Waste heat management in electric motors using thermoelectric generator integrated with phase change material and metal foam-embedded heat sink

The waste heat management process from various thermal sources is associated with promising results in the energy conversion field. Thermoelectric generators integrated with phase change materials containing metal foams are useful means for recovering waste heat and converting it into electrical energy. Installing these hybrid cases on common heat sources and providing a practical strategy for waste heat management addresses a significant research gap in this field. The aim of this study is to manage waste heat from a three-phase asynchronous electric motor of a milling machine for the first time using a novel prototype thermoelectric system. Four thermoelectric modules (connected electrically in series) with zero-cooling energy phase change material and copper foam heat sink were embedded on the motor body. Hence, continuous and fluctuating loads were imposed on the motor, starting from ambient temperature. This caused the motor body to heat up and transfer the wasted heat to the module and the environment. The results of this study show that the proposed system was successfully started via the waste heat of the motor body. Thermal energy was absorbed from the hot side of the module, and the hybrid heat sink controlled the temperature of the cold side. Moreover, an appropriate temperature difference was provided across the module, and the system produced electricity for a long time during milling operation. The maximum output voltage in constant and periodic loads, with on/off durations of 180 s and 360 s, was recorded as 960 mV, 1280 mV, and 1440 mV, respectively. The mentioned hybrid thermoelectric system provides a unique solution for waste heat management in industrial applications, improving economic savings.