Recent studies have focused on Thermoelectric Generators (TEGs) as a key to sustainable energy, using thermal power through temperature differentials to produce electric power. Despite the promise of TEGs, there is diversity of TEG models and the shortage of comprehensive evaluations on energy conversion. In particular, measuring the output of electrical energy and time of production across temperature variances, which has impeded their broad adoption. This research conducted a comprehensive analysis of TEG models. It used a new test rig designed in SolidWorks and actualized, coupled with MATLAB simulations to validate the predicted results. This includes developing a wearable device such as a helmet-mounted warning light for motorcyclists or cyclists. In the study, five different thermoelectric generator models (TEG1-12703, TEG1-12706, TEG1-12709, TEG1-12712, and TEG1-12715) were tested, these models showed varying power outputs of 66.46, 97.51, 117.5, 191.72 and 358.74 mW. Their efficiencies were 1.78 %, 1.982 %, 2.097 %, 2.567 % and 2.93 %, respectively, when ΔT reaches 30 °C. The experimental and theoretical data indicate discrepancies in results and thermal response delays due to heat transfer and energy conversion within the test rig’s layers. These discrepancies were addressed to adjust simulations closer to reality. A differential correction ratio (19.133 % for power, 17.94 % for efficiency) was applied to enhance prediction accuracy. After adjustment, the maximum power generation reached 1.64355, 2.8386, 3.83433, 4.6843, 4.96746 W. The maximum efficiency peaked at 2.236, 3.59462, 4.1184, 6.278154, 6.75779 %, respectively, when ΔT reaches 70 °C. The output power and efficiency from these TEGs could run certain sensors.The study shows that TEG model 12,715 excels in generating electrical energy with large temperature differences. However, its output nearly vanished under a 1 °C differential, ending tests prematurely. In contrast, the model 12,703 consistently generates electricity over long periods (more than 420 min) under minimal temperature differential, while it is unable to produce high power under greater differentials. This suggests that using diverse TEG models and integrating together to enhance the efficiency and continuity of free energy generation, depends on the models’ varied performance and temperature differences. Utilizing the results, five TEG units connected in parallel were installed on a cyclist’s helmet to power a rear warning light, this installation enhances night-time safety. These TEG models demonstrated continuous power generation, producing an average of 55.7 mW per hour with a temperature difference ΔT between 3.2 °C and 7.4 °C.
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