P09451 Final P09451 Final Project ReviewProject Review

Bryan McCormick (ME) Project ManagerBryan McCormick (ME) Project ManagerAndy Freedman (ME) Heat Transfer/Fluids Analysis & Andy Freedman (ME) Heat Transfer/Fluids Analysis &

DesignDesignJohn Kreuder (ME) Thermal ModelerJohn Kreuder (ME) Thermal Modeler

Ken McLoud (ME) Structural DesignerKen McLoud (ME) Structural DesignerJon Holdsworth (EE) Electrical System DesignerJon Holdsworth (EE) Electrical System Designer

Gabriela Santa Cruz (IE) Engineering EconomicsGabriela Santa Cruz (IE) Engineering Economics

Sponsored by:Sponsored by:

Previous SystemPrevious System

Previous SystemPrevious System

Project DescriptionProject Description Improved test stand for studying thermo-Improved test stand for studying thermo-

electric moduleselectric modules

High Level Customer Needs:High Level Customer Needs: Implement air-cooling on cold side of thermo-electric Implement air-cooling on cold side of thermo-electric

array in addition to the water-cooling system.array in addition to the water-cooling system. Be able to experimentally validate thermoelectric Be able to experimentally validate thermoelectric

system models and enable more parameters to be system models and enable more parameters to be explored.explored.

Improve user interface and data acquisition to allow Improve user interface and data acquisition to allow greater ease of use of the test stand.greater ease of use of the test stand.

Improve set-up and shut-down procedures to reduce Improve set-up and shut-down procedures to reduce assembly times assembly times

System ArchitectureSystem Architecture

PipingPiping

PipingPiping

Valves for Air/H2O Interchange

Power UnitPower Unit

Improved Tool Clearance

Force Sensors

Power UnitPower Unit4 zones

Interchangeable Fins

Power UnitPower Unit

Power UnitPower UnitPermanently Mounted Thermocouples

Current StatusCurrent Status

Assembly completeAssembly complete Labview completeLabview complete System test incompleteSystem test incomplete

Current StatusCurrent Status

On target to meet budgetOn target to meet budget Melcor thermoelectric modules still Melcor thermoelectric modules still

outstandingoutstanding Wire to arrive todayWire to arrive today

Schedule: Schedule: Design completed on scheduleDesign completed on schedule Machining/Assembly took much longer than Machining/Assembly took much longer than

anticipatedanticipated Testing not yet completeTesting not yet complete

Current SystemCurrent System

Current SystemCurrent System

Test ResultsTest Results

System is operationalSystem is operational More testing is required to prove More testing is required to prove

functionalityfunctionality

Successes/FailuresSuccesses/FailuresSuccessesSuccesses

User Interface ImprovementsUser Interface Improvements Cross-flow air coolingCross-flow air cooling Ability to interchange air cooling Ability to interchange air cooling

and water coolingand water cooling Addition of 4th zoneAddition of 4th zone Additional temperature Additional temperature

measurementsmeasurements Temperature measurements at Temperature measurements at

inlet and outlet of each zoneinlet and outlet of each zone Additional pressure Additional pressure

measurementsmeasurements Elimination of manual Elimination of manual

measurementsmeasurements Consistent positive positioning of Consistent positive positioning of

thermocouplesthermocouples Additional tool clearance on Additional tool clearance on

components of power modulecomponents of power module Safety shutoff sensor for heaterSafety shutoff sensor for heater Multiple heat sinksMultiple heat sinks

FailuresFailures MOSFET power-tracking MOSFET power-tracking

systemsystem Inability to use control system Inability to use control system

for peak power (due to for peak power (due to MOSFETs)MOSFETs)

Machining time Machining time underestimationunderestimation

Insufficient time for testingInsufficient time for testing

Questions?Questions?