CAMPFIRE CHARGER

NAMA NO PEND

1. MOHAMAD ZULHISYAM BIN MD DENAN 09DEE12F2004

2. SAFINAH BINTI ABU TALIP 09DEE12F2003

ELECTRICAL ENGINEERING DEPARTMENT

POLYTECHNIC IBRAHIM SULTAN

JUNE 2015

ii

VERIFICATION OF PROJECT REPORT

Our project report entitled "Campfire Charger" has been submitted,

reviewed and certified as meeting the requirements and need Writing

Project, as set

Checked by:

Supervisor’s Name : Madam Rosmanira binti Mamat

Supervisor’s Signature :

Date :

Checked by:

Coordinator’s Name :

Coordinator’s Signature :

Date :

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“The content of this document is the original work based on our own research and

to the best of our knowledge it has not been presented elsewhere for academic

purposes.”

Signature :

Name : MUHAMAD ZULHISHAM BIN MD DENAN

Matrix No. : 09DEE12F2004

Date :

Signature :

Name : SAFINAH BINTI ABU TALIP

Matrix No. : 09DEE12F2003

Date :

iv

ACKNOWLEDGEMENT

We would like to say thanks to God because the kindness that given we can

completing our final project, finally it can be done successfully. Many obstacles and

challenges resulting effort never waned even sometimes find its way straits. With cries

of distress words surely find solutions because permanent efforts continue to yield solid

momentum positive thoughts and prayers continue.

On this occasion we would like to extend our sincere thanks to our supervisor En

Ahmad Amirulhafiz bin Mohd Nor and Pn Rosmanira binti Mamat because of they

views and moral support in this project. Further, we also like to thanks friend who

helped in the success of this project particularly to DEE6. Our final thanks to oour

beloved parents because of the grace and support so that we can complete this project.

Only God can repay to all your kindness.

Last but not least, we hope to this project can be a reference to others and bring a

lot of benefit to other people.

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ABSTRACT

The idea of this project is to utilize the waste heat energy being generated during

campfire. It involves the trapping of heat energy being generated from the heat source in

campfire and convert to electrical energy which can be used for many appliances. The

heat energy and the temperature from the heat source is being sensed by the

thermoelectric module and is converted to electrical energy by a device called

Thermoelectric Generator which works on Seebeck effect. The electric potential

produced in thermoelectric generator is boosted by the step up circuit thereby increasing

the magnitude of voltage, required for charging the electronic appliance such as

smartphone.

Keywords: Thermoelectric Generator; Seebeck effect; Electric potential

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ABSTRAK

Idea projek ini adalah menggunakan tenaga haba buangan yang dihasilkan semasa

membuat unggun api . Ia melibatkan memerangkap tenaga haba yang dihasilkan

daripada sumber haba dalam unggun api dan menukar kepada tenaga elektrik yang boleh

digunakan untuk pelbagai peralatan. Tenaga haba dan suhu dari sumber haba akan

dikesan oleh modul termoelektrik dan ditukarkan kepada tenaga elektrik dengan

mengunakan Penjana Termoelektrik yang berfungsi melalui teori kesan Seebeck .

Keupayaan tenaga yang dihasilkan oleh Penjana Termoelektrik ini akan ditingkatkan

nilai voltannya menggunakan litar ‘step up’ yang diperlukan untuk mengecas peralatan

elektronik seperti telefon pintar dan lain-lain.

Kata kunci: Termoelektrik Generator ; Kesan Seebeck ; Potesi elektrik

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LIST OF CONTENTS

CHAPTER CONTENTS PAGES

1 INTRODUCTION

1.1 Introduction 1

1.2 Problem statement 2

1.3 Objectives 3

1.4 Scope 3

2 LITERATURE REVIEW

2.1 Introduction 4

2.2 Understanding the concept of Thermoelectric 5

Generator

2.3 Type of components 9

2.4 Soldering equipment components 12

2.5 Soldering tools 14

3 METHODOLOGY

3.1 Introduction 15

3.2 Work procedure 15

3.2.1 Gantt chart 15

3.3 Flow chart 18

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3.3.1 Tittle selection by supervisor 20

3.3.2 Identify problem, creates scope, and objectives 20

3.3.3 Scientific research 21

3.3.3.1 Thermoelectric Generator Module 22

3.3.3.2 Heat Sink 23

3.3.3.3 Cooling Fan 23

3.3.4 Development of circuit 25

3.3.5 Producing PCB (Printed Circuit Board) 28

3.3.5.1 Producing of PCB 29

3.3.5.2 Process of drilling on the PCB 30

3.3.5.3 Installation of components on PCB 30

3.3.5.4 Check the continuity of the circuit 30

3.3.5.5 Solder process 31

3.3.5.6 Process of cutting the legs of components 32

3.3.6 Precaution in soldering process 33

3.3.7 Testing after solder 33

4 ANALYSIS

4.1 Introduction 34

4.2 Analysis 35

4.3 Experimental setup and operation 36

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5 DISCUSSION

5.1 Introduction 39

5.2 The problem faced 40

5.3 A step to overcome the problem 40

6 CONCLUSION AND SUGGESTION

6.1 Introduction 42

6.2 Conclusion 43

6.3 Suggestion 43

REFERENCE 45

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LIST OF TABLES

NO.TABLE TITLE PAGES

2.3.1 Type of components 11

2.4.1 Soldering equipment 13

2.5.1 Soldering tools 14

3.2.1.1 Activities of semester 5 by weeks 17

3.2.1.2 Activities of semester 6 by weeks 18

3.3.3.1.1 Specification of the Thermoelectric module 22

3.3.3.1 List of components 24

3.3.3.4 List of components for step up circuit 26

3.3.4.1 List of components for voltage regulator 28

circuit

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LIST OF FIGURES

NO.FIGURES TITLE PAGES

2.2.1 TEP device in both cooling and 7

power generation configurations

3.3 Implements Flow chart 19

3.3.3.1.1 Thermoelectric generator 22

3.3.3.2.1 Heat Sink 23

3.3.3.3.1 Cooling Fan 24

3.3.4.1 Schematic diagram of step up circuit 25

3.3.4.2 Step up circuit 25

3.3.4.3 Schematic diagram of voltage regulator 27

Circuit

3.3.4.4 Voltage Regulator circuit 27

3.3.5.5.1 Solder equipments 31

3.3.5.5.2 A correct way to solder 32

4.2.1 Front view 35

4.3.1 Side view 35

4.3.2 Block diagram 36

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4.3.1 Step up circuit 37

4.3.2 Voltage Regulator circuit 37

4.3.2 Line Graph 38

CHAPTER 1

INTRODUCTION

1.1 Introduction

Thermoelectric generators also called Seebeck Generators are devices that

convert heat or temperature differences directly into electrical energy using a

phenomenon called the Seebeck Effect. In 1821, Thomas Johann Seebeck discovered

that a thermal gradient formed between two dissimilar conductors produces a voltage.

At the heart of the thermoelectric effect is the fact that a temperature gradient in a

conducting material results in heat flow. This results in the diffusion of charge carriers. .

2

The flow of charge carriers between the hot and cold regions in turn creates a

voltage difference. By the ways, thermoelectric generators have lower efficiency but for

small applications, thermoelectric can become competitive because they are compact,

simple, inexpensive and scalable. Thermoelectric systems can be easily designed to

operate with small heat sources and small temperature differences. Such small

generators could be mass produced for use in automotive waste heat recovery or home

co-generation of heat and electricity. Thermoelectric have even been miniaturized to

harvest body heat for powering a wristwatch.

1.1 Problem Statement

Emerging technologies are making our life simpler these days. With the

introduction of a smartphone with GPS and maybe other electronics, life has changed

rapidly. Mobile phones merged land line telephone systems. These days, there are a lots

of advancements in the mobile phones were introduced. But although there are so many

advancement in the technology, we still have the problem with the power to charge the

smartphone, especially when do several days of hiking or camping and we always bring

a smartphone with GPS and maybe other electronics. They need electricity and have

used spare batteries or solar chargers to keep them running. When we need it as most it

is either raining or other circumstances that makes it impossible to charge with solar

panels. Even when it is clear weather it simply takes too long to charge. Batteries are

good but too heavy.

3

It is possible to generate electricity by using a “waste heat recovery” concept. At

least a fire steel to make they own heat.

1.2 Objectives

The project will aim ;

i. To introduce the other ways to produce electricity.

ii. To study the application of Thermoelectric Generator.

iii. To utilize the waste heat energy being generated during campfire.

iv. Convert heat energy directly into electrical energy.

1.4 Scope

1) The source of the electricity will produce from fire (heat energy).

2) The fuel is the Renewable Biomass (Twigs, Wood Pallets, and etc.)

3) This project focus for camping and hiking activities.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

In this chapter there will be the literature review of this project. This chapter

consist briefly the Understanding the concept of Thermoelectric Generator.

5

2.1 Understanding the concept of Thermoelectric Generator.

Thermoelectric power is the conversion of a temperature differential directly into

electrical power. Thermoelectric power results primarily from two physical effects there

are the Seebeck Effect, and Peltier Effect.

The Seebeck effect is named after Thomas J. Seebeck, who first discovered the

phenomenon in 1821. Seebeck noticed that when a loop comprised of two dissimilar

materials was heated on one side, an electromagnetic field was created. He actually

discovered the EM field directly with a compass.He noted that the strength of the

electromagnetic field, and therefore the voltage, is proportional to the temperature

difference between the hot and cold sides of the material. The magnitude of

the Seebeck coefficient (S) varies with material and temperature of operation.

The Seebeck coefficient is thus defined as:

In this equation ΔV is the voltage difference between the hot and cold

sides; ΔT is the temperature difference between the hot and cold sides. The negative

sign comes from the negative charge of the electron, and the conventions of current

flow. A negative Seebeck coefficient results in electrons being the dominant charge

carriers (n-type), whereas holes are the dominant carrier (p-type) in materials with a

positive Seebeck coefficient. The majority charge carriers are said to move away from

6

the heated side toward the cooler side. Minority charge carriers move in the opposite

direction, but at a slower rate due to phonon drag and charge carrier diffusion

rates. Thus, both n-type and p-type materials are required to realize current flow in a

device.

There are a few things to remember about the Seebeck effect:

o Solids have charge carriers that facilitate the flow of electrical power

o The charge carriers come in two flavors negative electrons "n-type" and positive

"holes" that we use to keep track of mobile positive charge in "p-type" solids

o Heating one end of a conducting solid pushes on the charge carriers concentration

and the distribution of charge creates voltage that can be measured this is called

the Seebeck effect

The Peltier effect was first discovered in 1834 by Jean C.A. Peltier, for whom it

was named. Peltier discovered that whenever a circuit of two dissimilar materials passes

current, heat is absorbed at one end of the junction and released at the other. This is a

linearly dependent and thermodynamically reversible process, unlike Joule heating

which is irreversible and quadratic in nature mean. This process forms the basis for

thermoelectric cooling and temperature control, these are currently the widest

applications of thermoelectric devices.

7

However, applying a temperature differential the reverse process occurs, and

current is caused to flow, thereby generating power. The figure below shows

a TEP device in both cooling and power generation configurations.

Figure 2.2.1: TEP device in both cooling and power generation configurations.

A thermoelectric cooler and power generator, current flow is labeled in the

direction of the electrons.

8

The efficiency by which a material is capable of generating power is governed by

the figure of merit (Z). As seen in the equation below, the figure of merit is most

dependent on the Seebeck coefficient of the material.

In the above equation, the figure of merit is defined in terms of

the Seebeck coefficient, the electrical conductivity, and the thermal

conductivity. Maximum power generation requires the minimization of the thermal

conductivity, while maximizing the Seebeck coefficient and electrical conductivity.

9

2.1 Type of components

No Components Function

1 Thermoelectric Generator

Converting heat source directly into electricity

TEP1-1264-1.5

2 Heatsink

A heat sink is a passive heat exchanger that

transfers the heat generated by an electronic or a

mechanical device into a coolant fluid in motion.

3 Fan

Cooled heat sink on the TEG.

5V/9V input voltage fan.

10

4 Capacitors

It can be aluminium electrolytic capacitor/

tantalum electrolytic capacitors/niobium

capacitors. The large capacitance makes them

particularly suitable for passing or by passing

low-frequency signals up to some mega-hertz

and storing large amounts of energy. It also used

in input and output smoothing as a low pass

filter if the signal is a DC signal with a weak AC

component.

5 Diode

Forward current flows through a solid state

diode there is small voltage drop across its

terminals. A silicon diode has a typical voltage

drop of 0.6 to 0.7 volts, while a schottky diode

has a voltage drop of 0.15 to 0.45 volts. This

lower voltage drop can be used to give higher

switching speeds and better system efficiency

6 Inductor

Other name called a coil or reactor is a passive

two-terminal electrical component which resists

changes in electric current passing through it. It

consists of a conductor such as a wire, usually

wound into a coil. When a current flows through

it, energy is stored temporarily in a magnetic

field in the coil.

11

7 IC Regulator

Voltage Regulator is a voltage regulator that

outputs +5 volts.

LM7805

8 IC

The TL496C power-supply control circuit is

designed to provide a 9-V regulated supply from

a variety of input sources. Operable from a 1- or

2-cell battery input, the TL496C performs as a

switching regulator with the addition of a single

inductor and filter capacitor.

Table 2.3.1: Type of components

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2.2 Soldering Equipment Component

No Hand tools Function

1. Nozzle Plier

Form the component and hold

small objects.

2 Side Cutter Cut the wire and legs of the

component.

3 Wire Stripper

Remove the insulation of wire.

13

4 Electrical Solder

Melt the material solder when

soldering work.

5 Solder Sucker

Inhale solder material during

repair work / correction circuit is

done .

Table 2.4.1: Soldering Equipments

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2.3 Soldering Tools

No Tools Function

1 Solder Tool Holder

To hold the hot electric soldering

tool.

2 Solder Material

The molten solder material is easy

to include the component on the

circuit boards . When cool , the

solder will harden and stick

permanently listing .

3 Span

Cleaning tip bits.

Table 2.5.1: Soldering Tools

CHAPTER 3

METHODOLOGY

3.1 Introduction

In this chapter contains schedule or steps that need to be complete, detailed

reports of studies done to achieve aim objectives. This chapter explains the procedure

taken to complete the projects. It consist the detail development of this project.

3.2 Work Procedure

Firstly, after made a title selection, we proceed to material and components

selections for making this project. The component and materials are able to exchange the

heat from the fire into electricity and we must build a step up circuit to increase the

voltage from the heat

16

Secondly, after all material was selected, we will sketch a design to show how

the system runs. Thirdly, we conduct the experiment to allow us more understand the

concept of thermoelectric. We have form the circuit and study about how the heat related

to electricity.

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3.2.1 Gantt Chart

Project

Weeks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Figure out the

idea for the

Project

Researching

for the

information

Preparing

Proposal

Submit

Proposal

Survey about

materials and

the cost

Purchase the

Materials and

Apparatus

Conducting

Experiment

Build the

hardware

project

Testing

Prepare for

presentation

Presentation

Timetable 3.2.1.1: Activities of semester 5 by weeks

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Timetable 3.2.1.2: Activities of semester 6 by weeks

3.3 Flow Chart

In implementation stage, project planning is the most important aspects. Proper

planning should be emphasized to make sure the project will be constructed successfully

and also to minimize the difficulties while undertaking the project. It is very important to

have this schematic planning and implementation in order to complete the simulation

Planning Weeks

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Project

registration

Project execution

Project

preparation and

log book

Demo of projects

and presentation

EECE

Submission of log

book

Project

completely done

100%

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software and the prototype on time. The methodology of flow chart on figure 3.3 shows

the overall for this project.

Figure 3.3 Implementation’s Flowchart

start

Identify problem, Create scope and

objectives

Scientific Research

Designing the circuit

Simulation and test the TEG

module

Successful

Set up the circuit

End

Research about:

i.Components

ii.Circuits

Research sources:

i.Internet

ii.Magazines

iii.Books

iv.Articles

Yes No

Testing

the project

Yes

No

Title selection by supervisor

Yes

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3.3.1 Title Selection with Supervisor

We came out all idea with the new way to produce electrical power and think all

about something new can bring useful and help to the make user feel convenience while

charging phone and other uses related to low power devices. Then, gather all idea from

all member and supervisor, and study the needs of our project. At the end, we came out

idea to supply the electrical power to the low power devices from the fire (heat).

We suggest the idea to the supervisor and the supervisor give blessing to proceed

our idea after other 4 ideas. The idea is the Campfire Charger.

3.3.2 Identify problem, create Scope and Objective

First of all, we have to identify the problem about our project then proceed to

create a scope and objective for the project. After discuses, we decided to use

thermoelectric module to produce the electricity for the use of low power devices.

After the problem statement is identify, scope is set the objective was came out also,

the objective of this project is to produce the electricity from heat and develop a

technique to design the circuit.

21

All the scope and objective was gain bless from our supervisor to continue our

project.

3.3.3 Scientific Research

We need to study about our project, so we disscuss and use the result from the

disscussion than we make is to divided our team to search some detail and information

about our project. We do research about the components used, step- up circuit diagram,

voltage regulator circuit and the TEG. Our research source are from internet, magazines,

books, and articles. We have to try to understand all the circuits used,TEG the

components.

Beside we do research, we always refer to our supervisor if we do not understand

the information that we get during searching. After sometimes, we gather again to

combined our information and detail to get the best information before we create the real

project.

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3.3.3.1 Thermoelectric Generator Module

The TEP1-1264 -1.5 module is designed and manufactured by our unique

technology for converting heat source directly into electricity. The module is Bi-Te

based thermoelectric module that can work at the temperature of as high as 330 ˚C (626

˚F) heat source continuously and up to 400 ˚C (752 ˚F) intermittently. The

thermoelectric module will generate DC electricity as long as there is a temperature

difference across the module. The more power will be generated when the temperature

difference across the module becomes larger, and the efficiency of converting heat

energy into electricity will increase therefore.

Figure 3.3.3.1.1 : Thermoelectric generator

Hot side temperature ( ) 300

Cool side temperature ( ) 30

Match load output voltage (v) 4.7

Match load output current (A) 1.56

Table 3.3.3.1.1 : Specification of the TEG module

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3.3.3.2 Heat sink

The heat sink use is from old PC with the measurement of

BxWxH=60x57x36mm. This heat sink functions as a passive heat exchanger that

transfers the heat generated by an electronic or a mechanical device into a coolant fluid

in motion.

Figure 3.3.3.2.1 : Heatsink

3.3.3.3 Cooling Fan

This cooling fan is used 9v input voltage from the step up circuit and function as

cooled heat sink on the TEG.

24

Figure 3.3.3..3.1: Cooling fan

List of Components

Name of components Unit

TEP1-1264 -1.5 1

Heat Sink 1

Cooling Fan 1

Total cost RM230.00

Table 3.3.3.1 : Cost of components

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3.3.4 Development of circuits

This section will discuss about developing the step up circuit (1.5v to 9v) and

voltage regulator circuit.

Figure 3.3.4.1: Schematic Diagram of Step up circuit

Figure 3.3.4.2: Step up circuit

This circuit functions as boosting the voltage from TEG. This step up circuit is a

variable DC input voltage. For the operation of the step up circuit, when connecting the

input voltage to the flow, the magnetic field in the L1 will collapsing. The induced

26

current flows into pin 6, lead to increased pressure within the IC be 9 volt out to pin 8.

input pin 2, which may be voltage 1.5 to 3.0 volt. This low voltage circuit starts, the

feedback voltage to bias to transistors inside the integrated circuit. This means that a

short circuit, L1 is connected to pin 6 to ground, resulting in the accumulation of energy

in the form of a magnetic field on current in L1 increases until a maximum value at

about 1 amp. The IC internal circuit will reset itself. As a result, the transistor will open

circuit, so there is no current.

List of Component for step up circuit

Name of components Unit

IC TL496 1

220uF capacitor 1

50Uh inductor 1

Power terminal block 2

Total cost RM54.50

Table 3.3.4.1: Cost of component for step up circuit

27

Figure 3.3.4.3: Schematic Diagram of Voltage Regulator circuit

Figure 3.3.4.4 : Voltage Regulator circuit

The function of this voltage regulator circuit is to get the fixed 5V output. Then,

the output from the step up circuit will become the input for the voltage regulator circuit.

This circuit can be used in simple applications where heat sources are present.

28

List of Component for voltage regulator circuit

Name of components Unit

LM7805 voltage regulator 1

0.1uF capacitor 1

IN 5819 diode 1

10uF capacitor 1

Power terminal block 3

Total cost RM4.57

Table 3.3.4.1: Cost of Voltage Regulator circuit

Both of this circuits are design and simulates using software Livewire. Then,

tested by using breadboard to make sure the circuit can be function.

3.3.5 Producing PCB (Printed Circuit Board)

To produce a good printed circuit(PCB), student should optimize their creativity

and knowledge to change schematic diagram into PCB version, and then screwed of it

nicely into the box or casing. We have been use a software of Livewire to create

schematic diagram and PCB version, and also get a best designs. This is a ways to

prepare of PCB :

29

3.3.5.1 Production of PCB Board

Design of a circuit that will be change into PCB is implemented from a

schematic diagram which created at intial. This process is properly if done on the graph

paper, and then create a circuit which minimum / does not have jumper.

After that, once circuit completely drawn, it should be printed out by using laser

printer. A paper that is used to print of it should be a type of transparent. A circuit that

has been done printed on transparent sheet is applied on the Exposure UV. Print circuit

board is consisting of multiple divisions which are ultraviolet exposure process,

development process, etching process, drilling process, and lastly soldering. The

ultraviolet (UV) exposure is radiated onto the circuit layout which is printed initially

onto the transparent paper in PCB.

After completing the ultraviolet process, the PCB is prepared for development of

chemical liquid. The development of PCB consisting of 20 g of Sodim Hydroxide

powder which added to 1 liter of hot water. These combination were then mixed together

until the whole contens dissolved. The PCB is shaked by hand to speed up the developed

process. The developing process takes about 20 minutes. It is sometimes difficult to

guess when the developing is finished.

30

When the developing process is done, the PCB has to rinse before the etching

process. Etching process where the excess copper is removed to leave the individual

tracks or traces.

3.3.5.2 Process of Drilling on the PCB

Before process of drilling to make a drill point should be suitable with the size of

leg of components which will be installed. Size of hole that will be make is applied on

all components except a ICs. Polystyrene is used to protect the surface of workplace

from damage due to drilling process. Then, process of make a hole must be carry out

carefully as not to make copper circuit which has been etched be damage.

3.3.5.3 Installation of Components on the PCB

During process of install of components, there a few steps before and after

should be followed as to get a good result. The steps that should be taken are check the

continuity of the circuit, the polarity of the component, the ways to solder the

components and so on. This steps are important and must be carefully done, and also

applied on circuit which has been completely etched.

3.3.5.4 Check the Continuity of the Circuit

This testing is done after PCB is completed. It is also carry out using multimeter

through range of resistance. A process needed as to ensure a completed track can be

31

functioning well, and always connected. Range is set to x10. Probes are connected to

two tips or links of each tested track. If needle point shows to the zero resistance, that

means track of circuit is connected. If needle point does not move this mean track is not

connected. Circuit and components which has been completely tested is applied on the

PCB and will be soldered.

3.3.5.5 Solder Process

Components is inserted into PCB. Tapered nose pliers is used to bend a leg of

components as to make it fit into its place. A few rules should be followed while carry

out this process.

Tip of solder is cleaned first. Switch on as to make solder becomes hot and after

it is hot, coat the bit tip soldering with lead.

Figure 3.3.5.5.1 : Solder equipment

Process of soldering is start with solder the IC and tip of solder should be bears

remain at the foot of the IC. Then, touch the tin using the tip of solder and make it on

reverse side. When tins become melt and covering the hole of PCB and foots of IC, lift

32

the solder. This process should be done carefully because arrangements of legs of IC are

close enough.

After that, solder of resistors. Use nozzle plier for bend the legs of resistor of 60˚

as to make it easy to fit into the hole of PCB. Soldering process is same like process

which applied on the legs of IC. After soldered it, excessive foot of resistor is cut by

using cutter. A same process is applied on the legs of capacitors, coils, diodes, inductor

coil, and all of wire connection to the power supply parts, and also other terminals. The

polarity of diode ensure is correct before soldered.

After process of soldering is done, switch off the power supply and clean up the

solder by using a wet span. An excessive of legs of components should be cut.

Figure 3.3.5.5.2 : A correct way to solder

3.3.5.6 Process of Cutting the Legs of Components

After solder process is done, excessive legs of components should be cut. This

will contribute to neatness of a project. Cutting process must be finished using a sharp

33

cutter. It is not advisable to cut using knife, and cutting should be done with particular

suitability.

3.3.6 Precaution in Soldering Process

Avoid from using a lot of the tin as to avoid it touches other components leg.

Make sure while soldering take a time until the tin are stick to the hole of PCB and legs

of components. Then, avoid from blow the tin which still hot in order to avoid the effect

of cracks on the tin and make it long lasting.

3.3.7 Testing after Solder

The last process is testing of circuit. This to ensure a project can be well

functioned. For this process multimeter is needed for measure and to make sure there is

flows of current. Before process of testing, ensure check a project at initial. A legs of

components is checked as to ensure there is no short circuit and connected with correct

polarities.

Before circuits are inserted into a casing, it is should be tested at initial as to

ensure a circuits are well functioned after undergo a solder process. PCB that completely

soldered just now should be cleaned, excessive legs of components have to be cut, and

ensure circuits are free from short circuit. A board is cut according to a suitable size

which related to the circuits and casing.

CHAPTER 4

ANALYSIS

4.1 Introduction

The analysis is to study the performance and the operation of the project. In this

chapter, the theory of how the project works and the every component content in every

circuit in our project.

35

4.2 Analysis

The idea of a model is essential to ensure the selection of a design appropriate

to the function of model projects built. In addition, the cost of constructing the model

should also be taken. Next, there are several aspects to be taken in making of this model.

First, the position of both circuits because the position can effect of the function of the

circuit. Both of the circuit cannot near the heat source (fire). Second, the size of a model

and the weight. Last but not least, the design must appropriate to the project.

Figure 4.2.1: Front view

Figure 4.2.2: Side view

36

Figure 4.2.3: Block Diagram

4.3 Experimental setup and Operation

The experimental setup of this project involves TEG modules placed at the heat

source. The output from this module is given as the input to the Step up circuit, boosting

the voltage from TEG. This step up circuit is a variable DC input voltage used to charge

the electronic appliances.

For the operation of the step up circuit, when connecting the input voltage to the

input pin 2, which may be voltage 1.5 to 3.0 volt. This low voltage circuit starts, the

feedback voltage to bias to transistors inside the integrated circuit. This means that a

short circuit, L1 is connected to pin 6 to ground, resulting in the accumulation of energy

in the form of a magnetic field on current in L1 increases until a maximum value at

TEG

STEP UP CIRCUIT VOLTAGE REGULATOR

CIRCUIT

FAN LOAD

37

about 1 amp. The IC internal circuit will reset itself. As a result, the transistor will open

circuit, so there is no current flow, the magnetic field in the L1 will collapsing. The

induced current flows into pin 6, lead to increased pressure within the IC be 9 volt out to

pin 8.

Figure 4.3.1: Step up circuit

Then, the output from the step up circuit will become the input for fan to cooling

down the TEG and the input for the voltage regulator circuit. The function of this

voltage regulator circuit is to get the fixed 5V output. This circuit can be used in simple

applications where heat sources are present. By this method, the waste heat produced at

the source can be used for producing electricity. The block diagram for this experiment

is as shown below.

Figure 4.3.2: Voltage Regulator circuit

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Figure 4.3.2 : Line Graph

Based on the line graph shown , the value of the voltage is increase when the the

temperature increase until the 300 and start decrease after 300 . By the way, from the

graph also the output voltage can be variable depend on a temperature difference across

the module. The more power will be generated when the temperature difference across

the module becomes larger, and the efficiency of converting heat energy into electricity

will increase therefore

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

50 100 150 200 250 300 350

Output voltage Vs Temperature

Volt

Degree Celcius

CHAPTER 5

DISCUSSION

5.1 Introduction

This chapter will explain about the problems we faced during do this project and

we also will explain the ways to overcome that problems.

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5.2 The problems faced

The Thermoelectric generator (TEG) module has been completed tested. It does

not have problem convert the heat energy to electrical energy. Unfortunately, there is a

problem regarding to the output voltage of the TEG. The output voltage that we get only

2.2V and it is not enough for charging the smartphone because smartphone needs at least

5V and minimum 600ma to start charging.

The problem of low output voltage of TEG appear because of the difficulty to get

the different temperature between the hot side and the cool side of TEG module. Besides

that, we also have to face the problem of over limit the temperature on the TEG module.

For this type of TEG module, the higher temperature at the hot side will exceeding at

300 and the cool side at 180 . If the heat temperature is to higher, the TEG will break

down.

5.3 A step to overcome the problem

Based on the problem faced about the low voltage output of the thermoelectric

generator, we have design a step up circuit to boost the output voltage of the

thermoelectric generator. This step up circuit will receive the variable input voltage of

1.5V to 3V and it is suitable enough to combine with the TEG. By the way, the output of

this step up converter is 9V and it is too high for charge the electronic appliance like a

41

smartphone. So, to overcome this problem, we have design another circuit. There is

Voltage regulator circuit. We have used Ic regulator of LM7805 to get the fixed 5V

output voltage.

Besides that, to overcome the problem of the overheating of the TEG, we have

used the heat sink and a 5V DC cooling fan to cooling the TEG. At the same time, the

TEG have a different temperature between the hot and cool side. As the result, the

electrical energy will produce.

CHAPTER 6

CONCLUSION AND RECOMMENDATION

6.1 Introduction

In this chapter, we will discuss about the conclusion and the result on this

project. Besides that, we will explain the suggestion that can be used to improve this

project and make it more

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6.2 Conclusion

There is an increase in the demand for energy for our day to day activities, from

simple devices to complex systems. All these systems depend on the electricity board or

the power company for its operation. At one point of time, the scarcity for fuels occurs

causing the scarcity in electricity. Hence, it is important to conserve energy. This project

aims to conserve the electrical energy to some extent, by trapping the waste heat from

the heat source in fire. This project can also be applicable in home appliances, where the

heat from gas stoves can be trapped for producing electrical energy. By the efficient use

of waste heat energy, we can save some amount of energy for operating appliances.

6.3 Suggestion

After carry out this project, it can give a lot of benefit to a user because this

system is one of the other alternatives to produce electricity from the renewable energy.

Besides, the components that are used usually can be obtained and not too complicated.

To overcome weakness of this project, there is a few steps have been set :

i. Do more research about the TEG.

ii. Need the powerful thermoelectric generator (TEG) module.

iii. Provide a large heat sink and fan to overcome the increase the temperature of the

TEG.

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iv. The module is stuck with the high thermal conductivity graphite sheet on its both

sides of the ceramic plates to provide low contact thermal resistance, hence you

do not need to apply thermal grease or other heat transfer compound when you

install the module. The graphite sheet can work well in extremely high

temperature.

v. Use a sophisticated component and invent circuits which are more competitive,

neat and tidy of its arrangement.

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REFERENCE

Books:

1. Seebeck, T. J. (1825) Thermoelectric generator, page 265, "Magnetische

Polarisation der Metalle und Erze durch Temperatur-Differenz" (Magnetic

polarization of metals and minerals by temperature differences), Abhandlungen

der Königlichen Akademie der Wissenschaften zu Berlin (Treatises of the Royal

Academy of Sciences in Berlin), page. 265-373.

2. Seebeck (1826) Thermoelectric generator, (On the magnetic polarization of

metals and minerals by temperature differences), page 1-20, 133-160, 253-286.

Websites:

1. https://en.wikipedia.org/wiki/Thermoelectric_generator#cite_note-1, achieved at

22/07/2015

2. http://esatjournals.org/Volumes/IJRET/2015V04/I03/IJRET20150403050.pdf.

achieved at 22/07/2015

3. http://www.instructables.com/id/Thermoelectric-Generator-Project/ , achieved at

12/08/2015

4. http://www.eleccircuit.com/micro-dc-converter-3v-to-9v-using-tl496/ , achieved

at 10/09/2015