EnergyHarvestingDevice

TheOhioStateUniversity DepartmentofElectricalandComputerEngineering

BackyardScientists
ThomasR.Caly JoelMansfield SungOokChoi DerekReese

ExecutiveSummary 1.Introduction Todaysrisingworldenergyconsumptionisanincreasinglyimportantfactorinourchoiceofvehicles. Withthepushforincreaseddevelopmentandefficiencyinalternateenergy,weaimtodevelopa productdesigntoharvesttheenergyfrommotionandthermallossesinvehicleenginestobettermeet tomorrowspowerdemandsintheautomotiveindustry. 2.BackgroundResearch Tosuccessfullydesignandbuildtheseenergyharvestingdevices,itwasnecessarytoresearch thermoelectrictransducersandlineargeneratordevices.Designofvoltagerectifiers,regulatorsandthe linearmotor/generatorswerealsoresearched.Testingofthebothdeviceswasalsocompletedto obtainfeedbackandcontinuemakingmodificationstoourdesign. 3.RequirementsAnalysis Thelineargeneratorsandthermocouplesmustcapturelostthermalenergyfromvehiclemotionand engineblock.Thisenergymustbeconvertedtoelectricalenergyandusedtochargeorpowerasmall electronicdevicethroughavoltageregulatingmechanism. 4.DesignApproach Thedesignapproachofourenergyharnessingsysteminvolvesatopdownapproach.Basedon fundamentalswewereabletocreatethedesignusingfunctionalsystemblocks.Manyofthepiecesare createdbymanufacturingcompaniesandweresimplypurchasedforthisproject,suchasthe thermoelectricgenerator.Others,likethelinearmachine,areadaptedfromexistingmanufactured parts.Ultimately,allofthesefunctionalblocksmustbeintegratedtoworkwelltogetherandproduce thedesiredpoweroutput. 5.ReportofWork/Schedule AGanttchartwascreatedanditwasusedtoscheduledesignwork.Infigures2and3thischartnow outlinestheactualworkthathasbeenperformedinTheOhioStateUniversityelectricalandcomputer engineeringdesignclass.Thealreadycompletedworkincludesdocumentationandformulationofa welldefinedplan,fabricationofprototypesandtesting. 6.Personnel Thisgroupiscomposedof4peoplewhoareundergraduatestudentsinElectricalandComputer EngineeringattheOhioStateUniversity.Eachgroupmemberhasavarietyofacademicandindustrial experiencerelatingwiththisproject.Individualtasksweredividedintoseveralpartsbyspecialization andpreferenceofeachmemberhowevereachmembermightsupportothertasks. 8.DesignReviewStrategy Reviewofourprojectyieldedsignificantchangestoourdesign.Itwasdecidedtousethelinear generatorinconjunctionwithathermoelectricgeneratortoobtainenoughpowerforthechargingof smallelectronicdevicesinanautomobileorwornonapersonforuseinthemilitary.Adecisionwasalso madetoeliminatetheimplementationofamicrocontrollerwhichwasoriginallydesignedfordecision makingandmotoringapplications.Thesechangesrequiredfurthertestingandresearch.

TableofContents ExecutiveSummary TableofContents

1.

Introduction..4 1.1. Purpose..4 1.2. ProblemStatement.....4 1.3. Scope4

2.

Design5 2.1. LinearGenerator...5 2.2. ThermoelectricGenerator.6 2.3. Microcontroller...11

3. 4. 5.

ReportofWork/Schedule.9 Personnel.10 DesignReviewStrategy11

ListofFiguresandCharts Fig1.SystemDiagram.5 Fig2.ThermoelectricGenerator.7 Fig3.ThermoelectricGeneratormodel..8 Fig4.LinearGeneratorSchematic..6 Fig5.HighlevelMCUSchematic..12 Fig6.CircuitForVoltageControl..9 Fig7.DetailedSchematicofMCU12 Fig8.ADC10BlockDiagram13 Fig9.ADC10BlockDiagram..14
3

Introduction Purpose ThisdocumentservesastheprojectreportfortheseniorElectricalEngineeringcapstonecourseproject ofJoelMansfield,SungookChoi,DerekReeseandThomasCalyatTheOhioStateUniversity.Wehave developedanenergyscavengingdevicethatcanpowersmallconsumerelectronicswhiledecreasingthe needtouseenergysourcesderivedfromfossilfuelssuchasoilandnaturalgas. ProblemStatement Intodaysworld,energyconsumptionisamajorconsiderationinthevehiclesthatwebuy.Withafinite supplyofpetroleumresources,averagefuelcostsarerising.Andalsowithhybridandfuelcell automobilesbecomingmorepopularandavailable,itishighlydesirabletoharnessamaximumamount ofenergyfromthesepowersourcesasthiscanreducetheeffectbatterycharginghasonthe environment. Scope Theprojectwillfocusonthedesign,fabrication,and/orimplementationofboththelinearelectric motorandthethermoelectricgenerator.Theextentoftheirimplementationincludesusingthese energyscavengerstochargeorpowerasmallelectronicdevicethroughthewastedenergyintheform ofheatandmotioninatypicalinternalcombustionenginepoweredautomobile.Thisincludesinstalling thelineargeneratorandthermoelectricgeneratoronavehicleandcreatingausableoutputfromthese devicestoprovide5VDCsupplyforchargingamobilephonewhiledrivingthevehicle. Design ThesystemleveldesignoftheBackyardScientistenergyscavenginginstallationcanbeseeninfigure1 below.ThissystemconsistsoffourmaindevicestoachieveaDCvoltagesourcecapableofpoweringa smallelectronicdevice.ThelineargeneratorcreatesavaryingACsignalthatisrectifiedbyaTIUC3611 Schottkydiodebridge.TheDCsignalfromthediodebridgechargesasupercapacitorwhichactsto stabilizethesignalandstoreenergy.ThethermoelectricgeneratorisaDCvoltagesourcewithamplitude thatisproportionaltotheheatdifferentialacrossthedevice.Asthevehiclesenginetemperaturerises toitsoperatingpoint,thevoltagewillriseandalsocontributetothechargingofthesupercapacitor.The voltageregulatorcircuitwillcreateaconstant5voltsourcewhenevertheinputisabovesixvolts.Since 4

theinputcomesfromthevoltageofthecapacitor,theoutputofthelineargeneratorandthe thermoelectricgeneratorneedstobeabovesixvoltsonaverage.Thelastiteminthediagramisthefive voltchargingcircuit.Thischargingcircuitusestheoutputofthevoltageregulatorasasourceand providestheproperamountofcurrenttotheportableelectronicdeviceforchargingpurposes.This chargingcircuitoutputisconnectedtoastandardtypeAfemaleUSBport.Thistypeofchargingportis usedsincetherearemanydevicesthatcurrentlyareabletobechargedthroughacomputersUSBport.

Figure1:Systemdiagramforenergyharvestingdevice.

LinearGenerator Thelineargeneratorisadevicethatproduceselectricityfromvibration.Aschematicofthisdevicecan beseeninfigure4.Thisdeviceworksoffthebasicprinciplesofelectromagnetics.Asthedevice experiencesavibrationthemagnetwillmovebackandforthpassingthroughthecoilofwire.The actionofthemagnetmovingthroughthecoilofwireproducesachangingmagneticfluxinsidethecoil. Thischangingmagneticfluxinducesanopposingmagneticfluxinthecoilofwirewhichinturnproduces acurrent.Atypicalpermanentmagnethasapositiveandanegativepole.Aseachpolepassesthrough thecoil,thedirectionofthemagneticfluxwillchangewhichwillchangethedirectionoftheinducedflux andinturntheinducedcurrent.Thiscreatesasinusoidalcurrent. ToproduceaDCcurrent,afullwaverectifier,seeniffigure4,isused.Afullwaverectifierusesthe propertiesofpnjunctiondiodes,inwhichcurrentisonlypermittedtoflowinonedirection.Withthe

properarrangementofthefourdiodesasshowninthefigure,aDCcurrentisproducedwhichcharges thecapacitor.

Figure2:Lineargeneratorandrectifierbridge.

Inthepresentdesignaratherlargevibrationisrequiredtomovethebackandforththroughthecoil.A maximumoutputofapproximately15Vpeakwasobservedwithanoscilloscope.Toreducethetime thatthemagnetisnotinsidethelengthofthecoil,magnetswereaddedatbothendsofthegenerator tubestructuretoactasmagneticsprings.Thisdesignresultsinapeakofonlytenvolts,butthecenter magnetismovedwithsmallervibrationamplitude.Areductioninthepeakvoltagewiththeadditionof themagneticspringsimpliesthemostofthevoltageisproducedfromthefieldsattheendsofthe magnet.Amoreindepthstudyisneededtodecidewhichsetupproducesmorepowerduringnormal drivingconditions. ThermoelectricGenerator Thethermoelectricgeneratorisactuallyathermoelectriccooler(TEC).Thesedeviceshavenotyetbeen putintowidespreaduseforenergyharnessingapplications.Fromtheirname,TEC,itcanbeunderstood thatthesedevicesareusedprimarilyasaheatpumpstomoveheatawayfromvariousheatsources suchaselectronicswhereheatcontrolhasbecomeaproblem.Evenwithtechnologicaladvancesinlow powercomputerprocessors,therearestillundesirableamountsofheatproduced.Conventionalheat sinkandfanapplicationshavetogrowinsizetomeetthecoolingdemandsandarelessappealing becauseofincreasednoise.InthisprojectweareusingaTECinitsinversemodeofoperationand becauseofthiswewillcallitathermoelectricgenerator(TG).TheTGusedinthisprojectisshownin 6

figure2.Youcanseethatitismadeupofmanyseparateelements.Theseelementsareexplainedina functionaldrawingoftheTG,whichcanbeseeninfigure3.Thethreeprimaryfunctionalelementsare thecopperconnectorsinblue,theptypedopedBismuthTelluridemetalindarkredandthentype BismuthTelluridemetalingray.Theseareallconnectedinseriessothattheirproducedvoltagesadd. TheprinciplebehindtheTGliesinthephenomenonknownastheSeebeckeffect.TheSeebeckeffect describestheinteractionbetweenthetwodissimilarmetalswhentheyareconnectedatoneendand theassociatedvoltageacrosstheirnonconnectedendswhenthereisatemperaturedifferenceacross theserespectiveends.Ifatemperaturedifferenceisconstant,thentheoutputvoltagewillbeconstant. Thisispreciselythemechanismbehindthermocoupletechnology.Sincethermocouplestypicallyhavean outputofonlyafewmillivolts,thenthereasonbehindtheTGhaving252thermocouplesbecomes clear.ThemetalsusedinthisTGhoweveraremuchmoreefficientthantheaveragethermocouple material.Sincethisdeviceiscapableofanestimated12voltsofoutput,thismeanseachindividual thermocouplecangenerateabout47.6mV.

Figure3:MarlowIndustriesthermoelectricgeneratorDT122.5.Source: http://www.marlow.com/Products/DataSheets/1020160.pdf


Figure4:Thermoelectricgeneratormodel.

FromwhatwasjustdescribeditisapparentthattheTGcanbeusedforcreatingpowerwhereverthere isaheatsource.Asshownintheblockdiagramoffigure1,thisiswhattheTGistobeusedfor.The outputofthethermoelectricgeneratoristobeconnectedinparallelwiththelineargeneratorandthe voltageregulatorforuseinchargingandpoweringlowpowerelectronics.Topreventreversecurrent comingfromthelineargeneratoradiodewillbeplacedinserieswiththepositiveterminaloftheTG. ThevoltageoftheTGwillactasaDCcomponenttothevoltageofthelineargenerator.Theircombined sourceswillbeintroducedtothevoltageregulatorforpowerconditioning. Currently,theprojectteamhastwoTGmodulesthermallyconnectedtotheengineblockofoneteam memberscar.TheseTGmodulesareconnectedinseriestogetthemaximumvoltageoutput.Themost recenttestsshowavoltageoutputofabout2volts.Thereasonsforthevoltagebeingsolowisthat thereisnotadequateventilationaroundtheheatsinksoftheTGs.Increasedventilationwillallowfora greateramountofheattransferthroughtheTG. VoltageRegulator ThevoltageregulatorcircuitusestheTILM317adjustableregulator.Intheavailableapplicationnotes fortheLM317,figure5belowshowsanexampleimplementationtoachieveaparticularvoltageoutput. Theoutputvoltageisasdescribedintheformula:

Figure5:CircuitForVoltageControl
Source:TILM317Applicationnoteshttp://focus.ti.com/lit/ds/symlink/lm317.pdf

ChargingCircuit Thepurposeofthechargingcircuitistoprovidetheproperamountcurrentforthedeviceundercharge. Eachdevicewillhaveacertaincurrentlimitandoptimalcurrentatwhichitcharges.Thereforean adjustablecircuitwouldbebeneficial.Thesimplestofchargingcircuitswouldbeavariableresistorin serieswiththeregulatoroutput.TheT.I.eZ430RF2500microcontrollercouldbeusedtomonitorthe currentandefficiencylevelssothattheresistorcouldbeadjustedaccordingly.Moreinformationonthe microcontrollercanbefoundintheappendix. ReportofWork/Schedule Throughoutthisquarterthefollowingtaskswerecompleted: TestedThermoelectricGeneratortodeterminecapabilities o Todetermineamountofcoolingneeded o Todetermineresponsefromloading 9

InstalledThermoelectricGeneratoronCar AnalyzedDesignofLinearGeneratorwithOscilloscope BeganProgramminganddebuggingmicrocontrollertomonitorvoltagelevels

Personnel SungookChoihasextensiveexperiencebydesignprojectofLowNoiseAmplifierDesignProjectand AnalysisandSimulationofaSequentialMachine.Inaddition,hehaslaboratoryexperiencewithNoise FigureMeter,NetworkAnalyzer,AutoCADProfessional8,VHDL,XilinxISE10.Hewillbesupervisingthe circuitboarddesign. DerekReesehasfocusedprimarilyonelectromagneticsandpowerwithintheElectricalEngineering departmentbuthassomeexperiencewithcircuitandcontrols.Hewillbeoverseeingtheselectionand programmingofthemicrocontrollerandplanstohelpwiththepowerelectronics.Hewillalsobetaking anindependentstudywinterquartertofurtherhisknowledgeinmicrocontrollersandorpower electronics. JoelMansfieldhascurrentresearchexperienceintheareasofelectromagneticsandimagingtechniques. Hiseducationalfocusesareinelectromagneticsandpower.Heiscapableofusingmanytypesof electronicmeasurementequipmentsuchasoscilloscopes,multimeters,networkanalyzersand frequencygenerators.Additionally,heisknowledgeableinsoftwareprogramslikeAgilentADSand MATLAB.Hewillbeinchargeofthetaskofsystemintegrationandthermoelectricgeneratorinstallation andtuning. ThomasCalyisaseniorelectricalengineeringstudentattheOhioStateUniversity.Having studiedinFranceattheINSAdeLyonandcompletedaninternshipintheelectromagneticcompatibility, hismainareaoffocusisinelectromagneticsandmorespecificallyantennadesign,microwave(RF) circuits,integratedoptics,anddataacquisitionandprocessinginSyntheticApertureRadar.Hewillbe supervisingthedesignofthechargingcircuit/powerelectronics. 10

 DesignReview Atthebeginningofthisprojectitwastheteamsgoaltobuildashockabsorberusingalineargenerator. Thisgoalturnedouttobeabitunrealisticgiventheallowedtimeforthisproject.Anewplanwas devisedtoreducethesizeofthelineargeneratorandusethisforapplicationsonasmallerscalesuchas supplyingenergylowpowerelectronicdevicesusedinthefieldbythemilitary.Thiswouldprovide greatbenefitbecauseitwouldreduceneedtorelyonbatterypower.Thedesignofthislineargenerator wouldbequietsimplebutveryreliable.Somechangeswerediscussedaboutthedesignofthislinear generator.Duetotheneedforlargevibrationstomovethemagnetthroughthecoil,magneticsprings weresuggested.Infact,whenthesewereadded,itgreatlyreducedtheforcerequiredtomovethe magnet. Theteamalsobroughtabouttheideatoproduceelectricityfromheatusingathermoelectricgenerator. Giventhespecsonthegenerator,itwasbelievedthatthiscouldbeusedtochargeabatteryofacar. Therewereproblemsachievingthisthoughduetocoolingissues.Thethermoelectricgeneratorisnow goingtobeusedtopowersmallelectronicdevices. Theoriginaldesigndidnotincludeawaytologthepoweroutputofthedevice,sosomepreliminary workwasdonetoachievethiswiththeTIMSP430seriesmicrocontroller.Thedetailsoftheworkis shownintheappendix. 11

Appendix MicrocontrollerT.I.eZ430RF2500 Sinceourlastprojectproposal,theuseofthemicrocontrollerhaschangedseveraltimes.Initslatest implementation,theT.I.eZ430RF2500MicrocontrollerisusedinsteadoftheeZ430F2013.This decisioncamefromafundamentalneedtousethemicrocontrollerasbothacontrollerforthevoltage regulatorandadataloggingdevice.TheMCUsprimarypurposeistoreadtheoutputvoltageofthe thermoelectricgeneratorandlineargenerator,converttheanalogsignaltoadigitalone,storeitin memoryandthenoutputtheresultsinrealtimetoacomputerthroughthewirelesscapabilitiesofthe RF2500.Itmustalsoactontwovoltagecontrolledswitchestoactiveanadjustablefixedlowdropout voltageregulatorwith5voltoutputcircuit,andserveasitsownpowersupply.

Figure6:HighlevelSchematicofMCU

TheAnalogDigitalConverter

12

TheADCmoduleofthemicrocontrollersupportsfast,10bitanalogtodigitalconversionswithaneasy tousedatatransfercontroller(DTC).TheADCwillbeusedtoconverttheanalogvoltageoutputofthe thermoelectricgeneratorandlineargeneratorintoadigitaloutputthatcanbestoredintheRAMofthe MCUandthenusedforvariousfunctions. TheADC10modulecanbeusedthroughtheprogrammingofvariouscontrollers,namelyADC10CTL0, ADC10CTL1,ADC10AE0,ADC10AE1,ADC10DTC0, Figure7:DetailedSchematicofMCU ADC10DTC1,and

ADC10SA.Forourconfigurationwedecidedonthefollowingparameters,whichcanbereferencedto theblockdiagraminFigure6: Internalvoltagereference(SREFx)Vr+=Vref+andVr=Vss ADC10SampleandHoldtime(ADC10SHTx)64xADC10CLKs Multiplesampleandconversionon(MSC)continoussampleconversions Referencegeneratorvoltage(REFON)setto2.5V Interrupts(ADC10IE)Enabled InputChannelSelect(INCHx)andAnalogInputEnableRegister(ADC10AE0x)A1 SampleandHoldSource(SHSx)ADC10SCbit ADC10DataFormat(ISSH)StraightBinary ADC10ClockSourceSelect(ADC10SSELx)MCLK ConversionSequenceMode(CONSEQx)RepeatSinglechannel ADC10Oneblocktransfermode(ADC10DTC0),EnableonENC,startconversionon ADC10SCset 64Transfersperblock(ADC10DTC1)withstartaddressof0200h027Fh

Forinformationonindividualbitsettingforeachcontroller,pleaserefertotheTIMSP430F2xxxFamily UserGuide. ThemaintwocontrolregistersbeingADC10CTL0andADC10CTL1,theyaresetasfollows: 13

ADC10CTL0 bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 0 0 1 1 1 1 1 0

0 0 0 0 1 1 0 IFG ENC ADC10SC

Figure8:ADC10BlockDiagram

ADC10CTL1 bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 ADC10BUSY

Figure9:ADC!0BlockDiagram

MSP430xxProcessorcode voidmain(void) { WDTCTL=WDTPW+WDTHOLD; ADC10CTL1=INCH_1+ADC10SSEL_2+CONSEQ_2;//Repeatsinglechannel,MCLK,A1 ADC10CTL0=SREF_1+ADC10SHT_3+MSC+REFON+ADC10ON+ADC10IE+REF2_5V; ADC10DTC1=0x40;//64conversions ADC10AE0|=0x02;//P2.1pinA1ADCoptionselect for(;;) { ADC10CTL0&=~ENC; //EnableConversion

while(ADC10CTL1&BUSY);//WaitifADC10coreisactive ADC10SA=0x200;//DataAddressbufferstart ADC10CTL0|=ENC+ADC10SC;//Samplingandconversionstart } }

14