Description:Field of Invention
The present invention focuses on how the Thermoelectric Energy Harvesting System enables efficient dual-zone heat recovery in aircraft by autonomously allocating power to onboard systems. It enhances energy sustainability through integrated thermal-electric conversion, battery management, and intelligent alert mechanisms using a combination of embedded hardware and software controls.
Background of the Invention
Aircraft systems require reliable and uninterrupted power, especially during critical operations such as emergency events or partial system failures. The present invention introduces a Thermoelectric Energy Harvesting System specifically designed to recover waste heat from dual thermal zones within an aircraft and convert it into usable electrical energy. This system not only supports energy sustainability but also ensures autonomous power allocation to onboard systems, such as emergency lighting, communication modules, and avionics.
The design incorporates SP1848 thermoelectric modules for efficient heat-to-electricity conversion, temperature sensors for real-time thermal monitoring, and a battery management system that tracks the state of charge (SOC) of energy storage units. In the absence of sufficient thermoelectric output, the system simulates battery discharge to maintain continuous power delivery, ensuring no disruption in essential operations. Additionally, an LCD display provides real-time status updates, while LED indicators and a buzzer alert mechanism notify the crew if the backup system fails to receive power.
Unlike traditional aircraft systems that depend solely on engine-driven generators or static battery reserves, this invention introduces an intelligent fall-back mechanism powered by ambient thermal gradients. A pushbutton is included to simulate thermoelectric failure, which activates an autonomous battery-powered mode and provides auditory and visual alerts. The system also includes an auto-reset feature to restore its default operational state after each simulated or actual event, ensuring uninterrupted readiness.
Various aircraft power backup systems exist today, but many are either manual in nature or lack autonomous fault handling and dynamic power distribution. The proposed thermoelectric solution stands apart by integrating real-time thermal conversion, intelligent battery support, and autonomous control within a single system. For instance, systems like US20200278917A1 explore waste heat utilization in vehicles, but this invention uniquely focuses on aircraft-specific constraints and dual-zone recovery with SOC tracking and alert feedback.
By addressing the need for autonomous, renewable energy backup in aerospace environments, this invention enhances operational reliability, especially in scenarios where main power sources are unavailable. Its integration of real-time monitoring, energy harvesting, and autonomous response makes it an indispensable component for modern aircraft power resilience.
Summary of the Invention
The Thermoelectric Energy Harvesting System is designed to enhance onboard power reliability in aircraft by converting waste heat from dual thermal zones into usable electrical energy. This innovative system autonomously allocates power to critical subsystems, such as avionics or emergency lighting, especially in scenarios where conventional power sources are insufficient or unavailable. It integrates key components including SP1848 thermoelectric modules, temperature sensors, an LCD display for real-time monitoring, LED indicators, a buzzer for alert generation, and a pushbutton to simulate system failure.
The primary objective of this invention is to provide a sustainable and intelligent backup power solution that ensures continuous operation of essential systems. The system not only tracks battery state of charge (SOC) over time but also simulates discharge when thermoelectric input is lost, demonstrating the effectiveness of its autonomous power switching mechanism. By utilizing onboard heat gradients, the system reduces reliance on traditional energy sources and supports improved energy efficiency.
Internal communication between sensors, power modules, and the control unit ensures rapid response and system coordination. The inclusion of an automatic reset function guarantees that the system is immediately ready for future use, maintaining operational readiness throughout flight operations. This invention significantly improves energy resilience in aircraft by combining renewable power harvesting, real-time monitoring, and autonomous control in a compact, integrated setup.
Brief Description of Drawings
The invention will be described in detail with reference to the exemplary embodiments shown in the figures where in:
Figure 1:System Behavior During Normal Operation (TEG Power Available) Simulation.
Figure 2:Isometric view of Base Model Modelled in CATIA.
Figure 3: Final Model with Integration (Isometric View).

Detailed Description of the Invention
The Thermoelectric Energy Harvesting System for Dual Zone Heat Recovery in Aircraft with Autonomous Power Allocation is a self-sustaining, intelligent, and safety-oriented solution designed to utilize waste heat from different zones of an aircraft to generate electrical energy. The system is particularly valuable during emergency scenarios or when auxiliary power units fail or become temporarily unavailable. Designed with aerospace safety and sustainability in mind, the invention is focused on powering essential systems such as emergency lighting, avionics, and communication modules, thereby acting as a renewable secondary power supply embedded within the aircraft's existing structure.
This invention uses thermoelectric modules to recover waste heat from two key thermal zones of the aircraft. The first zone typically consists of a high-temperature region such as the engine nacelle or exhaust duct, where intense thermal energy is available for harvesting. In contrast, the second zone focuses on areas with moderate but consistent heat exposure, such as the aerodynamically heated wing surfaces, which generate thermal energy due to air friction and boundary layer effects during flight. These zones are selected based on the natural presence of a thermal gradient, which is critical for the functioning of thermoelectric modules. When installed correctly with proper thermal interfaces and insulation, these zones provide sufficient temperature differences for energy conversion during most phases of flight, including climb, cruise, and descent.
The system’s primary energy harvesting elements are SP1848-27145SA thermoelectric generator (TEG) modules, chosen for their efficiency, durability, and suitability for moderate to high-temperature ranges. These modules are placed between heat sources and heat sinks (either internal or ambient), with thermal paste applied to improve heat conduction and reduce resistance. Each TEG produces a DC voltage when exposed to a temperature gradient. The energy harvested from both thermal zones is routed through a smart power management system that ensures stable charging of onboard energy storage devices, in this case, two 3.7V 2200mAh lithium-ion batteries mounted securely in a dual-holder configuration.
The battery charging process is handled by the TP4056 Lithium-Ion charging module, which includes built-in overvoltage, overcurrent, and short-circuit protection features. The output voltage, once stored, is regulated using an MT3608 adjustable boost converter. This converter ensures the output voltage remains steady and sufficient to power downstream components and aircraft systems, even as the battery voltage fluctuates. The charging system is configured to optimize energy storage during flight and retain charge for use during critical low-power scenarios, such as auxiliary power unit (APU) failure, emergency descent, or idle ground operation.
The control system is centered around an Arduino Uno microcontroller, which acts as the brain of the entire operation. It interfaces with multiple sensors and components, including temperature sensors placed on both hot and cold sides of the TEG modules, battery voltage sensors, and SOC logic. The Arduino collects and processes data continuously and makes intelligent decisions on when to switch between thermoelectric charging mode and emergency battery discharge mode. A key innovation lies in its ability to simulate thermoelectric module failure using a dedicated pushbutton, allowing to demonstrate the system’s emergency behaviour without requiring actual environmental changes.
In the event of thermoelectric power losseither simulated or realthe system transitions into emergency mode, automatically disabling power flow from TEGs and sourcing energy exclusively from the pre-charged battery bank. During this state, the LCD (with I2C module) updates live data such as current voltage, estimated battery percentage, and whether the system is in “Charging” or “Discharging” mode. LEDs provide visual alerts: green indicates normal operation with thermoelectric generation, while red signifies battery fall back mode or system alert. Simultaneously, an onboard buzzer generates a sound alert, notifying the crew or operators of the change in power status.
To support continuous monitoring and clarity, the LCD screen remains active throughout the flight, even during battery-only operation. This screen allows quick visualization of system health without needing external devices or interfaces. The inclusion of real-time SOC tracking and temperature display improves operational transparency, especially in scenarios where environmental conditions fluctuate rapidly, such as when flying through various altitudes and ambient temperatures. In more advanced applications, this data can also be logged for flight analysis, predictive maintenance, or research purposes.
An integral part of the system’s design is its automatic reset function. Once thermoelectric input is re-establisheddue to a return in heat differentialthe system automatically transitions back to power harvesting mode. The LEDs turn green again, the buzzer turns off, and the Arduino reactivates the TEG input line while ceasing battery discharge. This ensures that the system is always ready for the next cycle, providing seamless operation without manual intervention. The reset mechanism is designed to work in real-time, with minimal delay, to preserve the efficiency and readiness of the system.
The system is also capable of simulating long-term energy use by discharging the battery when no thermoelectric output is present, and plotting the SOC curve over time using the Arduino serial plotter. This feature is extremely useful for validating the system under various simulated failure durations. It also helps in refining the threshold levels for triggering alerts and optimizing the load connected to the system to ensure energy-efficient use during emergencies.
From a structural point of view, the system is lightweight, modular, and easy to integrate into existing aircraft compartments without significant alterations. All components are mounted on a non-conductive platform and connected using durable wiring and soldered joints where needed. The I2C module with the LCD helps minimize pin usage on the Arduino, allowing room for future expansion with additional sensors or modules. The use of widely available, low-cost components such as the TP4056 and MT3608 ensures that the entire setup remains economical while still achieving high reliability and functionality.
This thermoelectric system is not limited to manned aircraft. Its scalable architecture makes it suitable for drones, high-altitude long endurance UAVs, and even satellites, where weight, autonomy, and power efficiency are critical. Additionally, it can be implemented in ground vehicles or remote sensing platforms where access to conventional power supplies is restricted, and waste heat is available. In the future, the system can be expanded with MPPT (Maximum Power Point Tracking) circuits, wireless data logging modules, or adaptive load balancing based on remaining battery percentage.
The invention provides substantial advantages over traditional backup systems, which are often either passive or manually controlled. In contrast, this system features autonomous switching, real-time visual and auditory feedback, dual-zone energy input, and continuous battery health trackingall working together to provide an intelligent layer of power assurance. It also enhances flight safety by preventing the sudden loss of electrical power during critical phases and providing immediate alerts to crew for corrective action.
In summary, the Thermoelectric Energy Harvesting System for Dual Zone Heat Recovery in Aircraft is a well-rounded, forward-compatible, and sustainable invention that addresses key challenges in aerospace energy management. By converting existing waste heat into electrical power, intelligently distributing that power through real-time logic, and maintaining system visibility through displays and alerts, the system offers a proactive and highly functional solution for emergency power assurance. It aligns with modern aviation’s goals of electrification, sustainability, and fault tolerance, offering benefits across commercial, defence, and unmanned aviation domains. , Claims:The scope of the invention is defined by the following claims:

Claim:
1. A novel system and method for autonomous dual-zone thermoelectric energy harvesting in aircraft, designed to convert spatially separated waste heat sources into regulated electrical power, with real-time power allocation, emergency fallback, and alert signaling, all integrated into a modular and reconfigurable hardware framework.

a) A dual-source energy harvesting method wherein thermoelectric modules are deployed across two distinct heat zones a first high-grade thermal zone such as an engine nacelle or exhaust manifold, and a second moderate-grade aerodynamic heating zone such as the aircraft wing leading edge to extract differential thermal gradients for optimized energy conversion.
b) A dynamic boost-regulation system configured to receive input from spatially separated thermoelectric modules and autonomously adjust output voltage via an MT3608 or equivalent DC-DC converter to ensure reliable battery charging and uninterrupted supply to critical avionics or emergency systems.
c) A system for intelligent energy allocation that prioritizes essential onboard functions based on sensed battery state of charge (SOC), load demand, and thermoelectric input, using an Arduino-based control logic platform coupled with real-time LCD feedback.
d) A simulation-trigger mechanism, comprising a physical toggle switch or pushbutton, configured to emulate TEG (thermoelectric generator) failure conditions, wherein the system bypasses TEG input and draws solely from battery reserves to test autonomous emergency operation, while simultaneously activating multimodal alerts including LEDs and buzzers.
e) An automatic system-reset protocol post-alert or battery-depletion condition, restoring initial monitoring and harvesting cycles without manual intervention, ensuring continuous power assurance across variable thermal environments during aircraft operation.

2. According to claim 1, the spatially optimized dual-zone configuration wherein the thermoelectric modules are independently placed in two thermally uncorrelated regions one exposed to combustion-related waste heat, and the other utilizing friction-induced aerodynamic heating thereby ensuring redundancy and enhancing net energy yield.

3. As per claim 1, the fully integrated power monitoring and fault simulation system comprising a user-activated TEG-failure emulator, real-time SOC tracking, visual (LED) and auditory (buzzer) alerts, and automated fallback to battery power, enabling proactive safety checks and power assurance in the event of thermal input loss.