DESIGN OF THERMOELECTRIC ENERGY HARVESTER USING LTC 3108

BOOST CONVERTER

MUHAMMAD ZULHAIZER BIN AB RASHID

This Report Is Submitted In Partial Fulfillment Of Requirements For The Bachelor

Degree of Electronic Engineering (Industrial Electronic)

Fakulti Kejuruteraan Elektronik dan Kejuruteraan Komputer

Universiti Teknikal Malaysia Melaka

June 2013

UNIVERSTI TEKNIKAL MALAYSIA MELAKA

FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER
BORANG PENGESAHAN STATUS LAPORAN

PROJEK SARJANA MUDA II

Design Of Thermoelectric Energy Harvester Using LTC3108
Tajuk Projek

Sesi
Pengajian

Boost Converter
0

Saya MUHAMMAD ZULHAIZER BIN AB RASHID mengaku membenarkan Laporan Projek

Sarjana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1.

Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2.

Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3.

Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi
pengajian tinggi.

4.

Sila tandakan ( ) :

SULIT*

*(Mengandungi maklumat yang berdarjah keselamatan atau

kepentingan Malaysia seperti yang termaktub di dalam AKTA
RAHSIA RASMI 1972)

TERHAD**

**(Mengandungi maklumat terhad yang telah ditentukan oleh

organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

__________________________
(TANDATANGAN PENULIS)

___________________________________
(COP DAN TANDATANGAN PENYELIA)

Tarikh: ..

Tarikh: ..

iii

I declare that this thesis entitled Design of Thermoelectric Energy Harvester Using
LTC3108 Boost Converter is the result of my own research except as cited in the
references. The thesis has not been accept for any degree and is not concurrently
submitted in candidature for any other degree.

Signature

Author

: MUHAMMAD ZULHAIZER BIN AB RASHID

Date

: 10th JUNE, 2013

iv

I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in
term of scope and quality for the award of the Bachelor of Electronic Engineering
(Electronic Industries) With Honours

Signature

Supervisor name

: ENGR HAZLI RAFIS BIN ABDUL RAHIM

Date

: 10th JUNE, 2013

Specially dedicated to my beloved parents, family members and fellows friend

vi

APPRECIATION

First of all, praise to Allah S.W.T., because of His grace, I was able to implement
my final year project till the end without any problems. I want to take this opportunity to
express my appreciation to those who have helped me a lot throughout completing my
PSM whether directly or indirectly. Special thanks to my family especially both of my
parent who non-stop gave me morale supports and financial resources. Thanks also to
my supervisor, Eng. Hazli Rafis Bin Abdul Rahim, for guiding me throughout getting an
analysis and also gave some advice for my project. Lastly for my love, housemate and
fellow friends, thank you so much for helped me out when I need an idea or something
that related with my project. I express my gratitude for everyone that I not mention
above and hope God will repay you well one day.

vii

ABSTRACT

Renewable energy technique is the process of converting available ambient

energy into usable electrical energy through the use of a particular material or
transduction mechanism. Nowadays, the evolution of new technology which involving
renewable energy technique and smart grid system has a huge potential in the energy
market. In line with the current technology interest in the smart grid technology, power
transformer health condition becomes one of the main issue need to be considered. The
way to monitor health condition of the power transformer has started to evolve from
typical monitoring technique to a new development of using energy harvesting
technology to activate sensors network for the monitoring purpose. For this project,
Thermoelectric Power Generator (TEG) is used to convert the heat energy get from the
power transformer into small electrical energy in order to power up electronic devices
that will triggering up the monitoring system. TEG only produces small electrical
energy, so the boost converter is needed in order to increase the electrical energy from
the TEG and get its maximum power point tracking (MPTT). The boost converter is a
type of DC-to-DC converter which has a greater output than the input voltage. So, the
result of this project will show us the small electrical energy, converted from the heat
energy , range between 20 mV to 1.5V that is get from the TEG will be raised up until at
least 5V using a boost converter. 5V is the minimum volts to trigger up the PIC circuit
or any others small electronic appliance that has low power consumption.

viii

ABSTRAK

Teknik tenaga boleh diperbaharui adalah proses menukarkan tenaga ambien yang
sedia ada kepada tenaga elektrik yang boleh digunakan melalui penggunaan bahan
tertentu atau mekanisme transduksi. Kini, perkembangan teknologi baru yang
melibatkan teknik tenaga boleh diperbaharui dan sistem grid pintar mempunyai potensi
yang besar dalam pasaran tenaga. Selaras dengan kepentingan teknologi semasa dalam
teknologi grid pintar, keadaan transformer kuasa menjadi salah satu isu utama yang
perlu dipertimbangkan. Cara untuk memantau keadaan transformer kuasa telah berubah
mengikut peredaran masa sehinggalah penghasilan teknologi baru melalui penuaian
tenaga untuk menghidupkan rangkaian sensor sebagai tujuan pemantauan.Untuk projek
ini, penjana thermoelectric (TEG) digunakan untuk menukarkan tenaga haba yang
diperolehi daripada transformer kuasa kepada tenaga elektrik kecil yang mampu
menghidupkan alat-alat elektronik yang akan mencetuskan satu sistem pemantauan.
TEG akan menghasilkan tenaga elektrik kecil, jadi penukar tingkat diperlukan dalam
usaha untuk meningkatkan tenaga elektrik daripada TEG dan mendapatkan pengesanan
titik kuasa maksimum (MPTT). Penukar tingkat adalah sejenis penukar DC ke DC yang
mempunyai keluaran yang lebih besar daripada voltan masukan. Jadi, hasil daripada
projek ini akan menunjukkan kepada kita tenaga elektrik kecil, ditukar daripada tenaga
haba, julat antara 20 mV sehingga 1.5V yang didapati daripada TEG akan ditingkatkan
sehingga sekurang-kurangnya 5V menggunakan penukar tingkat. 5V adalah volt
minimum untuk menghidupkan litar PIC atau mana-mana perkakas elektronik lain yang
mempunyai penggunaan kuasa yang rendah.

ix

TABLE OF CONTENTS

CHAPTER

CONTENT

PAGES

PROJECT TITLE

DECLARATION

iii

DEDICATION

APPRECIATION

vi

ABSTRACT

vii

ABSTRAK

viii

TABLE OF CONTENTS

ix

LIST OF TABLES

xiii

LIST OF FIGURES

xiv

LIST OF ABBREVIATIONS

xvi

LIST OF APPENDICES

xvii

II

INTRODUCTION
1.1 Project Introduction

1.2 Project Objective

1.3 Problem Statement

1.4 Scope of Work

1.5 Brief Description of Methodology

1.6 Report Overview

BACKGROUND STUDY / LITERATURE REVIEW

2.1 Basic Understanding of Boost Converter (Ideal Circuit)
2.1.1 Mathematical Model of Boost Converter

8
11

2.2 Literature Review From Related Journal

12

2.3 Basic Introduction Based On Literature Review

17

2.3.1 List of Hardware Involved

17

2.3.1.1 TEG

17

2.3.1.2 LTC3108 IC

21

2.3.1.2.1 Pin Configuration of LTC3108

22

2.3.1.2.2 Operation of LTC3108

26

2.3.1.3 SMT Component

2.3.1.3.1 History of SMT

33
35

xi

2.3.1.3.2 Advantage and Disadvantage of SMT

36

2.3.1.3.3 Type and Size of SMT Component

38

2.3.1.4 Custom Made Double Layer PCB

2.3.2 List of Software Involved

III

39
40

RESEARCH METHODOLOGY
3.1 Project Background

41

3.2 Project Methodology

43

3.2.1 Phase of Method and Approach

IV

3.2.1.1 First Phase (Literature Review)

45

3.2.1.2 Second Phase (Design, Simulation and Analysis)

45

3.2.1.3 Third Phase (Implementation)

49

3.2.1.4 Fourth Phase (Thesis Writing)

49

RESULT AND DISCUSSION

4.1 Introduction

50

4.2 Structure of the System

51

4.3 Final Design

52

4.3.1 Circuit Diagram (Schematic)

52

4.3.2 Circuit Diagram (PCB Layout)

53

xii

4.3.2.1 Pin Name and Function

54

4.4 Final Product

55

4.5 Analysis of TEG and LTC3108 Boost Converter

58

4.5.1 Voltage Output Versus Current (TEG)

58

4.5.2 Temperature Versus V out (TEG)

59

4.5.3 Vin Versus Vout (LTC3108 Boost Converter)

60

4.6 Final Output of LTC3108 Boost Converter

62

4.7 Final Discussion

62

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

63

5.2 Potential of Commercialization

64

5.3 Recommendation

64

REFERENCES

65

APPENDICES

67

xiii

LIST OF TABLES

NO.

DESCRIPTION

PAGES

2.1

Pin Function of LTC3108

23

2.2

Regulated Voltage Using Pins VS1 and VS2

25

2.3

Operation of LTC3108

27

4.1

Pins Name and Its Function

54

xiv

LIST OF FIGURES

NO.

DESCRIPTION

1.1

Power Transformer in Distribution System

1.2

Hot Spot Measurement of High Voltage Transformer

2.1

Basic Circuit of Boost Converter

10

2.2

ON and OFF State of Basic Boost Converter

11

2.3

Example of TEG Device

18

2.4

The Seebeck Effect Due To Temperature Gradient

19

2.5

Basic Structure of Thermoelectric Couple

20

2.6

Equivalent Thermoelectric Model

21

2.7

Pin Configuration of LTC3108

23

2.8

Block Diagram of LTC3108

27

2.9

Output Voltage Sequencing with Vout Programmed

for 3.3V (Time Not to Scale)

PAGES

33

xv

2.10

Comparison between SMT Component (left) with

Through-hole Component (right)

34

2.11

Surface-mount Capacitor

34

2.12

Size of SMT Component

38

3.1

Flow of Project

43

3.2

Methodology Flowchart

44

4.1

Structure of the System

52

4.2

Schematic Diagram of the Project

53

4.3

PCB Layout Diagram of the Project

54

4.4

Final Product Using LTC3108 IC And Surface

Mount Component

56

4.5

Real Size of the Product Which Is Compact

57

4.6

Final Product Inside the Packaging

57

4.7

Vout, V VS Current,I

59

4.8

Temperature, C VS Vout, V

60

4.9

Vin, V VS Vout, V

61

4.10

Final Output

62

xvi

LIST OF ABBREVIATIONS

TNB Tenaga Nasional Berhad

TEG Thermoelectric Generator
V - Voltage
PIC Programmable Integrated Circuit
IC Integrated Circuit
DC Direct Current
PWM Pulse Width Modulator
SMD Surface Mount Device
SMT Surface Mount Technology
PMC Power Management Circuit
PCB Printed Circuit Board
I Current
C - Celcius

xvii

LIST OF APPENDICES
(noted that the appendix section is start at page 67)

NO.

DESCRIPTION

ELECTRICAL AND TYPICAL PERFORMANCE

PAGES

CHARACTERISTIC OF LTC3108

APPENDIX A-1

TYPE OF SMT PACKAGE

APPENDIX B-1

GAANT CHART

APPENDIX C-1

COMPONENT SELECTION

APPENDIX D-1

CHAPTER I

INTRODUCTION

1.1

Project Introduction

Renewable energy technique is the process of converting available ambient

energy into usable electrical energy through the use of a particular material or
transduction mechanism. Nowadays, the evolution of new technology which involving
renewable energy technique and smart grid system has a huge potential in the energy
market. Although the application of new technology in the smart grid system has
evolved rapidly, devices such as power transformer is still be a major component in the
power distribution system. Thus, in line with the current technology interest in the smart
grid technology, power transformer health condition becomes one of the main issues
considered.

Figure 1.1: Power Transformer In Distribution System

In this situation, the health condition of power transformer is about how much
the heat generate during the transformer operated. Heat is generated due to the high
voltages that need to be step-up or step-down by the transformer. Overheat may cause
minor or major damage to the transformer and this will affect the performance of the
transformer and this also will lead to failure of the transformer. So to reduce and
overcome this problem, we must have a device that could monitor the heat generate by
the power transformer. This monitoring system will be used to inform the relevant
authority, for example Tenaga Nasional Bhd. (TNB) or other electric supply company,
whether the temperature of the transformer is in control or not. This will allowed them to
make any maintenance before the transformer malfunction or get any another major
damage.

Figure 1.2: Hot Spot Measurement of High Voltage Transformer

The way to monitor power transformer has started to evolve from typical
monitoring technique to a new development of using energy harvesting technology to
activate sensors network for the monitoring purpose. The ambient heat energy obtained
from the power transformer will be harvested to turn on power electronic compensator
and driven the sensors.

In producing an auto monitoring system for the power transformer, the

Thermoelectric Power Generator (TEG) can be used as a device which will generate a
small electrical energy. Normally TEG will generate an electrical voltage between 20
mV to 1.5 V, depend from the heat generated. When the temperature increases, the
voltage generated also increases. The output of TEG is normally very small and varies.
This is because the output is depend on the temperature different between 2 different
plate inside the TEG, so this small electrical energy need to be boost up to a higher level
which can be used to triggering up the PIC circuit. Normally PIC usually need around
5V to 5.5V to be operated. Therefore, the input get from the TEG must be boost up at
least 5V to let the PIC switch ON. There are two function of this PIC circuit in this
situation. First, PIC circuit is used to triggering up the communication device such as
Zigbee or Xbee to the user. Secondly, this PIC circuit reads the surrounding heat
temperature using a heat sensor so that this temperature reading can be sent through the

communication device and be used by the user whether the temperature of power
transformer is still in control or not.

This project only covered up until the operation of TEG and the design a boost
converter which used LTC3108 IC and also Surface Mount Device (SMD). This design
of boost converter must be compact and able to step-up the voltage produce by the TEG
which in range between 0.7V to 1.5V into a minimum output level which is at least 5V.

The LTC3108 is a highly integrated DC-DC converter ideal for harvesting and
managing surplus energy from extremely low input voltage sources such as TEGs
thermopiles and small solar cells. The step-up topology operates from input voltages as
low as 20mV.

Using a small step-up transformer, the LTC3108 provides a complete power

management solution for wireless sensing and data acquisition. The 2.2V LDO powers
an external microprocessor, while the main output is programmed to one of four fixed
voltages to power a wireless transmitter or sensors. The power good indicator signals
that the main output voltage is within regulation. A second output can be enabled by the
host. A storage capacitor provides power when the input voltage source is unavailable.
Extremely low quiescent current and high efficiency design ensure the fastest possible
charge times of the output reservoir capacitor.

The LTC3108 is available in a small, thermally enhanced 12-lead (3mm 4mm)

DFN package and a 16-lead SSOP package.

1.2

Project Objective

i.

To design a compact DC-DC boost converter using LTC3108 IC and SMD in

order to increase and stabilize the output voltage generated from the TEG.

ii.

To demonstrate experimentally DC/DC boost converter using LTC3108.

iii.

To analyze and evaluate the characteristic of TEG and output range produced
from the boost converter whether it capable to supply a sufficient voltage and
activated at least small electronic devices.

1.3

Problem Statement

i.

TEG generated power which is varies, intermittent and limited, so the power
management circuit (PMC) using DC-DC boost converter which use an
LTC3108 and SMD component can be used to stabilize the power to the load and
also extract maximum power.

ii.

The needs of alternative power supply to power the sensor system to grant the
effectiveness of the sensor system.

iii.

The maintenance cost to change the battery is a big issue as batteries is known to
have short lifetime

iv.

A renewable energy is an energy that have a large potential in the market

nowadays, so we need to design a new source of energy using a renewable
energy to power up small or low voltage device by manipulating an energy
harvesting technique

1.4

i.

Scope of Work

Determine the output voltage that can be harvested from the TEG circuit based
on temperature different from surrounding. This output voltage will be used as an
input to the boost converter circuit.

ii.

Developed circuit which is used to power up the PIC circuit that involving the
TEG and boost converter using LTC3108 IC, SMD component and fabricated
circuit . Where SMD component consists of resistor, capacitor and small
transformer.

1.5

Report Overview
Design of Thermoelectric Energy Harvester using LTC3108 boost converter is

the title of this report where it contains a combination of five chapters from the
introduction of this project to the outcome, expected result and conclusion of this
project. The report is written in detail on each of every step to take under consideration
on the progression of the project.

Chapter 1 elaborate briefly what the project is all matter. Here clearly stated the
background of the project, the objective, the scope of work of this project, brief
description of methodology and the overview of each of the chapter contains.

Chapter 2 is some of the literature review from an article, paper work, book,
website and all the written text that are related to the project topic. Where in this thesis,
it is included a literature review on TEG, Boost converter, SMD component and
LTC3108 as all of the materials is used in this project.

Chapter 3 is on the methodology of overall project. It will discuss about the

project background and also project methodology. At project methodology we will
discuss further the way how this project will going on. It is not limited to the hardware
choose, it also discuss on the software implementation choose.

Chapter 4 will discuss about the result that had been obtain from the project such
as the structure of the system, finished product and analysis taken. This chapter also we
will discuss about the overall data that have been collected.

Chapter 5 will concludes the overall view of the project. This chapter will
summarize the findings of the project, analysis achievement, potential of
commercialization and suggest further research for the future.