COOLING JACKET USING PELTIER

SENSOR
B.E (Electrical), Batch 2016-17
Final Year Project Report
Prepared By:

Ariba Yousuf EE-16145

Syeda Hina Fasahat EE-16147

Mahum Abdali EE-16150

Saad Shakil EE-16224

INTERNAL ADVISOR EXTERNAL ADVISOR

Adnan Ali Fatima Saleem
Assistant Professor Lecturer
NEDUET NEDUET

DEPARTMENT OF ELECTRICAL ENGINEERING

N.E.D UNIVERSITY OF ENGINEERING & TECHNOLOGY
KARACHI-75270
 ABSTRACT

The project outlines the implementation of Photo-Voltaic Wearable Cooling

Jacket using Peltier Sensor. Due to Climate change, overall temperature of the world
has been increased which has started the workforce to affect from its serious
complications. Heat Stroke[1], Heat Rash and Heat Syncope are the major examples
of it and bike rider and user of two-wheel automobiles are more exposed to it. In order
to overcome this problem, we decided to come up with an idea of cooling jacket that
will provide cooling effect to bike riders in the scorching beam of the sun. The basic
model which was developed and presented in the mid evaluation has been design in
such a way that it will lower the temperature up to 32 degree Celsius through current
controlled circuit in conjunction with the temperature sensor. The backbone of the
model is Peltier module, which is a thermoelectric cooler, a source of providing
cooling to the coolant (water). The report also includes the designing of jacket material
and flexible solar film designing. Lastly, through the MATLAB simulation of Peltier
Module, performance of thermoelectric Cooler (Peltier Sensor) has been determined
and evaluated whose results have been shared in the report.

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 TABLE OF CONTENTS

ABSTRACT ................................................................................................................. ii
LIST OF FIGURES ..................................................................................................... v
LIST OF TABLES ...................................................................................................... vi
ACKNOWLEDGEMENT ......................................................................................... vii
CHAPTER 1 ................................................................................................................ 1
INTRODUCTION ....................................................................................................... 1
BRIEF INTRODUCTION ....................................................................................... 1
1.1 PROBLEM STATEMENT ................................................................................ 2
1.2 OBJECTIVES .................................................................................................... 2
1.3 SCOPE OF THE WORK ................................................................................... 2
1.4 SIGNIFICANCE OF THE RESEARCH ........................................................... 3
CHAPTER 2 ................................................................................................................ 5
LITERATURE REVIEW ............................................................................................ 5
2.1 HARDWARE ANALYSIS ............................................................................... 6
2.1.1 VEST WITH RECHARGING ICE PACKS ............................................... 6
2.1.2.EVAPORATIVE COOLING VEST ........................................................... 6
2.1.3 GEL COOLING VEST ............................................................................... 7
2.1.4.TEMPERATURE SENSOR JACKET ........................................................ 8
2.1.5.AIR COOLING JACKET............................................................................ 8
2.2 SOFTWARE ANALYSIS .............................................................................. 9
2.2.1.KRYOTHERM SOFTWARE ..................................................................... 9
2.2.2 TEC-CALCULATOR ............................................................................... 12
CHAPTER 3 .............................................................................................................. 14
METHODOLOGY .................................................................................................... 14
3.1. PROPOSED WORK ................................................................................... 14
3.1.1. PELTIER MODULE ........................................................................... 15
3.1.2 WATER PUMP .................................................................................... 16
3.1.3 HEAT SINK ......................................................................................... 17
3.1.4. TEMPERATURE SENSOR ................................................................ 21
3.1.5. MICROCONTROLLER ...................................................................... 23
3.1.6. COOLANT .......................................................................................... 23
3.1.7 DIFFERENT FABRICS USED FOR COOLING JACKET ............... 24

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 3.1.8 DESIGN OF JACKET .............................................................................. 28
3.1.9 SOLAR MODULE (DESIGNING OF SOLAR FILM) ........................... 30
STEP 01: LOAD ANALYSIS ............................................................................ 30
STEP 02: SOLAR PANEL SIZING…………………………………………………...31

STEP 03: SOLAR PANEL SIZING ................................................................... 31

3.2 WORKING....................................................................................................... 33
3.2.1 HARDWARE ...................................................................................... 33
3.2.2 SOFTWARE ......................................................................................... 34
3.3. OBSERVATION ......................................................................................... 37
3.3.1 HARDWARE ...................................................................................... 37
3.3.2 SOFT WARE ....................................................................................... 38
CHAPTER 4 .............................................................................................................. 41
RESULTS .................................................................................................................. 41
CHAPTER 5 .............................................................................................................. 44
FUTURE RECOMMENDATIONS AND CONCLUSION ...................................... 44
5.1 FUTURE RECOMMENDATIONS ................................................................. 44
5.2 CONCLUSION ................................................................................................ 45
REFERENCES .......................................................................................................... 46
APPENDIX ................................................................................................................ 48

iv
 LIST OF FIGURES

FIGURE 1.1 KARACHI HEAT INDEX ........................................................................................................04

FIGURE 2.1 VEST WITH RECHARGING ICE PACKS ..................................................................................06
FIGURE 2.2 EVAPORATING COOLING VEST ............................................................................................07
FIGURE 2.3 GEL COOLING VEST .............................................................................................................07
FIGURE 2.4 TEMPERATURE SENSOR JACKET ...........................................................................................08
FIGURE 2.5 AIR COOLING JACKET ...........................................................................................................09
FIGURE 2.6 PERFORMANCE OF GRAPH ...................................................................................................10
FIGURE 2.7 CHOICE OF MODULE ...........................................................................................................11
FIGURE 2.8 THERMOELECTRIC SYSTEM.................................................................................................11
FIGURE 2.9TEC-CALCULATOR ..............................................................................................................13
FIGURE 3.1 BLOCK DIAGRAM ...............................................................................................................14
FIGURE 3.2 TEC-12708 MODULE ...........................................................................................................15
FIGURE 3.3 TEC-12706 MODULE ...........................................................................................................15
FIGURE 3.4 SUCKING PUMP ...................................................................................................................16
FIGURE 3.5 SUCKING PUMP ...................................................................................................................16
FIGURE 3.6 ACTIVE HEAT SINK .............................................................................................................17
FIGURE 3.7 PASSIVE HEAT SINK ............................................................................................................18
FIGURE 3.8 COPPER HEAT SINK .............................................................................................................18
FIGURE 3.9 ALUMINUM HEAT SINK .......................................................................................................19
FIGURE 3.10 STAMPED HEAT SINK ........................................................................................................19
FIGURE 3.11 EXTRUDED HEAT SINK ......................................................................................................20
FIGURE 3.12 FORGED HEAT SINK ..........................................................................................................20
FIGURE 3.13 CNC MACHINED HEAT SINK .............................................................................................. 21
FIGURE 3.14 LM35 TEMPERATURE SENSOR ...........................................................................................22
FIGURE 3.15 DHT11 TEMPERATURE SENSOR .........................................................................................22
FIGURE 3.16 UNO MICROCONTROLLER..................................................................................................23
FIGURE 3.17 COTTON CANVAS FABRIC .................................................................................................25
FIGURE 3.18 COTTON DUCK FABRIC .....................................................................................................25
FIGURE 3.19QUILED FABRIC ..................................................................................................................26
FIGURE 3.20 NYLON FABRIC..................................................................................................................26
FIGURE 3.21 SHERPA FABRIC.................................................................................................................27
FIGURE 3.22 POLYESTER FABRIC ........................................................................................................28
FIGURE 3.23 INNER SIDE OF JACKET .....................................................................................................28
FIGURE 3.24 BACK INNER SIDE OF JACKET ...........................................................................................29
FIGURE 3.25 OUTER SIDE OF JACKET ....................................................................................................30
FIGURE 3.26 MODEL .............................................................................................................................. 35
FIGURE 3.27GRAPH 1.............................................................................................................................38
FIGURE 3.28GRAPH 2.............................................................................................................................39
FIGURE 3.29GRAPH 3.............................................................................................................................40

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 LIST OF TABLES

TABLE3.1 LM35 TEMPERATURE SENSOR SPECIFICATIONS ................................................................ 21

TABLE3.2 DHT11 SPECIFICATIONS ....................................................................................................22
TABLE 3.3 LOAD ANALYSIS .................................................................................................................30
TABLE 3.4 SOLAR PANEL................................................................................................................32

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 ACKNOWLEDGEMENT

We are really grateful to ALMIGHTY ALLAH, Who has enabled us to

proceed through our final year project & report. We would like to thank Mr. Adnan
Ali, for his timely supervision, much interest & encouragement at each phase of our
project

We express our valuation to Miss Fatima Saleem for giving us such an

interesting project. We are very much thankful to Dr Umbrin Sultana and Miss
Ayesha Khan. We are highly obliged for their continuous kindness & cooperation and
for helping us out in the problems we faced during the project.

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 CHAPTER 1

INTRODUCTION

BRIEF INTRODUCTION

Global warming has made the world menace due to its rising temperature and
has a very adverse impact in human life's, plants and animals. As a consequence of
increase in temperature, the glaciers are melting; floods are increasing, land sinking
and erosion of coastal areas of the world. In the recent years, South Asian countries
like Pakistan, India and Bangladesh have witnessed a severe increase in temperature.
Karachi, the largest city and the business hub of the country have witnessed a death
roll of almost 2000 precious lives in the mid-year of 2015. According to World Bank
report, 800 million lives are at stake due to constant rise in temperature. Thus, due to
these major issues arise to our health i.e. hypothermia, heat stroke and heat rashes.
People become victim of these extreme temperatures and some of the people died due
to this.

Pedestrians and Bike riders are most vulnerable to temperature rise as they are
more exposed to it. In order to provide comfort to them, a number of jackets models
have been developed previously, which includes a decision-making protective jacket
built in with temperature sensors[2] which senses the temperature and provides
information about temperature only, another model which consist of two fans that
regulates the temperature using the atmospheric air. A serious disadvantage with this
model is the blocking of air due to air tightening and thus it couldn’t work for long
period. The proposed jacket model works on Peltier phenomenon [3]by using Peltier
Sensor along with the water block and water pump in which the fluid (water) works as
a coolant which passes through colder side of the Peltier sensor using water pump
which cooled the water and these pipes are circulated around the inner portion of the
back side of the jacket. Heat exchanger is also placed for draining of hot air into the
atmosphere. The main component of the model Peltier Sensor is a thermo-electric
device that operates and gives off heating and cooling effect when electric current
penetrates between two conductors. As the voltage is applied between the two ends, it
produces difference in voltage and heat flows due to temperature difference which is
defined by Peltier effect[4].

1.1 PROBLEM STATEMENT

• To overcome the heat stroke issue by formulating a cooling jacket for the bike riders
particularly for the summer season.
• To perform simulation of the proposed model using MATLAB Software and
analyzing its results.

1.2 OBJECTIVES

• To develop a jacket, this will act as a coolant for motorcyclist.

• To ensure the temperature to remain same at each and every part of the jacket so that
it wouldn’t affect body tissues and other enzymes of the body.
• Selection and designing of jacket material.
• Sizing and selection of the Solar films for the proposed model. (Mathematically)
• To perform Simulation of the proposed model using MATLAB software and
analyzing results which are mentioned below
1) COP versus Input Current,
2) Qc versus Input Current
3) Input Current versus temperature difference.

1.3 SCOPE OF THE WORK

Conclusively, the prototype has been designed for the bike riders who spend
most of their time in the scorching beam of the sun and are directly exposed to sun in
hot weather conditions which has serious effect on their health. Furthermore, it can
also be expanded to pedestrians and people who works in high temperatures places
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like Boiler, furnace etc. with some modification in the system. However, scope of the
project is highly dependent upon the improvement in the equipment’s technology that
is used in the prototype.

1.4 SIGNIFICANCE OF THE RESEARCH

One of the major benefits of this prototype is to protect people from heat stroke.
It is a state where the cooling mechanism of body is suppressed by heat at above 40
degree Celsius in adults which is accompanied by mental state changes and causing
failure of body’s cooling mechanism when exposed to heat. Some of the complications
that arise due to heat stroke are mentioned below.

1) Damage to internal organs

2) Seizures
3) Coma
4) Severe injury and fatal.

Another possible benefit is to reduce the chances of heat cramps as because

heat cramp causes loss of excessive amount of salt. This dearth in salts leads to loss
of essentials minerals from the body. People with heart, lung and kidney problems are
more affected due to heat cramps if they are frequent bike riders or pedestrians.

Heat rashes is also noticed among the people in summer season as their skin
get burn and their skin are not been able to sweat properly which causes itching in the
skin.

3
 karachi heat index
normal temperature max temperature heat index

70
60
temperature oC

50
40
30
20
10
0
17 18 19 20 21 22 23 24
june 2015 (days)

Figure1.1 Karachi heat index

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 CHAPTER 2

LITERATURE REVIEW

From the past few years, people are facing problems due to severe weather
conditions issues. for example, Hyperthermia, Heat stroke, Heat rash, and etc., caused
because of inconvenience of temperature have been a constant trouble for individual
since its commencement. What is significantly more common is that people are un-
satisfied with the weather at different season of the year. Individuals always carp that
the weather condition is extremely cold or extremely hot. Due to current technological
innovation, Air-Conditioner have made considerable progress, which facilitated in
sustaining thermally relaxed temperature in individual's dwelling (for example. home,
car, industrial sectors, offices). The extremities of weather are causing difficulties for
people in outdoor environment. If one must be out in climate, the deduction of layers
with loosening up garments or sea shore wear, are the most dependable arrangements
however don't generally yields fulfillment, as burn from the sun is a significant issue
So, it has become very essential for people to cover their major organs from all these
weather stressors. [5]

In past few years, a lot of models were designed and the working principles of
all the proposed models were based on the well-known phenomenon named as Peltier
effect which was developed by Jean Peltier. Thermoelectric coolers work in a relation
to the Peltier effect. The Peltier effect generates a difference of temperature via
transferring heat between two electrical junctions. Across attached conductors, voltage
is implemented to generate an electric current. Peltier module based on Peltier effect
is used in many devices for cooling purpose where usual cooling systems are failed to
provide cooling. In the late 1800’s, William Thomson developed a relationship
between See-beck and Peltier Effect then Russian scientists developed another
module based on modern semiconductor technology in which by semiconductor
material are doped with metals [5]. In 2006, researchers made Refrigerated jacket that
functions in accordance with the atmospheric conditions. So, the point is that, several
systems have been designed up-till now, but every system have some flaws in it [6].

2.1 HARDWARE ANALYSIS

2.1.1 VEST WITH RECHARGING ICE PACKS

In this jacket, icepacks were placed on the vest lined to allow effective cooling
to the body. But the problem with this jacket was that, it used to take a long time to
cool down the body because when the ice packs become warm then thermoelectric
device gets activated and go back to change the temperature then it provides cooling.
But this required huge amount of power and it was large in size.

Figure 2.1 Vest With Recharging Ice Packs

2.1.2. EVAPORATIVE COOLING VEST

This jacket uses air as a cooling medium; air is blown over the sweat on the
body. In this jacket, cooling is provided by transferring heat and body mass in the form
of air. For the exhaustion of hot air, multiple tubes were used with blower. But the
problem with this jacket was that, it only provides when it is wore directly on the skin

6
and nothing is placed between body and jacket which becomes quite uncomfortable.
Also, the blowers are too costly and heavy.

Figure 2.2 Evaporative Cooling Vest

2.1.3 GEL COOLING VEST

The cooling in this jacket is provided through gel placed in between the layers
of jackets. The gel is entered and leaves through the opening placed at the back of the
vest. The problem with this jacket was that, it has no moving parts so we could not
pump the gel inside the tubes easily as we need to use pump for the transportation of
the fluid. And the main issue associated with this jacket was that the gel needs to be
changed after every two hours, so the refilling of the gel was quite difficult, and it is a
costly model as well.

Figure 2.3 Gel Cooling Vest

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2.1.4. TEMPERATURE SENSOR JACKET

This protective Jacket has built in sensors that help workers in taking decision
in cold climate. These sensors are only used for sensing not for controlling. It only
gives information about temperature without interrupting the workers regardless of
their job.

Figure 2.4 Temperature Sensor Jacket

2.1.5. AIR COOLING JACKET

This jacket consists of air conditioning system having two fans that adjust the
temperature which gives cool air, but it does not provide as much cooling effect as
water provides as a fluid. The problem with this jacket was the balloon effect, which
is caused due to air flow in the pipes and due to which mostly air lock occurs.[6]

8
 Figure 2.5 Air Cooling Jacket

2.2 SOFTWARE ANALYSIS

Due to the global pandemic, the project was shifted towards software. A
number of software were searched and analyzed, so that the hardware prototype can
be implemented and validated through graphs. There are various software available
for testing of thermoelectric coolers so, two software were found to be relevant
somehow to this project namely Kryotherm software and TEC Calculator.

2.2.1. KRYOTHERM SOFTWARE

KRYOTHERM software is used for the selection of Thermoelectric Peltier

Modules and for the calculation of Thermoelectric cooling systems. This software
allows users to estimate the functioning of thermoelectric modules and pick single or
multiple thermoelectric modules for implementation, where the values of thermal
resistance are known on the hot side as well as on the cold side according to the
resistance of insulation. In order to calculate the resistance of heat sinks and water
coolers, this software also contains estimation tools. The software also contains tools
for determining heat load. This software assists users in predicting the performance of

9
thermoelectric modules. The main purpose of this software is to design the
thermoelectric cooling systems.[7] This software is divided into three sections:

2.2.1.1. PERFORMANCE GRAPHS

Under various state of operation, the graphs of constraints of thermoelectric

cooler parameters in different forms are shown in this section.

Figure 2.6 Performance of Graphs

2.2.1.2. CHOICE OF MODULES

In order to select different optimal and multiple thermoelectric coolers for

the any TEC system according to the thermal and electrical requirements, this
section is used.

10
 Figure 2.7 Choice of Modules

2.2.1.3.THERMO-ELECTRIC SYSTEM

This section rechecks the calculation and enables user to generate the
computerized model of the specific system and to carryout the analysis regarding its
operation, connections, supplied power and selected type and quantity of
thermoelectric coolers.

Figure 2.8 Thermo-Electric System

11
2.2.1.4. KEY FEATURES

• The functional parameters of thermoelectric module are estimated.

• Up-gradation of configuration due to performance and cost.
• For thermal resistance of heat sink, estimation tool is incorporated.
• Shows performance graphs for all standard thermoelectric modules.

2.2.1.5. DRAWBACKS

This software helps in predicting the Peltier module based on the electrical and thermal
values like, the amount of heat is supplied to the system and how much heat is
exhausted out from the system. But this software itself does not contain the block or
feature of Peltier module which is supposed to be the main component of this cooling
jacket. So, it was not possible to simulate the circuit on the Kryotherm software
without Peltier module as it was not possible to analyze performance of Peltier
Module.

2.2.2 TEC-CALCULATOR

TEC-Calculator is a means of estimating the performances of different TECs

with different loads and different input voltages. This calculator has a feature of
selection of TZs to select the DC Source. Number of DC sources are available which
is connected in parallel to each other. It also enables users to select the percentage of
input voltage and Qmax, the maximum amount of heat moved or cooled. It also has
a feature of DT which shows the maximum temperature difference between hot side
and cold side.

Users can change current input voltage and maximum heat load according to
their devices. Thermoelectric coolers are basically rated on the following
temperatures i.e. 25 and 50 degree Celsius. It is important to set the ratings before

12
calculation because it affects the performance of TEC. Total heat load used in the
calculation is actually the sum of heat transmit from hot side to the cold side, There
is an option of delta that shows the reduction of temperature from hot side temperature
to cold side temperature. Here load can be reduced, and other parameters may also
change as per the requirement.

The graph shows the hot side temperature, cold side temperature and COP.
Considering the efficiency graph, if the graph is plotted towards left or right, it means
the system for which the temperatures and efficiency is being measured is not efficient
enough. But the efficiency can be increased by reducing the input voltages and the
graph which will ultimately moves towards the center so COP will become one (1)
which means now the system is 100% efficient. So, this is the method of testing TECs
by varying load and amount of heat used.

2.2.2.1. DRAWBACKS

This TEC-calculator calculates the hot side temperature and cold side
temperature of the selected TEC module only. But for the simulation of this cooling
jacket, other components are also required which are not available in this software.

Figure 2.9 TEC-Calculator

13
 CHAPTER 3

METHODOLOGY

3.1. PROPOSED WORK

The system proposed is a Cooling jacket which provides cooling effect

according to the temperature requirement for the body of user. The temperature can be
measured by the inbuilt temperature sensors. The cooling effect is attained by using
the Peltier. One side is embedded with heat sink and other with water block. It has
many advantages. It is user convenient, friendly, comfortable and extensive range of
temperature change could be measure. The temperature measured by the temperature
sensor of the system is displayed on the digital display screen. The cooler will facilitate
user to give cooling effects by using cooling jacket that helps user to tolerate hot
weathers, and saves them from different health disorder.[8]

Figure 3.1 Block diagram

The major components used in this project are:

3.1.1. PELTIER MODULE

It is the cooling and heating module. It is compact in size. It works on the

principle of Peltier effect which creates difference of temperature to voltage. When
voltage is provided to a module, one side of the module will become cool and other
will become hot. When current flows across a junction, heat is absorbed or given
out.[9]

3.1.1.1 TEC-12708
The Peltier module readily available in market is TEC1-12708. It is made up
of ceramic plate. The Max Voltage provided is 15.5VMax and the Input Current is 8A
both the voltage and current are higher than the required.

Figure 3.2 TEC-12708 modules

3.1.1.2 TEC-12706
The module used in this project is a TEC1-12706 module. It create difference
of a temperature among sides of the Peltier module when current flows. Its max current
is Max Current: 6.4A and Max Voltage is 14.4V (Hot side at 25°C), The Max
Refrigerating Power is: 50W (Hot side at 25°C), Dimensions: length 40mm , width ,
3.8mm height.[10]

Figure 3.3 TEC-12706 modules

15
3.1.2 WATER PUMP

In this project, pump is used for the suction of water from the water tank and
then it flows through the pipe which is connected to the water block. The other nozzle
of the water block is going back into the water tank via pipe thus creating a loop. The
main function of the pump is to make the continuous flow of water to provide cooling
effect. There are different types of pumps available in the market. Some of them are
mentioned below.

Figure 3.4 Sucking Pump

The above sucking pump has following features.

1) Head 4m
2) Flow rate 1litre/min
3) 12 V dc
4) Air/Water pump

Figure 3.5 Sucking Pump

16
Features of this sucking pump are

1) Head 5m
2) Flow rate 10 lit/min
3) 12 Vdc
4) Air/water pump

On the basis of above specifications, the 2nd pump is selected due to its properties and
easily available in the market.

3.1.3 HEAT SINK

It is a submissive heat exchanger which is used to transfers the amount of heat

produced by mechanical or an electronic device. It used fluid medium. It can be air or
a liquid coolant to dissipate the heat and permit the regulation of temperature of device
at best possible levels.[11] The two major categories of the heat sink are:

3.1.3.1 ACTIVE HEAT SINK

Active heat sink has a blower and fan embedded to each other. Performance of
this heat sink is excellent. They have moving parts and are expensive.[12]

Figure 3.6 Active Heat Sink

17
3.1.3.2 PASSIVE HEAT SINK

A passive heat sink has no moving parts. There is no fan attached with it. The

disadvantage is that if the dissipated heat is too much it is difficult to remove it without

forcing it.

Figure 3.7 Passive Heat Sink

On the basis of material in can be divided into 2 types.

3.1.3.3 COPPER HEAT SINK

It has better thermal conductivity as compared to aluminum. Its disadvantages

are its weight and cost. The use of metal is best where the significance of thermal
conductivity is more important than weight.

Figure 3.8 Copper Heat Sink

18
3.1.3.4 ALUMINUM HEAT SINK

It is the most used heat sink material. Aluminum heat sinks used in most
projects. It is light weight and has fine thermal conductivity.

Figure 3.9Aluminum Heat Sink

There are different types of heat sink according manufacturing process:

3.1.3.5 STAMPED HEAT SINK

In this type of heat sink fins are made up of metal. Their base is stamped and
soldered. They are mainly suitable for less-power applications. The biggest problem
with this heat sink is its low performance.

Figure 3.10 Stamped Heat Sink

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3.1.3.6 EXTRUDED HEAT SINK

Most of heat sinks are manufactured by the extruded aluminum. It is practical

for most applications. It has low cost and can be easily made. Its performance can be
varying from low-high range.

Figure 3.11 Extruded Heat Sink

3.1.3.7 FORGED HEAT SINK

They are manufactured by compressing copper or aluminum. It can be hot or

cold forged. They have selected design capabilities.

Figure 3.12 Forged Heat Sink

3.1.3.8 CNC MACHINED HEAT SINK

They have good heat conductivity, and most compound geometries can be
achieved by this process. They have high cost and the manufacturing time for single
piece greater for the high volumes.

20
 Figure 3.13 CNC Machined Heat Sink

Active type of heat sink is selected which is made up of aluminum and extruded heat
sink is chosen by considering their advantages.

3.1.4. TEMPERATURE SENSOR

Temperature is the degree of coldness and hotness. The device used to measure
the temperature is called temperature sensor. It is sensing device which measured the
temperature (hot or cold) and gives electrical signal accordingly. Different types of
temperature sensors are available in the market i.e. LM35 and DHT11.

3.1.4.1. LM35 (SPECIFICATIONS)

Operating Voltage 3.5v to 5.5v

Operating Current 0.3Ma(measuring) 60Ua (stand

by)
Temperature Range 0oC to 50oC

Humidity range 20% to 90%

Accuracy ± 1oC and ± 1%

Table3.1 LM35 temperature sensor specifications

21
 Figure 3.14 LM35 Temperature Sensors

3.1.4.2. DHT11 (SPECIFICATIONS)

Minimum and Maximum input 35v and -2v respectively

voltage
Drain current Less than 60uA

Temperature range -50oC TO 150oC

Accuracy ±0.5oC

Table3.2 DHT11 Specification

Figure3.15 DHT11 Temperature Sensor

22
LM35 and DHT11 are used to sense temperature having specifications mentioned above but
LM35 is preferred instead of DHT11 because of high operating range defined for LM35. For
LM35 there is linear relationship between operating voltage and temperature that is a rise of
0.01v for every 1OC rise in temperature. It is available at low cost hence it will be cost effective.
For compact designing the size of each component should be small hence it is small in size
and suitable for remote applications.

3.1.5. MICROCONTROLLER

Micro controller used in this project is Arduino. It consists of a programmable

circuit board known as a microcontroller and a software, or Integrated Development
Environment which runs on computer, and used to upload code of the computer to the
physical board. Microcontroller is used for the controlling of the temperature and
displaying the current value of temperature on the digital display

Figure 3.16 UNO Microcontroller

3.1.6. COOLANT

As the proposed model consist of water block, so next question that strikes,
which coolant to use in the model. There are many refrigerants (coolants) available in
the market that are used in refrigerator and these refrigerants depend upon the number
of variables. Some of them are mentioned below

23
3.1.6.1 R-22 (Chloro-fluor methane)

It is a common coolant used in fridges but depleting ozone refrigerant and is

not used anymore in modern refrigerator.

3.1.6.2 R-134A (Tetra-fluoranthene)

It is another refrigerant that was commonly used in fridges, but they are
banned due to their high (ODP) and GWP.

3.1.6.3 R-600A (Iso-Butane)

It has less environmental impact, low (GWP zero) global warming potential,
ODP (Ozone Depletion Potential) and non-toxic but it is flammable gas which can be
dangerous.

On the basis of coolant properties and feasibility, it was decided to use water as a
coolant which is easily available on earth and at the same time cost efficient and have
Zero ODP (Ozone Depletion Potential).

3.1.7 DIFFERENT FABRICS USED FOR COOLING JACKET

3.1.7.1 COTTON CANVAS FABRIC

Cotton Canvas is a low-cost and moderately rugged rough woven cotton fabric.
This fabric is very easy to clean; a coating of waterproof cloth is added on the top of
this fabric in order to convert into weather resistant fabric. But the main drawback is
that it gets damage due to direct contact of sunlight and it becomes faded and looks
dull because of its light weight.[13]

24
 Figure 3.17 Cotton Canvas Fabric

3.1.7.2 COTTON DUCK FABRIC

Cotton duck fabric is similar to cotton canvas, but it is knitted more stringent
as compared to cotton canvas. So, it offers more strength and durability. It also
provides UV protection and windproof but it gets fade in sunlight and it is also exposed
to shrinkage.[14]

Figure 3.18 Cotton Duck Fabric

3.1.7.3 QUILTED FABRIC

This fabric consists of a very dense and padded stuff because it is quilted by
stitching two different fabrics altogether, cotton and blended fabric, an insulating
material usually wool is placed within these two fabrics. This fabric is very
comfortable, warm and insulating but at the same time this fabric can store moisture
for a long period of time and it is very fragile and delicate[15]
25
 Figure 3.19 Quilted Fabrics

3.1.7.4 NYLON FABRIC

Nylon is a man-made fabric various type of nylon materials is available. It

was only used for parachutes in starting but now it is used for making raincoats, jackets
and backpacks. Nylon is very tough, long-lasting, and water repellent. Nylon also
provides UV protection and it does not even shrink but its main disadvantage is that it
is not breathable and difficult to wash.[16]

Figure 3.20 Nylon Fabric

26
3.1.7.5 SHERPA FABRIC

Sherpa fabric is basically the composition of three different fabrics namely

acrylic, polyester and cotton. It is commonly used for vests and jackets. This material
is very soft and insulating but this fabric is not warm, moisture wicking and get dirty
easily

Figure 3.21 Sherpa Fabric

3.1.7.6 SELECTED FABRIC (Polyester)

The fabric which will be best suited for the weather-controlled cooling jacket
is Polyester. It is a band of synthetic compounds. Polyester is very sustainable; it is
water repellent[17] so it does quickly dry and it is also abrasion resistive. It opposes
fading so that the color of this fabric remains for a quite long duration. It repels
stretching so it does not even shrink also it is very easy to wash. The jacket made from
the polyester can be even wear at those places having very high UV index. Polyester
fabric is also piling repellent. Furthermore, polyester fabric is best moisture-wicking
fabric, most flexible fabric, most wrinkle proof fabric, most fire-retardant fabric and
best high viscose fabric. And the best thing is this fabric is very economical, price of
waterproof polyester fabric ranges from Rs 335/meter in Pakistan[18]

27
 Figure 3.22 Polyester Fabric

3.1.8 DESIGN OF JACKET

In the design of jacket, all the three sides are clearly visible with the help of
the given sketches. The three sides of jacket are:

• Front side
• Back inner side
• Back outer side

3.1.8.1 FRONT SIDE

This is the front side of jacket and on the inner side of jacket front;
temperature sensors are placed at equal distances to sense the temperature throughout
the jacket. A belt is also given on the front of the jacket so that people can adjust it
according to their size.

Figure 3.23 Inner side of the jacket

28
3.1.8.2 BACK INNER SIDE

This is the back side of the jacket and on the inner side of jacket back, pipes
are attached with the help of loops or clamp to flow the fluid throughout the jacket.

Figure 3.24 Back inner side of the jacket

3.1.8.3 BACK OUTER SIDE

On the outer side of the back, solar films are placed. Furthermore, a dispatch-
able bag will be connected with the back of jacket in which attached module of Peltier
Sensor, heat sink and fan will be placed. The dispatch-able bag will attach with the
jacket with the help of zipper so that it can easily be separated from the jacket at the
time of washing.

29
 Figure 3.25 Outer side of the jacket

3.1.9 SOLAR MODULE (DESIGNING OF SOLAR FILM)

➢ STEP 01: LOAD ANALYSIS

QUANT
S.NO LOAD SPECIFICATIONS
ITY

Imax=6.4A
01 PELTIER MODULE (TEC-12706) 02 Vmax=14.4v
P=VI=92.16W

6W
02 WATER PUMP 01

Rate V=12v
03 DC FAN (Rated Speed10,000Rpm) 01 Rated I=0.08A
P=VI=0.96W

Operating V=3.5-
5.5V
04 LM35 TEMPERATURE SENSOR 04
Operating I=0.3mA
P=VI=1.65mW
Table 3.3 Load Analysis

30
➢ STEP 02: WATT-HOUR CALCULATION

TOTAL HOURS= 9AM - 5PM = 8HOURS

Total Wattage= 92.16(2) +6+1.65m (4) +0.96

Total wattage=191.2866W

E=P*T

E= 191.2866*8= 1530.2928Watt-Hour

Critical Daily energy required = 1531Watt-Hour.

Note: As it is already know that some part of the energy is lost when photons strike
Solar Cells i.e. some percentage of solar energy is convertable into electrical energy

➢ STEP 03: SOLAR PANEL SIZING

▪ For mono crystalline solar panel

It is made up of continuous crystal lattice structure and one cell of Mono-

crystalline is composed of single crystal. It's efficiency ranges from 15-20% .[19]

Assuming 20%

E=1531*1.2

𝟏𝟖𝟑𝟕.𝟐𝐖−𝐇𝐨𝐮𝐫
For panel sizing= 𝟖𝐡𝐨𝐮𝐫

= 229.65 = 𝟐𝟑𝟎𝒘

▪ For poly crystalline solar panel (that are mostly available in Pakistan and across
the world).
These panels are composed of small grains of Mono-Crystalline Silicon. It is
composed of wafers which is a combination of multiple fragments of Silicon
material. Its efficiency ranges from of 13-16% efficiency.[20]

Assuming15%
31
E=1531*1.15

E=1759.73W-hour

𝟏𝟕𝟓𝟗.𝟕𝟑𝐖−𝐇𝐨𝐮𝐫
For panel sizing = 𝟖𝐡𝐨𝐮𝐫

= 219.966 =220W

▪ For flexible solar panel

Flexible solar film is made up of thin film Photo-Voltaic. Its thickness

ranges from10-20 microns. It’s efficiency ranges from 10-16% mostly, Assuming

13% efficiency.[21]

E=1531*1.13

E=1730.03W-hour

For panel sizing = 𝟏𝟕𝟑𝟎.𝟎𝟑𝐖−𝐇𝐨𝐮𝐫

𝟖𝐇𝐨𝐮𝐫

= 216.25 = 𝟐𝟏𝟕𝒘

If least efficiency is assumed i.e. 10%

E=1531*1.1

E=1684.1W-hour
𝟏𝟔𝟖𝟒.𝟏𝐖−𝐇𝐨𝐮𝐫
For panel sizing= 𝟖𝐇𝐨𝐮𝐫

= 210.512 = 𝟐𝟏𝟎𝒘

Result Concluded

Solar panel Efficiency (%) Wattage

rating(W)
Mono crystalline 20% 230

Poly crystalline 15% 220

Flexible film rating 13% 217

Flexible film rating 10% 210

Table 3.4 Solar Panels

32
 For our proposed jacket, flexible solar films are selected due to its low weight
and the flexibility it provides which mono crystalline and poly crystalline panels fails
to offer.

3.2 WORKING

3.2.1 HARDWARE

A proposed model mainly comprises of Peltier module which is a thermo

electric device that produces dual thermal energy on its either sides using electrical
energy. It uses phenomena of Peltier effect which states that when a voltage is applied
between two different metals attached to a sample of semiconductor material,
temperature difference is created on either junction simultaneously. One junction
becomes hot at the same time another junction becomes cold. This approach is used
in the making of model. A final form of the model is achieved by doing various
amendments from the beginning. The model is composed of the components which
enable a system to work in an efficient way are Peltier module 12706, heat sink, 5V
DC fan, LM35 temperature sensors, 12 V DC battery, water blocks , water pipes,
water as coolant. Each component is readily available in the market. Thus, the
selection of each component is done on the basis of performance which is discussed
in proposed work heading.

Wearable Cooling Jacket model went through number of stages before getting final
picture of the model.

Step 1

A single Peltier device is experimented in order to check the effectiveness of

temperature in either side. By applying DC voltage at the terminal of sensor, it is
being observed that one side became so cooled in the meantime another side became
too hot.

33
Step 2

A prototype fridge is designed using thermo poles. Two Peltier sensors were
used which were connected in parallel and attached with the surface of heat sink. The
heat sink was attached with the hot side of Peltier surface and a DC fan with colder
side. The main purpose is to provide cooling within the thermo pole box. Temperature
sensors were placed at different positions inside the thermo pole box to check the
temperature status.

Step 3

Finally, core model of the project is designed. In this step two Peltier sensors
are combined in parallel with the DC battery and hot side of both sensors are attached
firmly with the help of thermal solution with the heat sink in order to transmit heat as
much as possible so that effective cooling can be achieved while colder side of each
sensor is fixed with water block using thermal solution. Furthermore, openings of
water block both inlet and outlet is connected with transparent pipe with the technique
such that liquid fluid i.e. water can flow through both the water blocks
simultaneously.

3.2.2 SOFTWARE

3.2.2.1 Performance of Peltier module

A basic model of a Peltier device which is working as a thermo electric cooler

has been developed by using MATLAB Software Simulink (MATLAB 2020). The
model is a combination of Peltier device, Solver Configuration, Current Source, Hot
side and the Cold side block which is very much similar to our hardware model. The
software model has been designed in such a way that it is quite relatable to our
hardware model, as it contains same characteristic of Peltier device that is use in the
prototype i.e. Bismuth Telluride. Most of the block’s directory is from Simscape

34
library. The current source that is provided across the terminal of Peltier is of range 0
to 6A. Heat sink is provided at the hot side of the device in order to dissipate the heat
and it is fixed at 45-degree C. On the other side a cold sink is attached. A solver
configuration block is used which is connected with the positive terminal of current
source as shown in the figure below.

The Peltier block used in this model is defined by:

• See beck coefficient = 295e-6 V/K.

• Internal resistance = 0.0234 Ohm.

• Thermal conductance = 1.2e-3 W/K.

Model

Figure 3.26 Model

NOMENCLATURE

TEC=thermoelectric cooler

QC= total heat transferred (W)

Pin= applied input power (W)

Th=hot side temperature (K)

Tc =cold side temperature (K)

∆𝐓 = cold side temperature(K)

I= current (A)

35
3.2.2.2. Coding

36
3.3. OBSERVATION

3.3.1 HARDWARE
This project is working on the principle of Peltier cooling effect. In the
implementation phase, first the testing of Peltier was done separately [22]. It is so
designed that is transfers the heat from one side to another. The cold side of Peltier can
cool up to 2.7 ◦C and hot side can reach up to the 50-60 ◦C. For the jacket, it is proposed
to cool till 32◦C not below this temperature otherwise it could have its repercussion as
well. The effect of hotness and coldness can be easily felt by tester by just touching it.
In order to check its effective cooling, another setup is designed in thermopol box
which works as refrigerator. In this setup heat sink attached with the fan is used, with
the heat sink the hot side of Peltier is attached so that it could easily exhaust its heat
outside through the fan. To operate this setup, supply of 12 volts and 6 amperes was
given to the system. The purpose of closed thermopol box was to check the cooling
effectively because its accurate effect cannot be check in the open atmosphere because
of different room temperature. The problem associated with this refrigerator setup was

37
that in this system attached model of heat sink and fan was used and it is not possible
to connect fan at the inner side of the jacket. Another problem incorporated with this
setup was that, it was not capable of circulating the fluid inside the jacket so; this
problem is rectified by the usage of water block, by which pipes can be attached
through which fluid can easily circulate throughout the jacket.

3.3.2 SOFT WARE

3.3.2.1. GRAPH 1

Figure 3.27 GRAPH 1

The first plot is comparing the co-efficient of performance (COP) w.r.t.

different current values. Effective cooling can be measured through Peltier device by
keeping its hot side fixed at atmospheric temperature i.e. is 45℃. To measure the
effectiveness of cooling of a Peltier device, Coefficient of Performance which is
known as COP is calculated. It is simply defined as total amount of heat transferred
through thermo electric cooler TEC over applied electric power.

total heat transferred

COP =
input power

Qc
COP =
Pin
38
As COP of Peltier device is measured in response to the input current. Initially fixing
the hot side temperature to 45℃ this is an atmospheric temperature normally in
summers. It can be observed from the graph that when we set cold side temperature
to 40℃, the difference of temperature between the two surface is only 5℃ , which
means to reach the desired temperature i.e. 5 ℃ , it will require less input power and
less work done on the system to reach the target because the target is low but if the
cold side temperature is 20℃, so now there is a larger temperature difference, So,
now more work done is required on the Peltier w.r.t. input current to reach to its
target. Thus, in this situation, COP of the Peltier decreases.

1
∆T ∝ ∝i
COP

3.3.2.2.GRAPH 2

Figure 3.28 GRAPH 2

The above graph is actually the relation between Qc and input power. Five
curves have been plotted by fixing hot side to 45℃ and analyzing five different graphs
by changing cold side to respective values 40℃ , 35℃, 30℃, 25℃, & 20℃ and
creating temperature difference of 5℃, 10℃, 15℃, 20℃, 25℃.

39
 It can be analyzed from the graph that when there is a temperature difference
of 5℃ between hot side which was set to 45℃ and the cold side i.e. at 40℃, Qc value
is highest at the corresponding input current which means that when little work done
is required by Peltier to reach to its target, it is not only having highest COP but also
having highest Qc value. Mathematically, COP value is also directly proportional to
Qc value which also satisfies the graph

3.3.2.3. GRAPH 3

Figure 3.29 GRAPH 3

In this graph, impact of different ranges of temperature difference on a Peltier

device is analyzed in terms of current drawing.

It is clearly observed that the rise in temperature difference is forcing a device

to draw more current in order to maintain the desired temperature at cold side.

40
 CHAPTER 4

RESULTS

1. To observe the effectiveness of Peltier sensors, water block is connected with Heat
Sink. Previously, without using Peltier Block, Peltier was not been able to transmit
heat to the receiving end. To overcome this, Water Block was used. Water Block is
designed in such a way that it transfers its heat to liquid that flows inside it. It is
configured with micro fins that not only increases the cooling surface but also channel
structure that will lead to work effectively.

2. After the testing being done, it is observed that it takes at least 10 minutes to cool
down the Hot water. To analyse the performance of Peltier Module, TEC-12706 Peltier
was run for 15-20 minutes by using Hot water. Hot water was used to relate with the
realistic condition as bike riders are exposed to high temperatures so there is a
possibility that the fluid used will become hot due to this. The temperature of the fluid
was around 50-60 degree Celsius, Thus, it almost takes 10 minutes to bring that
temperature back to normal temperature i.e. around 30 degree Celsius.

3. It is examined that how efficiently the water pump is working when connected with
the prototype. Water pump is used to suck water from the water tank and to pump it
through the pipes so that there is a regular flow of cold water in the pipes. The water
pump is connected with the Water Block via pipes.

4. The prototype model is found to be bulky because of the number of equipments that
are attached with Peltier but the heat sink was the major factor as because heat sink
that are available in the market are mostly extruded Aluminum heat sink of standard
size and shape. So, there were no other options to go with the other type of heat sink.

5.The selection of material is done on the basis of its durability, weight, color, cost,
water resistance, stretching, fire retardant and UV ray’s protection. On the basis of
these factors, a number of jacket materials have been analyzed that are explained above
which includes Cotton Duck fabric, Quilted fabric, Nylon, Polyester and Cotton
Canvas. By doing comparative analysis of the jacket, Polyester was found to be perfect
for our jacket. The polyester material is water repellant, so it will not affect electronic
and electrical equipments that are placed at the jacket. This material opposes stretching
which means it is reusable after washing as it wouldn’t get shrink. Lastly, the cost is
reasonable, and it is available easily in the market.

6.According to the solar module calculations, the proposed solar panel that is proposed
for the jacket is solar flexible film. The calculation is done on the basis of critical load
that is required for the prototype which includes water pump, DC fan, LM35
temperature sensor and Peltier module. The sizing of the panels is done for time
duration of 9am to 5pm, so that solar energy can be effectively utilized. On the basis
of load energy which is calculated to be 1.531KWhr, sizing of different types of solar
modules is made that are present in the market to analyze its performance (Mono-
Crystalline & Poly- Crystalline) with solar films on the basis of cost and efficiency.
Thus, the proposed solar module for the jacket is solar film primarily due to the
flexibility it provides which other modules cannot provide. The rating of Solar film
calculated is of 217W and 210W, providing 13% & 10% solar energy respectively
which are proposed for the prototype.

7.The simulation of the prototype of cooling jacket is done on MATLAB Software

where the working of the Peltier device is observed.

8.The graph 1 is between COP of Peltier Block w.r.t. input current values that is
applied at Peltier. Considering minimum temperature difference between hot side and
the cold side of the Peltier block.

Th = 45℃

Tc = 40℃

∆T = Th − Tc = 10℃

It is evident from the graph that when temperature difference is very low, very small
amount of current will be drawn by the device in order to achieve the desired value of
Tc hence performance will be maximum.

For maximum temperature difference

Th = 45℃

42
 Tc = 20℃

∆T = Th − Tc = 25℃

When difference gap between two temperatures reaches to a maximum value, which
means that required temperature at cold side is very low as compared to the hot side,
more current will be required for a device to attain the desired cold temperature results
in low co efficient of performance.

This graph proves that there is an inverse relation of temperature difference with COP
and direct relation with current.

1
∆T ∝ ∝i
COP

9.From graph 2, it is evident that when there is a less temperature difference between
hot side and the cold side, COP will be high and as a result Qc will also be high as Qc
is directly proportional to COP.

COP ∝ Qc

10. The Graph 3 proves that there is a direct relation between temperature difference
and current.

∆T ∝ i

43
 CHAPTER 5

FUTURE RECOMMENDATIONS AND CONCLUSION

5.1 FUTURE RECOMMENDATIONS

1. For future expansion, the size of the prototype can be reduced by using another
aluminium based heat sink attached with fan that offer minimal amount of weight and
required less space.
2. The proposed jacket will provide coolness to bike riders in extreme hot weather. In
future it can further modified to dual weather jacket means it could also provide
Hotness in cold weather.
3. The fluid which is circulating inside the pipes of the proposed model is water. For
future concerns, another fluid which is eco-friendly and offer low density with no
adverse effect on human health could be used.
4. A proposed jacket is only for bike riders, by implementing some changes; it can
also be used by pedestrians.
5. A temperature control circuit will be used in this proposed jacket that records the
variation in temperature, in future along with temperature sensors, humidity sensors
can also be used.
6. A 12 volts and 6 amperes lead acid battery is proposed for this system, because of
its low cost and high efficiency but the only drawback is that it requires frequent
maintenance. For the future scope any other premium battery that has longer life span
with little maintenance and higher efficiency could be used.
5.2 CONCLUSION

The modeling of the project requires greater theoretical knowledge, repeated

brainstorming and extensive research work. However, the designing of this basic
model which comprises of Peltier sensors, water block, and heat sink attached with a
fan, water pump and temperature sensor select provided a great learning experience
that augmented the knowledge and in shaping the technical skills in the domain of
electrical and electronics engineering. Designing of jacket material requires thorough
research as jacket that is proposed, will be used in summer seasons. In addition to that,
it must be water repellant so that electrical and electronic components that are
configured must remain protected with it. So, proper selection of the jacket was
critically important. Moreover, Designing of Solar films as the jacket needed to be
powered with solar energy was a critical step. The team believes in 3 E’s i.e.
Efficiency, Environment and Economics. That’s why solar film was proposed, and
sizing of solar film was made part in the report. The project was selected to overcome
the increasing effects of heat stroke and its impact. For this, the complications and
technicalities were learned and understood to model such a system that could be cost
effective, reliable and feasible for the masses. Thus, slight modifications in the model
will help the pedestrians and other people who worked near the furnaces and boilers
to avail this jacket. Furthermore, by using MATLAB software, performance of Peltier
Sensor has been observed w.r.t. different input current values, that how the
performance varies when there is an increase in temperature. Similarly, how heat
varies in the cold side when there is a change in current values. The simulation is
actually the implementation of the hardware prototype in MATLAB software.

45
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47
 APPENDIX

Peltier device

Figure 1 Peltier device 1

Figure 2 Peltier device 2

48
 Solver configuration

Figure 3 Solver Configuration 1

Figure 4 Solver Configurations 2

49
 Temperature source

Figure 5 Temperature Source

Cold side.

Figure 6 Cold Side

50
51