Optimized static configuration for output power maximization of thermoelectric generator arrays with hardware validation

Employment of the thermoelectric generator (TEG) device as a potential green energy source encounters a major challenge due to the power losses created between its modules because of the non-uniform temperature distributions (NUTDs). For this reason, several previous works in the literature proposed approaches to dynamically reconfigure the TEG arrays to alleviate such mismatched power losses under NUTDs. Yet, dynamic configuration-based approaches require the installation of switches and sensors, which would, in turn, increase the cost and complexity of the system. To alleviate these issues, this paper proposes the design and deployment of an Optimized Static Configuration (OSC) for TEG arrays as a unique layout to replace the standardized series–parallel (SP) one. The proposed OSC is determined via the solution of a Sudoku puzzle that aims to maintain homogeneous temperature distribution across the parallel strings of the TEG array to boost the yielded produced power. The developed OSC is examined with TEG arrays of two different sizes of 6 × 6 and 9 × 9 under various NUTD conditions. The results demonstrate that the TEG array’s power output can be improved by over 6.5 % compared to the original SP configuration. Additionally, experimental validation is carried out in a 4 × 4 TEG array to confirm the feasibility of implementing OSC in practice. Finally, the OSC approach is critically evaluated in comparison to recent dynamic reconfiguration methods, taking into account factors such as the ability to mitigate temperature distribution nonuniformity, the required switches, system complexity, and overall costs. The OSC saves about 1498.5 $ of the initial cost for the switches and sensors needed for the dynamic reconfiguration approaches for a 9 × 9 TEG array.