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According to the basic principle of heat transfer enhancement, a 1-kW compact thermoelectric generator (TEG) is proposed that is suitable for use at high temperatures and high flow speeds. The associated heat exchanger has a tube-row structure with a guide-plate to control the thermal current. The heat exchanger has a volume of 7 L, and the TEG has a mass of 8 kg (excluding the thermoelectric modules (TEMs)). In this paper, the heat transfer process of the tube-row exchanger is modeled and analyzed numerically; and the influences of its structure on the heat transfer and temperature status of the TEMs are investigated. The results show that use of the thin - wall pipes and increase of surface roughness inside the pipes are effective ways to improve the heat transfer efficiency, obtain the rated surface temperature, and make the TEG compact and lightweight. Furthermore, under the same conditions, the calculated results are compared with the data of a fin heat exchanger. The comparison results show that the volume and mass of the tube-row heat exchanger are 19% and 33% lower than those of the fin type unit, and that the pressure drop is reduced by 16%. In addition, the average temperature in the tube-row heat exchanger is increased by 15°C and the average temperature difference is increased by 19°C; the tube-row TEG has a more compact volume and better temperature characteristics.

The design structure and heat-transfer mechanism of a thermoelectric generator (TEG) determine its body temperature state. Thermal stress and thermal deformation generated by the temperature variation directly affect the stress state of thermoelectric modules (TEMs). Therefore, the rated temperature and pressing force of TEMs are important parameters in TEG design. Here, the relationships between structural of a fin-type TEG (FTEG) and these parameters are studied by modeling and “machine-thermal” coupling simulation. An indirect calculation method is adopted in the coupling simulation. First, numerical heat transfer calculations of a three-dimensional FTEG model are conducted according to an orthogonal simulation table. The influences of structural parameters for heat transfer in the channel and outer fin temperature distribution are analyzed. The optimal structural parameters are obtained and used to simulate temperature field of the outer fins. Second, taking the thermal calculation results as the initial condition, the thermal-solid coupling calculation is adopted. The thermal stresses of outer fin, mechanical force of spring-angle pressing mechanism, and clamping force on a TEM are analyzed. The simulation results show that the heat transfer area of the inner fin and the physical parameters of the metal materials are the keys to determining the FTEG temperature field. The pressing mechanism’s mechanical force can be reduced by reducing the outer fin angle. In addition, a corrugated cooling water pipe, which has cooling and spring functionality, is conducive to establishing an adaptable clamping force to avoid the TEMs being crushed by the thermal stresses in the body.