Part 3

Design, Analysis and Fabrication of Thermoelectric Lamp
Content
 Certificate…………………………...……………………………………………………. I
 Acknowledgement…………...……………………………………….…………………. II
 Declaration…………………………………………………………………….….….…. III
 Abstract…………………………………………………...………………………….…. IV
 Table of Content……………………………………….………….….…………………1-2
 List of Figures………………………………………………………..……………………3
 List of Tables……………………………………………………….…….…………….....4
Chapter 1 Introduction……………………………………………………………………… ...5-6
1.1 Project Overview………………………………………………………………...…. 6
Chapter 2 Literature Review …………………………………………………………...…….7-11
2.1 Thermoelectric Effect……………………………………………………….……….8
2.2 Application …………………………………………………………………………..8
2.2.1 Thermoelectric Generator………………………………………………………..8
2.2.2 Peltier Effect…………………..…………………………………………………8
2.2.3 Temperature Measurement……………………………...……………………….8
2.3 TEG Module…………………………………………………………………………9
2.3.1 Construction………………………………………………...……………………9
2.3.2 Thermocouples……………………………………………...………………….9
2.4 Uses of TEG………………………………………………………….……………..10
2.5 Finding Problem……………………………………………………………………10
2.6 Heat Extraction from TEG………………………………………………….………10
2.6.1 Fin Concept…………………………………………………………….……….11
Chapter 3 working principle………………………………………………………………….12-15
Chapter 4 Components of Prototype……...………………………………………………. 16-23
4.1Thermoelectric Generator………………………………………………………..17-18
4.2 Thermal Grease…………………………………………………….……………….19
Department of Mechanical Engg SOET Vikram University Ujjain Page 1

4.3LED Light…………………………………………………………………......…19-20
4.3.1 Basic ……………………………………………………………………………19
4.3.2 Principle Mechanism………………………………………………………...…19
4.3.3 Application……………………………………………………………...………20
4.4 Heat Source …………………………………………………………………...……21
4.4.1 Candle………………………………………………………………….……….21
4.4.2 Sprit Lamp…………………………………………………………..………….21
4.4.3 Kerosene Lamp…………………………………………………………...…….22
4.5 Heat Sink ………………………………………………………………………22-23
Chapter 5 Methodology ……………………………………………………………………...24-28
5.1 Selection of Component……………………………………………………………25
5.1.1TEG………………………………………………….…………………………25
5.1.2Heat Sink……………………………………………...…………………………25
5.1.3 LED Light ………………………………………………………………...……25
5.1.4 Thermal Grease…………………………………………………………………25
5.2 Manufacturing & Fabrication of Prototype…………………………………………26
5.2.1Applying Thermal Paste on TEG…………………………………………..……26
5.2.2Fixing Heat Sink & Al Plate……………………………………………………26.
5.2.3 Attach Al Plate on Plywood…………………………………………………….27
5.2.4 Connect Generator portion to base…………………………………..…………27
5.2.5 Making of thermally insulated chamber……………………………..…………28
Chapter 6 Design and analysis…………………......................................................................29-33
Chapter 8 References……………………………………………………………….……………34

List of Figures
Figure 1.1 Heat Dissipation on Fin………………………………………………………………11
Figure 1.2 Thermo couple………………………………………………………………….…….13
Figure 1.3 Electron Flow in Thermocouple………………………….………………………..…14
Figure 1.4 TE Module……………………………………………………………………………17
Figure 1.5 Dimension of TEG……………………………………………….…………………..18
Figure 1.6 Thermal Grease………………………………………………………...…………….19
Figure 1.7 LED Light…………………………………………………………………...………..20
Figure 1.8 Candle……………………………………………………………………….…….….21
Figure 1.9 Kerosene lamp……………………………………….………………….……………22
Figure 1.10 Heat Sink ……………………………………………………………….…….……..22
Figure 1.11 TEG Module…………………………………………………………….………..…26
Figure 1.12 Drilling Operation………………………………………………….…………….…26
Figure 1.13 Generator Setup………………………………………………….……….…………27
Figure 1.14 Base Portion…………………………………………………………………………27
Figure 1.15 Insulating Chamber…………………………………………………………………28
Figure 1.16 CAD Model…………………………………………………………………………31
Figure1.17 Analysis of Al Plate………………………………………………………………….32

List of Table
Table 1.1 Specification of TEG -12706…………………………………………………………18
Table 1.1 Specification of Thermal Grease………………………………………………..…….19
Table 1.2 Specification of Heat Sink………………………………………………………….....23

Chapter 1
Introduction

Introduction
In today’s environment we are more focused and interested in deploying sustainable and
renewable energy that produce less carbon emission and eco-friendly energy. Energy users are
continuously asking for instruments that can gives us required amount of energy for their
domestic and other uses, at the time when power is unavailable.
Even though the world is fast changing and developing there are still many villages and far flung
areas where electricity is not reached and still a demand. We know that developing countries like
INDIA there was always shortage of electricity especially in rural areas and some of the remote
areas got only 10 hours of electricity in a day. Our target audience is student and workers who
are still compulsive to work in dim light of candle.
We are believing to design a thermoelectric generator that can use heat energy produce by
household things like candle that produce thermal energy. The major advantage of this generator
is that the electricity produced is clean, safe and user friendly.
Our project is take power from a paraffin candle that provide heat to the thermoelectric
generator. The working of a thermoelectric generator is based on Seebeck effect which converts
thermal energy directly into electrical energy.
A thermoelectric generator is made of P and N junctions of semiconductor material like bismuth

telluride. When P and N junctions maintained at some temperature difference the electrons are
flows through N junctions to P junctions and create voltage difference. For removing heat from
the cold side is done by heat sink. Usually heat sink is made by Aluminum and a fan is attached
for high efficient performance of heat sink that increase the efficiency of the system. The
electricity produce by thermoelectric generators is use to illuminate LED light. Where our
purpose of generating electricity is fulfil. The change is what study in a deem candle is far better
than an LED. A village who deep in the darkness now can enlighten by LED and shape their
future.
From twentieth century we are using electrochemical cells for illuminating torches. Batteries are
not a reliable option always because they have small life and high manufacturing costs. Also,
batteries are not totally recyclable so the increase hazardous waste that pollute environment and
cause of many disease in humans if they are reach to our food resources. If we compare a typical
thermoelectric generator to a battery a TEG have life about 10 years and it is very long as
compare to batteries. The thermoelectric generate are made from semiconductor metal which is
also recyclable so if we compare both than TEGs are far better than batteries.

Chapter 2
Literature Survey

Literature survey
2.1 Thermoelectric effect
The thermoelectric effect is the direct conversion of temperature differences to electric voltage
and vice versa via a thermocouple [1]. A thermoelectric device creates voltage when there is a
different temperature on each side. Conversely, when a voltage is applied to it, it creates a
temperature difference. At the atomic scale, an applied temperature gradient causes charge
carrier in the material to diffuse from the hot side to the cold side. This effect can be used to
generate electricity, measure temperature or change the temperature of objects. Because the
direction of heating and cooling is determined by the polarity of the applied voltage,
thermoelectric devices can be used as temperature controllers. The term "thermoelectric effect"
encompasses three separately identified effects: the Seebeck effect, Peltier effect, and Thomson
effect.
2.2 Application
2.2.1 Thermoelectric generators
The Seebeck effect is used in thermoelectric generators, which function like heat engines, but are
less bulky, have no moving parts, and are typically more expensive and less efficient. They have
a use in power plants for converting waste heat into additional electrical power (a form of energy
recycling) and in automobiles as automotive thermoelectric generators (ATGs) for increasing
fuel efficiency. Space probes often use radioisotope thermoelectric generators with the same
mechanism but using radioisotopes to generate the required heat difference. Recent uses include
stove fans, [2] body-heat—powered lighting [3] and a smartwatch powered by body heat. [4]
2.2.2 Peltier effect
The Peltier effect can be used to create a refrigerator that is compact and has no circulating fluid
or moving parts. Such refrigerators are useful in applications where their advantages outweigh
the disadvantage of their very low efficiency. The Peltier effect is also used by many thermal
cyclers, laboratory devices used to amplify DNA by the polymerase chain reaction (PCR). PCR
requires the cyclic heating and cooling of samples to specified temperatures. The inclusion of
many thermocouples in a small space enables many samples to be amplified in parallel.
2.2.3 Temperature measurement
Thermocouples and thermopiles are devices that use the Seebeck effect to measure the
temperature difference between two objects. Thermocouples are often used to measure high
temperatures, holding the temperature of one junction constant or measuring it independently
(cold junction compensation). Thermopiles use many thermocouples electrically connected in

series, for sensitive measurements of very small temperature difference.
2.3 TEG modules
Thermoelectric generators could be used in power plants in order to convert waste heat into
additional electrical power and in automobiles as automotive thermoelectric generators (ATGs)
to increase fuel efficiency. Another application is radioisotope thermoelectric generators which
are used in space probes, which has the same mechanism but use radioisotopes to generate the
required heat difference5
2.3.1 Construction
Thermoelectric power generators consist of three major components: thermoelectric materials,

thermoelectric modules and thermoelectric systems that interface with the heat source 6
Thermoelectric materials Thermoelectric materials generate power directly from heat by

converting temperature differences into electric voltage. These materials must have both high
electrical conductivity (σ) and low thermal conductivity (κ) to be good thermoelectric materials.
Having low thermal conductivity ensures that when one side is made hot, the other side stays
cold, which helps to generate a large voltage while in a temperature gradient. The measure of the
magnitude of electrons flow in response to a temperature difference across that material is given
by the Seebeck coefficient (S). The efficiency of a given material to produce a thermoelectric
power is governed by its “figure of merit” zT = S2σT/κ.
For many years, the main three semiconductors known to have both low thermal conductivity
and high-power factor were bismuth telluride (Bi2Te3), lead telluride (PbTe), and silicon
germanium (SiGe). These materials have very rare elements which make them very expensive
compounds.
2.3.2 Thermoelectric module
A thermoelectric module is a circuit containing thermoelectric materials which generates

electricity from heat directly. A thermoelectric module consists of two dissimilar thermoelectric
materials joined at their ends: an n-type (negatively charged); and a p-type (positively charged)
semiconductors. A direct electric current will flow in the circuit when there is a temperature
difference between the two materials. Generally, the current magnitude is directly proportional to
the temperature difference
2.4 Uses
1 Common application is the use of thermoelectric generators on gas pipelines. For example,
for cathodic protection, radio communication, and other telemetry.

2 Thermoelectric Generators are primarily used as remote and off-grid power generators for
unmanned sites. They are the most reliable power generator in such situations as they do not
have moving parts (thus virtually maintenance free), work day and night, perform under all
weather conditions, and can work without battery backup. Although Solar Photovoltaic
systems are also implemented in remote sites, Solar PV may not be a suitable solution where
solar radiation is low, i.e. areas at higher latitudes with snow or no sunshine, areas with lots
of cloud or tree canopy cover, dusty deserts, forests, etc.
3 Geotherm Global Power Technologies (GPT) formerly known as Global Thermoelectric
(Canada) has Hybrid Solar-TEG solutions where the Thermoelectric Generator backs up the
Solar-PV, such that if the Solar panel is down and the backup battery backup goes into deep
discharge then a sensor starts the TEG as a backup power source until the Solar is up again.
4 Many space probes, including the Mars Curiosity rover, generate electricity using a
radioisotope thermoelectric generator whose heat source is a radioactive element
5 Cars and other automobiles produce waste heat (in the exhaust and in the cooling agents).
Harvesting that heat energy, using a thermoelectric generator, can increase the fuel efficiency
of the car.
2.5 Finding problem
Providing clean light at unmanned and rural places where electricity grid is not available
Is very tough task because you are fully relay on batteries and we all know that batteries are not
safe reliable and longtime source. Solar PV cells are also a good option but they have constraints
like sunlight and temperature. They are no working under all working conditions and night. Also
lighting in the mines and snow areas is equally important and tough.
Students and workers life without light is nothing and in rural areas continuous supply of
electricity is not available.
A small light weight and compact lamp is required to fulfil their requirement and that uses house
hold easily available heat source Like candle kerosene lamp.
A candle or lamp is not sufficient to bright a room with clean light but an 12V LED do it better.
It is better for student and worker.
2.6 Heat extraction from TEG
TEG is working under temperature gradient. At one side heat is supply and other side heat can be
removed to operate TEG well. For removing heat from TEG surface a fin is appointed.
2.6.1 Fin – finned surfaces are manufactured by extruding, welding or wrapping a thin metal
sheet on a surface. Fines enhance heat transfer from a surface by exposing a larger surface area
to convection.

conservation of energy can be used to create an energy balance for a differential cross section of
the fin.
Figure 1.1 Heat Dissipation on Fin
for increase the rate of heat removal forced convection is applied. For this purpose, a fan is
mounted on the top of the fin and blow hot surrounding air from the fin. The heat transfer
coefficient is also increase for fin surface that increase the heat removal rate very effectively.

Chapter 3
Working Principle

Working Principle
Seebeck Effect: In 1821 Thomas Seebeck, a German physicist discovered that when two
dissimilar metal (Seebeck used copper and bismuth) wires are joined at two ends to form a loop;
a voltage is developed in the circuit if the two junctions are kept at different temperatures. The
pair of metals forming the circuit is called a thermocouple. The effect is due to conversion of
thermal energy to electrical energy.
Figure1.2 Thermo couple
The open circuit potential difference in the circuit whose junctions are maintained at
temperatures Th and Tc (< Th) is given by
∆V = SAB (Th - Tc)
Where the coefficient of proportionality is known as the thermoelectric power or the Seebeck
coefficient. The term thermoelectric power is a misnomer because it does not measure any power
and is measured in volt/ K. By convention, Seebeck coefficient's sign is the sign of the potential
of the cold end with respect to the hot end. Thus if SAB is positive, conventional current flows
from A to B at the hot junction. Seebeck coefficient is not a constant but is dependent on

temperature. The temperature dependence of a commercial thermocouple is usually expressed as

a polynomial expansion in powers of temperature T.
A complete understanding of Seebeck effect requires knowledge of behaviour of electron in a

metal which is rather complicated. The Seebeck coefficient depends on factors like work
functions of the two metals, electron densities of the two components, scattering mechanism
within each solid etc. However, a simple-minded picture is as follows. Seebeck effect is a
manifestation of the fact that if two points in a conductor (or a semiconductor) are maintained at
different temperatures, the charged carriers (electrons or holes) in the hotter region, being more
energetic (and, therefore, having higher velocities) will diffuse towards region of lower
temperature. The diffusion stops when the electric field generated because of movement of
charges has established a strong enough field to stop further movement of charges. For a metal,
carriers being negatively charged electrons, the colder end would become negative so that
Seebeck coefficient is negative. For a p-type semiconductor on the other hand, holes diffuse
towards the lower temperature resulting in a positive Seebeck coefficient. Performance of a
thermocouple is determined by the Seebeck coefficient of the pair of metals forming the
thermocouple. As it is impracticable to list the coefficient of all possible pairs, the Seebeck
coefficients of metals are usually given with respect to Platinum as standard whose Seebeck
coefficient is taken as zero. The following table gives the Seebeck coefficient (in mV/K) of some
standard thermocouple material at 0 0C.
Thomson Effect William Thomson (later well known as Lord Kelvin) discovered a third
thermoelectric effect which provides a link between Seebeck effect and Peltier effect. Thomson
found that when a current is passed through an wire of single homogeneous material along which
a temperature gradient exists, heat must be exchanged with the surrounding in order that the
original temperature gradient may be maintained along the wire. (The exchange of heat is
required at all places of the circuit where a temperature gradient exists.) Thomson effect may be
understood by a simple picture. A conductor has free charge carriers, which are, electrons in
metals, electrons and holes in semiconductors and ions in case of ionic conductors. Consider a
section of such a conductor whose one end is hotter than the other end. Charge carriers at the hot
end, being more energetic, will diffuse towards the colder end. The charge separation sets up an
electric field E→ . Diffusion of carriers would stop when the attractive force on the carriers due to
this field E→ is strong enough to retard the motion of the carriers due to thermal effect.

Figure 1.3
Electron Flow in Thermocouple
We can represent the effect of the thermal gradient responsible for the diffusive motion of the
carriers by an effective field E→ . This effective field is proportional to the thermal gradient and
can be written as
Where ⱷ is known as the Thomson coefficient for the material of the conductor. The Thomson
electromotive force is given by
Where T1 and T2 are the temperatures at the two ends of the rod.

Chapter 4
Component of Prototype

4.1Thermo electrical generator
Thermoelectric generators are all solid-state devices that convert heat into electricity.
Unlike traditional dynamic heat engines, thermoelectric generators contain no moving parts and
are completely silent. Such generators have been used reliably for over 30 years of maintenance-
free operation in deep space probes such as the Voyager missions of NASA Compared to large,
traditional heat engines, 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 home co-generation of heat and electricity. Thermo electrics have even been miniaturized
to harvest body heat for powering a wristwatch.
Working of a TEG The thermoelectric effect is the direct conversion of temperature differences
to electric voltage and vice-versa. A thermoelectric device creates voltage when there is a
different temperature on each side. Conversely, when a voltage is applied to it, it creates a
temperature difference. At the atomic scale, an applied temperature gradient causes charge
carriers in the material to diffuse from the hot side to the cold side. This effect can be used to
generate electricity, measure temperature or change the temperature of objects. Because the
direction of heating and cooling is determined by the polarity of the applied voltage,
thermoelectric devices can be used as temperature controllers. The term "thermoelectric effect"
encompasses three separately identified effects: the Seebeck effect, Peltier effect, and Thomson
effect. Textbooks may refer to it as the Peltier–Seebeck effect.

Figure1.4 TE Module
Specification of TEG -12706
Model No. - TEC1-12706
Hot side temperature DTmax(ºC) 70 79
Umax(Voltage) 16.0 17.2

Imax (amps) 6.1 6.1
Tolerance (%) ± 10 For thermal and electricity parameters
Figure1.5 Dimension of TEG

4.2Thermal Grease
Thermal grease, also called thermal paste or thermal compound, is a substance used to promote
better heat conduction between two surfaces and is commonly used between
a microprocessor and a heat sink. The air gaps are filled by applying a thin layer of thermal
grease to the top of the microprocessor and the base of the heat sink There are two types of
thermal grease: non-conductive and conductive. The non-conductive thermal grease types
include silicone and zinc thermal greases. The conductive types include silver, copper, and
aluminum-based greases.
Figure1.6 Thermal Grease
Type Non-curing compound
Capacity 0,5 g
Specific Gravity (g/cm³) ~ 2.5
Thermal Conductivity (W/m °K) 4
Thermal Resistance (°C/W) 0.265
Electrical Conductivity No

Temperature range -50°C bis +150°C
4.3LED Light
A Light-Emitting Diode in essence is a P-N junction solid-state semiconductor diode that emits
light when a current is applied though the device. By scientific definition, it is a solid-state
device that controls current without the deficiency of having heated filaments. Furthermore, a
light-emitting diode does not have any moving parts, which makes the device extremely resistant
to damage due to vibration and shocks. These characteristics make it ideal for purposes that
demand reliability and strength. LEDs therefore can be deemed invulnerable to catastrophic
failure when operated within design parameters.
Figure shows a typical traditional indicator LED. Traditional indicator LEDs utilize a small LED
semiconductor chip that is mounted on a reflector cup also known as the anvil, on a lead-frame
(whisker). This whole configuration is encased in epoxy which also serves the purpose of a lens.
LEDs have very high thermal resistance with upwards of 200K per Watt.
LEDs are highly monochromatic, only emitting a single pure color in a narrow frequency range.
The color emitted from an LED is identified by peak wavelength which is measured in
nanometers (nm). The peak wavelength is a function of the material that is used in the
manufacturing of the semiconductor. Most LEDs are produced using gallium-based crystals that
differ in one or more additional materials such as phosphorous to produce distinct colors.
Different LED chip technologies enable manufacturers to produce LEDs that emit light in a
specific region of the visible light spectrum and replicate different intensity levels. Thus, one
would vary the material used in the production of LEDs in order to obtain the desired results.
The graph below depicts the variation in response time for the specific wavelength of light.
Figure1.7 LED Light
Principle & Mechanism

The essential portion of the Light Emitting Diode is the semiconductor chip. Semiconductors can
be either intrinsic or extrinsic. Intrinsic semiconductors are those in which the electrical behavior
is based on the electronic structure inherent to the pure material.
Application
There are various materials that are used in the manufacturing of Light Emitting Diodes. Most of
the materials are gallium-based crystals and are used in high-brightness applications. Gallium is
a minor metal noted by its low melting point of 29.8 °C, the name being derived from Gallia, the
Latin for France, which was where it was discovered. Among these include AlGaAs (Aluminum-
Gallium-Arsenide), a semiconductor that typically generates the red spectrum, often used in
signs, displays and electronic equipment
Light Emitting Diodes are the cutting-edge technology of lighting today. Generally,
Light Emitting Diodes are categorized according to their performance. The performance of a
LED is linked to a few primary characteristics of the LED itself which includes color, peak
wavelength and intensity. As LEDs are highly monochromatic, LEDs are differentiated
according to their peak wavelength. Peak wavelength is a function of the LED chip material.
4.4 Heat source
In nature heat is available in many forms. our purpose is to utilized household heat source to
generate electricity green and clean way. For this purpose, we have any thinks like candle, spirit
kerosene lamp vegetable oil etc. generally a house hold heat source is generate small amount of
heat, they are light in weight, compact and reliable. Below we elaborate some source that are our
target to use in the project for heating purpose.
4.4.1 candle
A candle is an ignitable wick embedded in wax or another flammable solid substance such as
tallow that provides light, and in some cases, a fragrance. It can also be used to provide heat or
used as a method of keeping time.

Figure 1.8 Candle
4.4.2Spirit lamp
An alcohol burner or spirit lamp is a piece of laboratory equipment used to produce an open
flame. It can be made from brass, glass, stainless steel or aluminum.
4.4.3Kerosene lamp
A kerosene lamp (also known as a paraffin lamp in some countries) is a type of lighting device
that uses kerosene (paraffin) as a fuel. they are useful for lighting without electricity, such as in
regions without rural electrification, in electrified areas during power outages, at campsites, and
on boats.
Figure1.9 Kerosene lamp
4.5 Heat sink
For maintaining temperature difference, it is required to remove heat from other side. For this
purpose, we use heat sink with fan.

Figure 1.10 Heat Sink
Specification of Heat Sink
Heat sink : 85.4x85.4x41.5mm
Fan Size 1. : 70 x70mm
Bearing Type 1. : Rifle bearing
Rated Voltage 1. : DC 12V
Speed 3300 RPM±10%

Chapter 5
Methodology

Methodology
Steps is followed by group for construction of prototype.
5.1 selection of component
5.1.1 Selection of TEG
Selection of TEG is on the basis of the following criteria:
 Operating temperature
 Output voltage
 Size and area of TEG
 Semiconductor material
 Response time to produce current.
5.1.2 Heat sink
 High thermal conductivity material

 Maximum heat transfer condition
 Proper dimension to employ on TEG
5.1.3 LED light
 Maximum luminosity
 Minimum power consumption
 Light and compact design.
5.1.4 Thermal grease
 Better thermal conductivity and properties

 Working temperature should be high

 Good electrical conductivity

5.2 Manufacturing and fabrication of prototype.
5.2.1 Applying thermal past on TEG
Thermal paste is used to increase heat transfer of any surface. We are required to transfer
heat from one side of TEG very efficiently so we are applying a thick plate of thermal grease
before heating. Also, thermal grease prevents overheating of TEG. Thermal grease is applied on
the surface of TEG heat sink and aluminum plate for better heat conduction.
Figure1.11 TEG Module
5.2.2 Fixing Heat sink and aluminum plate
After applying thermal grease hot side of TEG is connect to aluminum plate and cold side
is connect to heat sink. For connecting both heat sink and aluminum plate with TEG we drill four
holes and screw up them.

Figure 1.12 Drilling Operation
5.2.3 Attach aluminum plate on plywood
In working condition aluminum plate get very hot and it is very risky so, we attach
plywood on aluminum plate. For attaching plate on plywood, a slot is make with the help of hack
saw.
Figure 1.13 Generator Setup
5.2.4 Connect Generator portion to base
After assembly of TEG on aluminum plate and heat sink to insulating plywood this
portion is attached to base by four spoke in rectangular formation. For attaching spoke we drill
holes in plywood and hinged spokes with the help of bolt.

Figure1.14 Base Portion
5.2.5 Making of thermally insulated chamber
For minimize heat loss we cover heat source to a thermally insulated chamber. This
chamber is made of aluminum foil that is supported by steel net. We also provide some
ventilation space for supply of oxygen to continuation of burning.
Figure1.15 Insulating Chamber

Chapter 6
Design & Analysis

Design and Analysis

In designing of CAD model of the prototype we use PTC CREO 2.0 software. Preparing CAD
models are the best way to convert your imagination to reality. Its best part is your think in your
way is display on screen and other people can know and improve the design easily. Also
understanding CAD models are not purely technical so even a common man who doesn’t know
related thing get knows what is going on.
Analysis is one of the most important part of developing a prototype. Preparing models in
physical and arranging setup for practical is time consuming, costly and laborious work. Now
days technology is changing very fast use of computer analysis is saving of time, resources and
money.
About PTC CREO 2.0
Creo is a family or suite of Computer-aided design (CAD) apps supporting product

design for discrete manufacturers and is developed by PTC. The suite consists of apps, each
delivering a distinct set of capabilities for a user role within product development. Creo runs
on Microsoft Windows and provides apps for 3D CAD parametric feature solid modeling, 3D
direct modeling, 2D orthographic views, Finite Element Analysis and simulation, schematic
design, technical illustrations, and viewing and visualization.

6.1 CAD model of prototype

A CAD model is prepare on CREO Parametric software that illustrate all part of the
model is shoeing below.

Figure 1.16 CAD Model
6.2 Analysis of Aluminum Plate

An aluminum plate is place between TEG and heat source. The source is a candle or a lamp with
a single flame so the distribution of temperature on the plate is very important factor because
Thermoelectric generators are purely working on the basis of temperature of their surface and if
proper temperature is not gain the current is not flow. By observation we measure temperature of
plate at flame side is developed up to 1200 C. now with the help of computer analysis program
CREO simulate we get temperature distribution across the plate.
Figure 1.17 Analysis of Al Plate

6.3 Analysis of Heating Chamber

Below analysis is show the temperature distribution and heat flux distribution of the
chamber.

 References
1.http://ffdenphys.uaf.edu/212_spring2007.web.dir/sedona_price/
phys_212_webproj_peltier.html
2.https://stovefanreviews.com/teg-module-and-Seebeck-effect/
3 http://www.gizmag.com/lumen-flashlight/39893/
4 https://www.technologyreview.com/s/602874/body-heat-powers-this-smart-watch
5 Adroja, Mr. Nikunj; Mehta, Prof Shruti; Shah, Mr. Pratik (2015-03-01). "Review of
thermoelectricity to improve energy quality". 2 - Issue 3 (March-2015). JETIR.
6 How Thermoelectric Generators Work - Alphabet Energy". Alphabet Energy. Retrieved

2015-10-28.
7 Lienhard, John H. IV; Lienhard, John H. V (2011). A Heat Transfer Textbook (4th ed.).
Cambridge, MA: Phlogiston Press. ISBN 9780486479316.

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Design, Analysis and Fabrication of Thermoelectric Lamp

1.1 Project Overview………………………………………………………………...…. 6

Chapter 2 Literature Review …………………………………………………………...…….7-11

2.1 Thermoelectric Effect……………………………………………………….……….8

2.2 Application …………………………………………………………………………..8

2.2.1 Thermoelectric Generator………………………………………………………..8

2.2.2 Peltier Effect…………………..…………………………………………………8

2.2.3 Temperature Measurement……………………………...……………………….8

2.3 TEG Module…………………………………………………………………………9

2.4 Uses of TEG………………………………………………………….……………..10

2.5 Finding Problem……………………………………………………………………10

2.6 Heat Extraction from TEG………………………………………………….………10

2.6.1 Fin Concept…………………………………………………………….……….11

Chapter 3 working principle………………………………………………………………….12-15

Chapter 4 Components of Prototype……...………………………………………………. 16-23

4.2 Thermal Grease…………………………………………………….……………….19

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4.3.1 Basic ……………………………………………………………………………19

4.3.2 Principle Mechanism………………………………………………………...…19

4.4 Heat Source …………………………………………………………………...……21

4.4.2 Sprit Lamp…………………………………………………………..………….21

4.4.3 Kerosene Lamp…………………………………………………………...…….22

4.5 Heat Sink ………………………………………………………………………22-23

Chapter 5 Methodology ……………………………………………………………………...24-28

5.1 Selection of Component……………………………………………………………25

5.1.3 LED Light ………………………………………………………………...……25

5.1.4 Thermal Grease…………………………………………………………………25

5.2 Manufacturing & Fabrication of Prototype…………………………………………26

5.2.1Applying Thermal Paste on TEG…………………………………………..……26

5.2.2Fixing Heat Sink & Al Plate……………………………………………………26.

5.2.3 Attach Al Plate on Plywood…………………………………………………….27

5.2.4 Connect Generator portion to base…………………………………..…………27

5.2.5 Making of thermally insulated chamber……………………………..…………28

Chapter 6 Design and analysis…………………......................................................................29-33

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Figure 1.1 Heat Dissipation on Fin………………………………………………………………11

Figure 1.2 Thermo couple………………………………………………………………….…….13

Figure 1.3 Electron Flow in Thermocouple………………………….………………………..…14

Figure 1.4 TE Module……………………………………………………………………………17

Figure 1.5 Dimension of TEG……………………………………………….…………………..18

Figure 1.6 Thermal Grease………………………………………………………...…………….19

Figure 1.7 LED Light…………………………………………………………………...………..20

Figure 1.8 Candle……………………………………………………………………….…….….21

Figure 1.9 Kerosene lamp……………………………………….………………….……………22

Figure 1.10 Heat Sink ……………………………………………………………….…….……..22

Figure 1.11 TEG Module…………………………………………………………….………..…26

Figure 1.12 Drilling Operation………………………………………………….…………….…26

Figure 1.13 Generator Setup………………………………………………….……….…………27

Figure 1.14 Base Portion…………………………………………………………………………27

Figure 1.15 Insulating Chamber…………………………………………………………………28

Figure 1.16 CAD Model…………………………………………………………………………31

Figure1.17 Analysis of Al Plate………………………………………………………………….32

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Table 1.1 Specification of Thermal Grease………………………………………………..…….19

Table 1.2 Specification of Heat Sink………………………………………………………….....23

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A thermoelectric generator is made of P and N junctions of semiconductor material like bismuth

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2.2.1 Thermoelectric generators

2.2.2 Peltier effect

2.2.3 Temperature measurement