To analyze the thermoelectric power generation for sports utility vehicle (SUV) application, a novel thermoelectric generator (TEG) based on low-temperature Bi2
thermoelectric modules (TEMs) and a chaos-shaped brass heat exchanger is constructed. The temperature distribution of the TEG is analyzed based on an experimental setup, and the temperature uniformity optimization method is performed by chipping peak off and filling valley is taken to validate the improved output power. An automobile exhaust thermoelectric generator (AETEG) using four TEGs connected thermally in parallel and electrically in series is assembled into a prototype military SUV, its temperature distribution, output voltage, output power, system efficiency, inner resistance, and backpressure is analyzed, and several important influencing factors such as vehicle speed, clamping pressure, engine coolant flow rate, and ambient temperature on its output performance are tested. Experimental results demonstrate that higher vehicle speed, larger clamping pressure, faster engine coolant flow rate and lower ambient temperature can enhance the overall output performance, but the ambient temperature and coolant flow rate are less significant. The maximum output power of AETEG is 646.26 W, the corresponding conversion efficiency is 1.03%, and the increased backpressure changes from 1681 Pa to 1807 Pa when the highest vehicle speed is 125 km/h.
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