Results in Engineering 16 (2022) 100627 Contents lists available at ScienceDirect Results in Engineering journal homepage: www.sciencedirect.com/journal/results-in-engineering A novel experimental case study on optimization of Peltier air cooler using Taguchi method Zuhair R. Abdulghani Department of Mechanical Engineering Technology, Yanbu Industrial College, Yanbu Al-Sinaiyah City, 41912, Saudi Arabia A R T I C L E I N F O A B S T R A C T Keywords: Cost rate Thermoelectric Peltier Optimization Taguchi Nowadays, the commercial application of Thermoelectric Peltier cooler has widely increased including portable air/water refrigerator, electronic cooling process, thermal management systems in medical science, water distillation process and so on. Many studies have proved that the thermal/exergetic/economic performance of Peltier cooler significantly depends on fluid flow conditions on both sides of the module, input power and number of Peltier modules. Hence, in this research, attempts are made to provide an experimental-based opti­ mization process for Peltier air cooler using well-known Taguchi method. Thermal fluid conditions, input power and number of modules (in the same total input power) are varied to optimize the cooler from COP (coefficient of performance), exergetic efficiency and cost per unit of cooling viewpoints. Number of modules are changed from 1 to 2, 3 and then 4 modules. The air flow rate and input power are varied between 30 and 78 m3/h and 22–60 W respectively for each tested mode. The results indicate that, the greater number of modules provides higher COP (in the same total input power). Optimum number of modules minimizes the cost per unit of cooling of the Peltier cooler. Increment of air flow on the cold side, increases and then decreases the COP of the cooler which is meaningful. Number of modules was found as the most effective factor while input power and thermal fluid conditions are as the second and the third effective parameters. Interestingly, Taguchi method can identify the impact level of each factor (number of modules, input power and air flow) on desired parameters (COP, cooling cost and exergy efficiency) as reported and discussed in this paper. 1. Introduction Thermoelectric Peltier cooler application is increased day by day including medical science [1], air cooler [2,3], portable refrigeration systems [4], water cooling process [5], electronic cooling [6] and so on. Portable picnic and automobile Peltier based refrigerators are now widespread available in the market [7]. Optimum working condition from all thermal, economic and exergetic aspects is crucial in such ap­ plications in which low power consumption means longer availability of the battery power. Many parameters such as capital cost of the thermoelectric materials (ceramic, n-type and p-type electrode), maintenance cost, power cost, exergy cost and operation costs are effective factors in economic consideration of thermoelectric cooler. That is why different techniques such as Exergy Economic Approach, Thermo-economic Functional Analysis, Specific Exergy Cost and so on have been presented by the experts for economic analysis of engineering systems. According to the attitude of the current study, the recent progress on optimization process of thermoelectric coolers and thermoelectric generator are summarized in the following. Yin and He [8] worked on optimization of thermoelectric cooler with temperature dependent materials using analytical method. They indi­ cated that the multi-parameter optimization can enhance the efficiency of the cooler by 30%. Lundgarad and Sigmund [9] designed a Peltier cooler using topology optimization by Numerical simulation. Lamba et al. [10] worked on efficiency optimization of a Peltier cooler from leg geometry viewpoint meaning trapezoidal leg shape. They employed genetic algorithm as their methodology. Provensi et al. [11] studied a counter current flow multi-stage thermoelectric air cooler and tried to determine the optimum number of modules as a function of thermal load. They concluded that the optimum number of modules is enhanced with cooling capacity. Gong et al. [12] numerically optimized a compact Peltier cooler from current, leg geometry and contact layers viewpoints. Based on their findings, smaller leg has stronger cooling efficiency while larger cross section results in higher operation reliability. Cai et al. [13] numerically optimized a Peltier cooling system as a CPU cooling device. Duan et al. [14] and Tian et al. [15] worked on material optimization of thermoelectric cooler for building cooling application. They showed that if the figure of merit is optimized to 3, the COP of the Peltier air cooler is E-mail address: abdulghaniz@rcyci.edu.sa. https://doi.org/10.1016/j.rineng.2022.100627 Received 10 July 2022; Received in revised form 14 August 2022; Accepted 1 September 2022 Available online 6 September 2022 2590-1230/© 2022 The Author. Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). Z.R. Abdulghani Results in Engineering 16 (2022) 100627 optimizations have been performed for cooling application of thermo­ electric module. Particularly, the mentioned optimization should be carried out from all economic, thermal and exergetic viewpoints simultaneously. The impact level (intensity of being effective either positive or negative) of input power, number of modules and fluid flow conditions (most important parameters for Peltier module as an air cooler) on COP, cooling cost and exergetic efficiency have not been investigated yet. Hence, in this research, attempts are made to provide an experimental-based optimization process for Peltier air cooler using well-known Taguchi method which is able to clarify the contribution of each parameter (impact level) in addition to their optimum value (both quantitative and qualitative). To reach the aim of this research, thermal fluid conditions, input power and number of modules (in the same total input power) are varied to optimize the cooler from COP (coefficient of performance), exergetic efficiency and cost per unit of cooling viewpoints. Nomenclature Ċ COP e E k ṁ n P Q R S/N T V y Z Ż ε U w Cost rate ($/s) Coefficient of performance Mass-related specific exergy (J/kg) Exergy, (W) Thermal conductivity, (Wm− 1 K− 1 ) Mass flow rate (kg/s) Number of tests Power, (W) Heating/cooling capacity, (W) Electrical resistance, (Ω) Signal to noise ratio Temperature, (K) Electrical voltage, (V) Response factor Capital investment cost ($) Capital investment cost rate ($/s) Effectiveness Uncertainty Power or work, W 2. Problem definition and process strategy Thermoelectric cooler is recently used in commercial scale for different purposes such as portable refrigerators, water cooling process, local air-cooling process and so on. Previous studies indicate that the main characteristics of thermoelectric cooling i.e., COP, exergetic effi­ ciency and cost of cooling significantly depend on thermal fluid condi­ tions on both sides of the module, input power into the thermoelectric and number of employed Peltier modules for a given input power. Not only the impact of these parameters can be positive or negative, their level of impact (percentage of contribution) is different from each other. Hence, decision making process requires an optimization process to identify their impacts in terms of both quantitative and qualitative as­ pects. Hence, in this research, Taguchi optimization method is employed to address the mentioned problem for a thermoelectric air-cooling unit in which the water fluid passes through the hot side while the air fluid passes through the cold side. The required information was gathered through a set of experiments as are described step by step in the following. increased to 1.42–7.44. Moria et al. [16] experimentally investigated the exergoeconomic characteristics of a Peltier air cooler. They found out that, a greater number of modules can provide higher COP. However, capital cost and other economic factors limits the number of modules. Higher input power reduces the COP while its effect on cooling cost depends on the electricity price of the region. Pohls and Mozharivskyj [17] tried to optimize thermoelectric material using scattering-dependent model. Miao et al. [18] optimized a thermoelectric generator for an industrial application. They concluded that the mini­ mum cost of power generation process by TEG in industrial scale is 1.76 $/W. Demeke et al. [19] utilized genetic optimization technique to optimize the segmented thermoelectric power generator to find an efficient design for thermoelectric generator. In another investigation, Ge et al. [20] tried to optimize the thermoelectric generator with vari­ able cross-section leg from geometric viewpoint for solar energy appli­ cation using finite element method. According to their results, internal resistance of optimized TEG is more than that of common rectangular TEG. Chen et al. [21] compared a segmented thermoelectric generator with convectional structure of TEG using a mathematical model to find the optimized converting angle. Zaher et al. [22] performed an opti­ mization study for annular thermoelectric generator applicable for heat recovery process. Yan et al. [23] tried to determine the most efficient channel cross-section shape applicable in thermoelectric power gener­ ators mounted on hot/cold surface. Based on their results, rectangular cross-section can provide the highest output power and thermal effi­ ciency. Tian et al. [24] proposed annular segmented thermoelectric generator and tried to identify the impact of all geometric characteristic on thermoelectric generator performance. Cao et al. [25] proposed a thin film solar thermoelectric generator. They found out that the effect of leg thickness in this specific application is much more important than the effect of leg length and other geometric aspects. Co-axial ring-shape leg was introduced by Tian et al. [26] and Li et al. [27] and investigated from economic, mechanical and energetic aspects. Kishore et la [28]. optimized the segmented thermoelectric generator using Taguchi method. The impact of all design parameters such as height of seg­ mentation, hot/cold side temperature and load resistance were investi­ gated. They believe that limited required number of experiments (25 tests rather than 3125 test-run) is a potential feature of Taguchi technique. Based on literature review, extremely few experimental-based 3. Taguchi optimization process (step-by-step) Taguchi method [29,30] is one of the popular and practical optimi­ zation tools to determine the optimum working conditions through a limited number of experiments. Taguchi method not only reduces the effects of uncontrollable factors but also decreases the required time and costs associated with the optimization process. Taguchi technique can identify the impact of any effective parameters while the rest of the parameters are constant. This process is repeated for all desired pa­ rameters. To consider the impact of all parameters, a matrix of all pa­ rameters with enough number of variations in appropriate range is required. The range and number of required testes are not arbitrary and should be selected based on specific criterion behind this strategy. The required steps to optimize a system via this technique is briefly sum­ marized in the following. 3.1. Identification of the objectives Step 1. is identification of the objective. The objective of the current optimization process is finding the optimum values of design and working conditions of a given Peltier air cooler, the impact level of the effective parameter (positive or negative) and their percentage contribution. 3.2. To identify the desired characteristics and their evaluation Step 2. is identification of the desired characteristics of the system. Desired important characteristics of any thermoelectric air cooler are 2 Z.R. Abdulghani Results in Engineering 16 (2022) 100627 mainly coefficient of performance (COP) which is indicator of thermal behavior of the cooler, cost per unit of cooling ($/kWh of cooling) which is an indicator of economic aspect of the cooler and exergetic efficiency which is the performance of the cooler from the Second Law of Ther­ modynamic viewpoint. Table 2 Taguchi L16 OA array. Experiment No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3.3. Selection of variable factors and their level Step 3. is Selection of variable factors and their level. For a thermo­ electric air cooler, the main effective variable parameters are air flow rate, total input power into the system and number of Peltier modules. It is noted that, for a given total input power, different number of jointed thermoelectric modules will result in different thermal, exergetic and economic characteristics [31–33]. More number of modules increases the COP. However, there will be a critical number after which the cooling cost may increase. The selected various factors in this research are “number of modules”, “input power” and “air flow rate”; and each factor is considered through four levels as provided in Table 1. Step 4. is selection of an orthogonal array which is an important step in Taguchi method. In this research there are three factors (number of modules, air flow rate and input power) and each of them has four levels. Hence, based on the strategy of the Taguchi system, an orthogonal array of L16 is used as shown in Table 2. It should be noted that, the arrangement of the matrix is not arbitrary and should be based on the theory behind the Taguchi method to appropriately consider the impacts of all factors on desired parameters [31] (Minitab software was employed for this aim). As can be seen in Tables 2, 16 set of experiments are required. The values of COP, Exergy efficiency and cost per unit of cooling should be evaluated for each tested condition using the data extracted from the experiments. In order to perform the required experiments shown in Table 2, the following test rig was designed (see Fig. 1). Generally, four thermo­ electric modules are placed in the line and 1, 2, 3 or all of them are connected into the input electrical power based on Table 5. Popular fin pin heat-sink is attached to the cold/hot side (air/water fluid). Water passes through the hot side as a common temperature adjustment technique for hot side. Air flow was adjusted and recorded using a professional digital air flow meter (SMC PFMB7501-04-F). Elaborate tiny grooves are created on the heat-sinks to measure the thermoelectric surface temperatures (required in evaluation of COP) using thin wire Ktype thermocouples. Inlet/outlet/surface temperatures are recorded by 12-channel BTM-4208SD data logger. Popular TEC1-12706 commercial thermoelectric is used in this study. As described above, COP, exergetic efficiency and cost per unit of cooling are the derided factors. All these factors are evaluated using measured experimental data for each row shown in Table 2. The evaluation process of COP and exergetic effi­ ciency are graphically illustrated in Fig. 2. Uncertainty analysis is carried out using the same technique described by Moffat [34]. In this method, the uncertainty value of any parameter is evaluated using the uncertainty value of its independent effective parameters. For example, the uncertainty of coefficient of performance (COP) depends on the uncertainty of cooling capacity and uncertainty of input power because COP = QP. Hence, its uncertainty can be calculated by Eq. (7) in which UCOP in uncertainty of COP, UQ is Level 1 Level 2 Level 3 Level 4 1 30 22 2 40 35 3 55 49 4 78 60 Air flow rate (m3/h) Input power (W) 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 30 40 55 78 30 40 55 78 30 40 55 78 30 40 55 78 22 35 49 60 35 22 60 49 49 60 22 35 60 49 35 22 Cost per unit of cooling (economic indicator) is evaluate using Spe­ cific Exergy Costing theory as explained in detail by Refs. [15,16]. It should be noted that, cost per unit of cooling depends on material, electricity, investment/capital/maintenance costs as well as exergy transfer cost and is evaluated using Eq. (8). ∑ ∑ Ċp,k + Żk + (Ċi )k = Ċq,k + (Ċe )k (8) i e where Ċp,k is exergy stream of power or work, Żk is capital/operating/ maintenance costs and Ċi is cost rate associated with entering exergy stream of mass transfer [15,16]. Ċq,k is exergy stream of heat transfer and Ċe is exiting exergy stream of mass transfer. Exergy stream of power and heat can be written in the form of Eqs. (4) and (5) in Fig. 2) in which cp and cq are the average cost per unit of exergy ($/kWh). Ėq is the same as ĖQC or ĖQh as provided in Fig. 2. Eq. (8) should be applied for hot side ceramic, cold side ceramic and thermocouples (as three main compo­ nents of the thermoelectric) and are solved as a system of equations. In-detail explanations on the value of any mentioned factors have been provided before by Refs. [15,16] and the same values are employed in this research. The required investment costs in evaluation process are summarized in Table 4 [15,16]. 3.5. Signal to noise ratio (S/N) Evaluation the signal to noise ratio (S/N), using Eq. (9), in which “n” is the number of tests and “y” is the response factor) which provides the desirable signal value and undesirable noise value respectively. Signal to noise ratio is the optimization criterion in Taguchi method. Three stra­ tegies are possible in Taguchi method to evaluate the SN ratio including “the higher the better”, “the lower the better”, and “the nominal is better”. For cooling characteristics or exergetic efficiency that is “the higher the better” while for the cooling cost it will be “the lower the better”. To analyze the obtained results using Taguchi method, Minitab Table 1 The factors, their level, and values through the optimization process. Number of Peltier modules Air flow rate (m3/h) Input power (W) Number of modules uncertainty of cooling capacity and UP is uncertainty of input power. It is noted that, these uncertainties should also be evaluated using the same formula with their own parameters. This process is continued till reach the basic parameters i.e., temperature, flow rate and so on which are directly measured by the instruments. The uncertainty of the basic pa­ rameters is the same as the accuracy/resolution of the measuring in­ strument and operator errors. The maximum uncertainty of the basic and other parameters is summarized in Table 3. √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ( )2 ( )2 ∂COP ∂COP UCOP . = . (7) UQ + UP ∂Q ∂P 3.4. Selection of an orthogonal array and required experiments Factors Parameters 3 Z.R. Abdulghani Results in Engineering 16 (2022) 100627 Fig. 1. General view of the experimental set-up. Fig. 2. Calculation process of thermal and exergetic factors. 4 Z.R. Abdulghani Results in Engineering 16 (2022) 100627 Table 3 Maximum uncertainty of parameters. Parameters Uncertainty Measuring of temperature Measuring of air flow Measuring of water flow COP Exergy efficiency Cost per unit of cooling ±0.1 ◦ C ±2% ±2% 7.3% 3.1% 6.2% Table 4 Investment costs of the materials. Investment cost Number of investment cost of modules ceramic 1 3.2 $ 2 6.4 $ 3 9.6 $ 4 12.8 $ Cost of electricity ($/s) investment cost of thermocouples 2.5 $ 5.12 $ 7.6 $ 10.24 $ Fig. 3. Comparison of COP between current study and Tian et al. [3]. Ċp = 10− 8 × Pin software was employed. ) ( n S 1∑ 1 = − 10 log N n i=1 y2i (9) 4. Results and discussions First, the evaluated COP, cost of cooling and exergetic efficiency for each set of experiment (see Table 2) are tabulated as Table 5; and then the optimization process by Taguchi method is reported and discussed. As described in the literature review, Tian et al. [3] has worked on a single thermoelectric air cooler (the same type of thermoelectric i.e., TEC1-12706). Although they tested different values of inlet air flow, their results of COP can be compared with the presents results as a sample comparison/validation process (see Fig. 3). The difference be­ tween the results can be related to the different values of the inlet air flows in these studies. They have used water fluid for the hot side (the same as current study). They did not provide any optimization process and they did not change the number of modules which are covered in this research. Fig. 4. SN ratio graphs for COP of the cooler at different levels of con­ trol factors. The obtained results for the optimization process of COP are pro­ vided in Fig. 4 for number of modules, air flow rate and input power. The maximum SN ratio is the optimum condition of each factor. As can be seen in Fig. 4, a greater number of modules provides higher COP (for a given total input power) and optimum number in the tested range, is 4 number of thermoelectric with signal to noise ratio of around 4. More number of modules (in the same total input power) provides higher COP. Based on the intrinsic feature of any individual Peltier Table 5 The obtained results from the experiments. Experiment No. Parameters Results Number of modules Air flow rate (m3/ h) Input power COP Exergy efficiency % Cost per unit of cooling ($/kWh) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 30 40 55 78 30 40 55 78 30 40 55 78 30 40 55 78 22 35 49 60 35 22 60 49 49 60 22 35 60 49 35 22 0.42 0.38 0.28 0.25 0.864 1.19 0.640 0.822 1.06 0.95 3.15 1.51 1.19 1.17 1.88 2.6 7.3 5.21 4.32 3.81 8.12 9.16 5.78 6.43 9.16 8.24 10.95 9.09 9.52 9.94 10.48 11 0.72 1.4 3.83 5.37 0.832 0.731 3.10 1.70 0.674 0.865 0.563 0.76 0.66 0.64 0.64 0.67 Fig. 5. COP variation of a single module with input voltage. 5 Z.R. Abdulghani Results in Engineering 16 (2022) 100627 module, higher input DC voltage (input power) provides more cooling capacity but lower COP. This can be seen in Fig. 5 which shows the variation of COP with input voltage for a single TEC12706 module published by the manufacture. As explained, if two, three or four modules are jointed to each other and the same total input power of a single module is applied to the system, each module will work with lower DC voltage (total power is distributed between them) and provides higher COP. Hence, the total COP of the system will be higher. However, it should be noted that, based on Fig. 4, the slope of the SN ratio is reduced with increment of the number of modules. It means that, the intensity of the COP improvement is reduced step by step; and for a given total input power there will be a critical number of modules after which the COP may not be increased (internal resistance of more number is accumulated as a negative feature). As can be seen in Fig. 4, for the air flow optimization from COP viewpoint, SN ratio is increases first and then is reduced. The maximum SN ratio belongs to the air flow rate of 55 m3/h. This curve is important as it shows a peak point in the mentioned value. When air flow is zero, the cold side of the module goes to the minimum value (for a given input power). With increment of air flow, the temperature of the colds side starts to become warmer as a portion of the generated cooling is trans­ ferred to the air. However, if the air flow is further increased to higher than 55 m3/h, no further cooling is transferred to the air and the COP may reduce as the maximum cooling has already been transferred to the air fluid. Based on Fig. 4, higher total input power reduces the SN ratio which means lower value of COP. The optimum input power takes place in the minimum input power. The reason of COP reduction because of higher input power was explained before above. Fig. 6 illustrates the optimization process for cost per unit of cooling with variation of three parameters including number of modules, air flow rate and input power. SN ratio for cost per unit of cooling, is increased with increment of number of modules and optimum value is shown for 4-modlue case. However, from three modules to the four modules, the slope of SN ratio is reduced. This is because of higher capital cost when the number of modules is increased. In other words, a greater number of modules is good from cooling viewpoint which is positive from economic view­ point. However, simultaneously, a greater number of modules causes higher capital/operation cost. As long as the increment rate of negative feature is lower than the increment rate of positive feature, the economic factor is increased. Nonetheless, if the number of modules is increased more and more, the SN ratio of the cooling cost may start to reduce. Hence, for a given input power, there will be a critical number of modules that should be considered in real applications. According to Fig. 6, increment of air flow and input power, reduces their related SN ratio. Thus, optimum value of these parameters from economic Fig. 7. SN ratio graphs for Exergetic effectiveness at different levels of con­ trol factors. viewpoint are their minimum value. Higher input power not only re­ duces the COP, but also it causes higher electricity price. The increment of cooling capacity due to higher input power (positive aspect of higher input power) is not able to overcome its negative aspects (lower COP and higher electricity price). That is why, it reduces the cost per unit of cooling. Fig. 7 illustrates the optimization process for Exergetic effectiveness with variation of three parameters including number of modules, air flow rate and input power. As can be seen in Fig. 7, the general curve behavior of SN ratio of the number of modules, air flow rate and input power for optimization of exergetic efficiency is similar to the cost per unit of cooling (however the slope of the curves are different). This shows how the economic factor and exergetic factor are dependent on each other and that is why many expressions such as Exergoeconomic have been emerged in recent de­ cades. The optimum values (maximum SN ratio) for number of module, air flow rate and input power are 4, 30 m3/h and 22 W respectively. The optimum conditions of all tested parameters are summarized in Table 6. As described before, one of the interesting features of Taguchi method is the identification of the contribution percentage of each factor on desired parameters [33]. It helps to determine the most effective factor on the value of desired parameters. The contribution of each factor on Cost per unit of cooling, COP and exergetic effectiveness is represented in Fig. 8. The number of modules plays a key role in thermal, economic and exergetic characteristics of the Peltier based air cooler. The second effective factor is input power and the third one in air flow rate. The contribution of air flow rate on COP is only 8% while its contribution on economic factor and exergy factor are around 25% and 15% respectively. Briefly, Number of modules play a key role (roughly 50%) in all factors. The contribution of air flow is small in all factors, and it is around 8% in COP. The impact of input power on cooling cost, COP and exergy efficiency are 33, 30 and 20% respectively. 5. Conclusion This paper shows how Taguchi method can be employed for Table 6 Optimum condition for Cost per unit of cooling, COP and Exergetic Effectiveness. Factors Number of Peltier modules Air flow rate (m3/h) Input power (W) Fig. 6. SN ratio graphs for cost per unit of cooling at different levels of con­ trol factors. 6 Cost per unit of cooling COP Exergetic Effectiveness Level Value Level Value Level Value 4 1 1 4 30 22 4 3 1 4 55 22 4 1 1 4 30 22 Z.R. Abdulghani Results in Engineering 16 (2022) 100627 Fig. 8. Contribution of each factor on Cost per unit of cooling, COP and Exergetic effectiveness. optimization process of a Peltier air cooler from energy, economic and exergetic viewpoints. Number of modules, air flow rate and input power are considered as the variant parameters. The results showed that, higher number of modules increases the COP, reduces the cost and in­ creases the exergetic efficiency. However, there will be a critical value for number of modules as capital and other marginal costs may over­ come to its positive feature. A peak point was observed for COP versus air flow rate. 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