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•An automotive thermoelectric generator (ATEG) is built and tested experimentally.•A method to predict the ATEG fuel economy is validated.•ATEG backpressure, power generation, weight and coolant pumping power are considered.•The maximum fuel economy point does not coincide with the ATEG maximum power generation.
Automotive thermoelectric generators (ATEG) have become a promising technology for exhaust heat recovering in vehicles. Many models and prototypes have been developed and validated with very encouraging results. Most of them have been analyzed in both steady-state and transient conditions in engine test benches. However, only very few have been tested on a real vehicle while injecting the power generated by the ATEG to the electrical system. The first part of this work deals with a real test of a new concept of ATEG in a mid-size vehicle under different steady-state engine regimes. The second part, which goes beyond the state-of-the-art of ATEGs, is focused on the validation of a new mathematical method for predicting the expected fuel economy.
The ATEG presented allows for saving up to 1.08% of fuel and CO2 emissions. In addition, the results show that the model enables the estimation of the ATEG savings accurately, with an average error of 11.27%. This data represents the accomplishment of the main objective of this paper providing original and unique data, and a useful tool for ATEG designers.