy The professional circuit board PCB needs to be ordered but to prevent mistakes an etched circuit board will be used for testing and the PCB will be ordered at a later date The cost of the PCB should yield no surprises when the time comes to order it In the event the wood burning generator goes over budget there is an extra unspecified feature that can be removed in order to recoup some money The current design calls for the boiler to be able to be removable for storage This involves the inclusion of two union fittings and two brass ball valves in the thermosyphon These add up to an additional cost of 30 88 and can be returned if needed to stay under budget With only a few more major components to purchase the budget outlook is positive The budget did increase due to the realities of shipping and taxation but not so
32. is threshold to prevent the battery from discharging too drastically The LED informs the user when the voltage of the battery drops below the 11 3 V 12 volts is the desired requirement keep the battery from entering into severe discharge The inverter has been integrated with the circuitry and tested in the encasement for size requirements Figures 19 and 20 page 29 show that there sufficient room for the electrical components including the inverter battery and circuit board 23 Figure 14 Etched Circuit Board Figure 15 Breadboard of Circuit 24 J2 Inverter Key Space D1 1N964B LM7812CT Ban VOLTAGE COMMON BJT_NPN_VIRTUAL A LED 1500 Figure 16 Circuit 2 R4 and R5 are the only values that have changed from the 2 round tests on page 44 25 9c Battery voltage V gt 10 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Table 3 3rd Round Testing with 14V 5W 1N5351B Zener Diode Battery Current 0 0040 0 0040 0 0040 0 0023 0 0107 0 0113 0 0117 0 0211 0 0352 0 0534 0 0484 0 0707 0 0825 Zener Current 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0009 0 0300 0 0580 0 0860 0 0942 0 1352 11 TEG voltage V 0 5 10 11 12 13 14 15 16 17 18 19 20 Battery Current 0 0044 0 0044 0 0044 0 0045 0 0002 0 0103 0 0115 0 0118 0 0186 0 0331 0 0511 0 068 N A Zener Current 0 0000
33. jojes Jed SHUN suoisuauliq Sue y aqeyleay v ap N39 Id v A ad L J9QUINN Hed IPPON SoJnjeo 4 9SION 3 nssa d MO ury peeds jualin9 f syor Buueag SNOLLVOIAIOIdS NVA DA VSN Vady Appendix D User Interface Inverter Parts Part Name Battery Supplier atbatt com Manufacturer Amstron Model Number AP 12180NB Datasheet Unavailable Specifications See Below Specifications Chemistry Lead Acid Voltage 12 Capacity 18 000 mAh 18 Ah Rating 216 Whr Connector R Terminal Length 7 13 inch 18 11 cm Width 3 03 inch 7 70 cm Height 6 57 inch 16 69 cm Color Gray Weight 11 02 Ib 4 998 56 g Warranty 1 Year UPC Code 880487220647 39 Part Name Inverter PowerVerter Supplier Buy com Manufacturer Tripp Lite Model Number PV375 375 Watts Datasheet Unavailable Specifications See Below General Specifications Weight Device Type Miscellaneous Cables Included Manufacturer Warranty Service amp Support Service amp Support Details Power Device Input Connector s Output connector s More Information Shipping Weight in pounds Product in Inches L x W x H Assembled in Country of Origin Origin of Components 2 2 Ibs DC to AC power inverter external 1 x power cable 1 year warranty Limited warranty 1 year 1 x automobile cigarette lighter 2 x power NEMA 5 15 2 25 6 0 x 3 0 x 4 0 Imported Imported 40 Data Sheet 1N5333B THRU 1N
34. olding tank and the boiler The one psi cracking pressure was assumed to be negligible during design but this turned out to be a poor assumption The weight of the water in the holding tank is insufficient to open the check valve and therefore the boiler may never be resupplied with liquid water After much effort a solution to the problem has not yet presented itself In fact it is not quite fully known whether it will be a problem or not Because of these two factors construction will continue assuming the valve works as designed and the problem will only be revisited if indeed it becomes a problem during future testing Despite construction taking a long time the tanks that are finished are high quality and function as desired Pressure testing is underway on the completed section of the thermosyphon All leaks so far have come from the connections but have been readily fixed by adding plumbing tape and tightening the connections All of the parts for the thermosyphon have been purchased with the exception of the condensing tubes and their associated fittings All of which can be bought locally when needed The thermosyphon has run into serious delays that affect the entire project However the design changes will make the wood burning generator a better product and were worth the additional time spent 18 Thermoelectric Generator Design and Progress The thermoelectric generator design has not been modified from the original Despite major
35. onfiguration that produces an output of approximately 14 volts and 23 amps 19 7V 4 5A 7V 4 5A 7V 4 5A B 7V 4 5A B 7V 4 6A 7V 4 5A E 7V 4 5A 7 7V 4 5A u 7V AGA B Figure 9 Thermoelectric Generator Configuration No changes have yet been made to the design of the thermoelectric generator The most likely change will involve modifications to the wiring configuration to get the proper voltage This change will be easy to implement and not affect the budget since it solely consists of rewiring Additional changes may become necessary once construction begins All of the parts for the thermoelectric generator have been bought For the generators themselves 10 Thermal Enterprises HT1 12710 thermoelectric generators were purchased Arctic Silver Ceramique Thermal Compound was chosen and purchased for the thermal paste Additional specifications for the generators and thermal paste can be found in Appendix B The wiring that will be used to connect the individual thermal electric generators together and to the user interface inverter is included in the user interface inverter budget and will be bought when construction begins 10 shows the purchased thermoelectric generators laid out in the desired configuration with the heat sinks in place Figure 10 Thermoelectric generators with heat sinks laid out in desired configuration 20 Cooling System Design and Progress The cooling system will remove heat from the top o
36. que SPEC Thermal Conductance gt 200 000W m2 C 0 001 inch layer Thermal Resistance lt 0 007 C in2 Watt 0 001 inch layer Average Particle Size lt 0 38 microns Specifications lt 0 000015 inch 67 particles lined up in a row equal 1 1000th of an inch Long Term 150 C to 125 C Coverage Area At a layer 0 003 thick one tube will cover approximately 20 square inches Features Features 2 5 graml 0 8 cc tube 35 Appendix C Cooling System Parts Part Name Fan Supplier Newegg com Manufacturer Link Depot Model Number 8025 B Datasheet Unavailable Specifications Size 80x80x25mm Current 0 16A Air Flow 38 2CFM Speed 3000RPM Power 1 92W Bearing One ball bearing Voltage 12VDC Noise 32 1dBA Name Heat Sink i L MAT Supplier Cool Innovations Hil Ii Model Number 3 151511U Datasheet Attached 36 1 5 X 1 5 MODERATE PIN CONFIGURATION Moderately Configured Aluminum Pin Fin Heat Sinks for Fansink Applications Designed for 40 mm fan predrilled mounting holes Round pin fin configuration generates optimal performance in impingement cooling mode Forged from highly conductive aluminum Lapped to achieve exceptional base surface finish and flatness Heat sinks height can be customized to any dimension between 0 2 to 1 1 Plating options Anodize black clear Electroless Nickel Fan sold separately RoHS compliant u mi DIA V 0120 DIA THRU 82 C
37. s being run with an increased resistance before the Zener diode to limit the current through it As of now Table 4 is the most recent set of test data It is important to point out the major successes of these tests The tests show a current flow through both the battery and the Zener diode More importantly the Zener diode current flows when the14V breakdown voltage is reached Also as the voltage at the battery is low approx 10 11V current is flowing through the battery when the TEG voltage is high This is important to show that the battery will charge when the voltage is low and the TEG voltage is supplying ample amounts of power The current that is negative on the tables just means that the current is flowing to and through the battery power supply due to the fact that the leads on the multimeter were reversed The battery is still going to provide or supplement power to the inverter when the thermoelectric generator power is not sufficient The battery that was selected and purchased was a 12 V 15 Ah SLA sealed lead acid battery and will be charged as needed The battery will be protected by the Zener diode The Zener diode breakdown voltage is 14 V and should allow current to flow when the voltage at the node above the diode reaches 14 V The LED is not illuminated when the voltage drops below 11 3 volts which is close to the desired 12 volts However a discharged battery is considered to be 11 9 volts Changes will be made to raise th
38. system have been bought Electrical construction is progressing at this stage The user interface circuitry has been breadboarded and testing has commenced The design has not changed from the original except for a new Zener diode that has been purchased to account for the current flowing through the diode Secondary testing is underway and will be finished soon The inverter circuitry will be integrated along with the battery and LED circuitry and a PCB will be etched and tested before ordering a professional PCB Construction of the encasement is near completion One major design change includes switching the material from steel to wood due to weight and construction issues This change will allow the encasement to be completed in much less time and for less money than before Except for some additional hardware all of the parts for the encasement have been bought With construction underway the team is behind schedule but under budget The thermosyphon is complete except for the condensing tubes The thermoelectric generator and cooling system have been successfully attached to the thermosyphon to test for integration The electrical components are currently under construction and are being tested before integrating them with the rest of the device Lastly construction of the encasement is well under way and progressing smoothly The team is confident that the prototype will be delivered working on time and under budget at the end of the semester
39. terest in today s market for sustainable energy Consumers are looking for devices that can provide electricity to their home not only when power is unavailable but also in addition to their normal usage The trouble with most products is that they are complex bulky and expensive Additionally energy sources for these generators are not always available wind solar fossil fuels What is needed is a low cost storable easy to use device that provides supplemental energy to the home or emergency electricity if the power is out We believe that a generator using an already built fireplace as the energy source is the natural choice for this request The major benefit of this generator is that the combustion chamber is already available and safe users know how to use it and fuel is readily available The Deliverables There are five deliverables as listed below 1 Working Prototype 2 System Specifications a Design Concept b Block Diagram c CAD Drawing and Analysis 3 Circuit Schematics and Simulation Results 4 User s Manual 5 Bill of Materials Principles of Operation The user will begin by installing the generator to their existing fireplace The device will not be permanent but instead will be installed only when used The actual generator will sit on the hearth outside of the fireplace A device will extend into the fireplace to collect heat and transport it to the generator Once a fire is built and the chamber reaches a sufficient temp
40. ther minor issue has arisen concerning the hinged panels on the lower section The first attempt at installing the hinges was unsuccessful The wooden panels were Figure 22 Encasement with Thermosyphon splitting and the door did not behave properly see Figure 23 To fix this notches will be cut in the panels to allow room for the hinge to behave properly Additionally drilling pilot holes for the hinge fasteners will keep the wood from splitting y 3 BEEN Figure 23 Hinge Problem Left and Proposed Solution Right 31 Appendices Appendix A Thermosyphon Parts Part Name Brass ASME Pop Safety Valve for High Temp 1 NPT Male Supplier McMaster Carr Catalog Number 9889K59 Datasheet Unavailable Specifications Opens at 150 PSI Operates at 40 F to 400 F Maximum flow is 659 ft minute Connection is 1 NPT Male Part Name Brass Piston Check Valve Spring Loaded 1 NPT Female Supplier McMaster Carr Catalog Number 7746K83 Datasheet Unavailable Specifications Maximum Pressure is 200 psi 225 F Cracking Pressure 1 psi Temperature Range 33 to 225 F Connections are 1 NPT Female Part Name Brass Ball Valve Supplier Lowe s Home Improvement Manufacturer American Valve Catalog Number M100 Datasheet Attached 33 AMERICAN VALVE Wi 1 00 FEATURES 100 Full Port Opening N b Solid Ball Brass Ball Valve ccc Most versatile valve available I
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