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Instituto Tecnológico Y De Estudios Superiores De Monterrey INSTITUTO TECNOLÓGICO Y DE ESTUDIOS SUPERIORES DE MONTERREY CAMPUS MONTERREY DIVISIÓN DE INGENIERÍA Y ARQUITECTURA PROGRAMA DE GRADUADOS EN INGENIERÍA HYBRID VEHICLE WITH STIRLING ENGINE AND THERMAL ENERGY STORAGE TESIS PRESENTADA COMO REQUISITO PARCIAL PARA OBTENER EL GRADO ACADÉMICO DE: MAESTRO EN CIENCIAS ESPECIALIDAD SISTEMAS DE MANUFACTURA POR ERIK WIELAND SEWE MONTERREY, N. L. MAYO 2010 INSTITUTO TECNOLÓGICO Y DE ESTUDIOS SUPERIORES DE MONTERREY CAMPUS MONTERREY DIVISIÓN DE INGENIERÍA Y ARQUITECTURA PROGRAMA DE GRADUADOS EN INGENIERÍA Los miembros del comité de tesis recomendamos que el presente proyecto de tesis presentado por el Ing. Erik Wieland Sewe sea aceptado como requisito parcial para obtener el grado académico de Maestro en Ciencias con especialidad en: SISTEMAS DE MANUFACTURA Comité de tesis: ________________________________ Dr. Noel León Rovira Asesor _______________________ _________________________ Dr. Ciro Ángel Rodríguez González Dr. Humberto Aguayo Téllez Sinodal Sinodal APROBADO ___________________________ Dr. Ciro Ángel Rodríguez González Director del Programa de Maestría en Ciencias con especialidad en Sistemas de Manufactura Mayo, 2010 to Alma, you were my motivation for this work Acknowledgements I would like to thank to … … Dr. Noel León for making possible this thesis. … Dr. Ciro Rodríguez, Dr. José Huertas and Dr. Humberto Aguayo for her time and advice. … Claudia Gonzales for her excellent work. … My family, for their constant support from Germany. … Luis Diego for friendship and feedback. … Daniel for reviewing the thesis. … All my friends. … ITESM and CONACYT for economic support. Abstract Advances in electric technology and automotive components make feasible a new kind of hybrid vehicles. The hybrid technology allows gathering advantages from different energy concepts and allows it to eliminate disadvantages which a single energy source or engine concept would present. Hybrid technologies allow using different power sources in one vehicle. Concentrated thermal solar energy is used as primer energy in a vehicle. Basic components are thermal energy storages and Stirling engines. Heat from the sun is gathered in a place outside the car and stored in a tank. The tank is placed in the vehicle and connected to a Stirling engine. A Stirling engine is a device that converts heat energy into mechanical power. The mechanical power is used in a generator to produce electric energy. The vehicle has an electric system with batteries serving as an energy buffer. Physical bases, components and vehicle concepts are described. A market study provides benchmark of Stirling engines and serial hybrid busses. In a case study several options for a possible prototype are revised. For the Circuito Tec service (a service for students living near the university) a detailed analysis is made. With a GPS the driving profile is recorded. A Matlab model uses this data to calculate energy storages sizes and required engine output. In Autodesk Inventor several CAD models are created in order to represent different space concepts. A vehicle with thermal energy storage based on molten glass is compared to conventional and alternative concepts. MSC Adams/car is used to simulate the vehicle dynamics. The influence of a thermal storage tank with the weight of 996kg is observed. Size, weight and price estimation of different thermal-electric vehicles are compared to conventional vehicles. Keywords Hybrid Vehicle, Stirling Engine, Thermal Energy Storage, Solar Energy i Table of contents Table of contents....................................................................................................................................................ii List of figures.........................................................................................................................................................iv List of tables ..........................................................................................................................................................vi Acronyms ..............................................................................................................................................................vii List of Symbols.....................................................................................................................................................vii Chapter 1. Introduction ..............................................................................1 1.1 Objective ........................................................................................................................................................1 1.2 Hypothesis .....................................................................................................................................................2 Chapter 2. Theoretical Background ..........................................................3 2.1 Stirling Engines ..............................................................................................................................................3 2.1.1 Engine configurations .............................................................................................................................3 2.1.2 The Stirling Cycle:...................................................................................................................................5 2.1.3 Alternatives to Stirling Engines...............................................................................................................5 2.2 Hybrid Vehicles ..............................................................................................................................................7 2.2.1 Comparison of different vehicle assemblies.........................................................................................10 2.2.2 Vehicles with Stirling Engines – History ...............................................................................................11 2.3 Patents .........................................................................................................................................................12 2.4 Solar Energy System Design.......................................................................................................................13 2.5 Materials.......................................................................................................................................................15 2.6 Thermal energy storage tank.......................................................................................................................17 2.7 Heat exchanger............................................................................................................................................17 Chapter 3. Macro vision ...........................................................................18 3.1 Vehicle to Grid..............................................................................................................................................18 3.2 Competitors and economic rivals.................................................................................................................19 3.3 Problems and backup solutions...................................................................................................................20 Chapter 4. Application: Minibus..............................................................21 4.1 Market Situation Serial Hybrid Buses ..........................................................................................................21 4.2 Components.................................................................................................................................................24 4.2.1 Market situation: Stirling Engines .........................................................................................................24 4.2.2 Cooling system for Stirling engine........................................................................................................26 4.2.3 Electric Energy Storage........................................................................................................................27 4.2.4 Electric engines ....................................................................................................................................27 4.2.5 Air conditioning .....................................................................................................................................28 4.2.6 Electric components .............................................................................................................................29 4.2.7 Vehicle Concepts..................................................................................................................................29 ii 4.2.8 Expreso Tec ......................................................................................................................................... 32 4.2.9 Circuito Tec .......................................................................................................................................... 33 Chapter 5. Modeling and simulation....................................................... 37 5.1 Load Cases.................................................................................................................................................. 37 5.1.1 Drive Cycle........................................................................................................................................... 37 5.1.2
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