Development of Thermoelectric Power Generation with Safety System for Electric Vehicles using IOT Technology

Abstract

Electric Vehicles (EVs) have emerged as a sustainable alternative to conventional transportation, but battery safety and energy efficiency remain critical challenges. This project presents the development of a Smart Safety System for EVs using Internet of Things (IoT) technology integrated with Thermoelectric Generator (TEG) modules. The system continuously monitors key battery parameters such as temperature, voltage, and current using sensors connected to an IoT-enabled microcontroller. Real-time data is transmitted to a cloud platform, allowing remote monitoring and instant alerts in case of abnormal conditions. When the battery temperature exceeds a predefined limit, automatic safety measures such as cooling activation and vehicle shutdown are triggered to prevent thermal runaway and fire hazards. Additionally, the TEG module converts waste heat generated from the battery into electrical energy, which is stored in a secondary battery to improve overall efficiency and extend vehicle range. This integrated approach enhances safety, optimizes energy utilization, and increases reliability, making it a cost-effective and scalable solution for modern electric vehicles.

Introduction

This project presents a Smart Safety System for Electric Vehicles (EVs) that combines IoT-based battery monitoring with thermoelectric energy generation to improve battery safety, efficiency, and reliability. It addresses key EV challenges such as battery overheating, thermal runaway, fire hazards, and energy loss due to waste heat.

The proposed system continuously monitors battery temperature, voltage, and current using sensors connected to an ESP32/Arduino-based IoT platform. Real-time data is displayed on a cloud dashboard, enabling remote monitoring and predictive maintenance. If unsafe conditions are detected, the system automatically activates cooling fans, fire protection mechanisms, vehicle shutdown, and user alerts to prevent battery damage.

To improve energy efficiency, the system uses Thermoelectric Generator (TEG) modules to convert waste heat from the battery into electrical energy using the Seebeck effect. The recovered energy is stored in a secondary battery and can support auxiliary loads, increasing overall vehicle efficiency and driving range.

The literature review highlights existing research on IoT monitoring, thermal management, AI-based fault detection, and thermoelectric energy harvesting. However, most previous studies address these functions separately, whereas this project integrates safety monitoring, automated protection, and energy recovery into a single system.

Testing showed that the system accurately monitored battery conditions, responded quickly to overheating by activating safety measures, and successfully generated usable electrical power from waste heat. The proposed design is compact, cost-effective, scalable, and suitable for various electric vehicles, contributing to safer and more energy-efficient electric mobility.

Conclusion

The developed Smart Safety System for Electric Vehicles successfully addresses critical challenges related to battery safety, thermal management, and energy efficiency. By integrating IoT technology with advanced sensors, the system enables continuous real-time monitoring of battery parameters such as temperature, voltage, and current. This ensures early detection of abnormal conditions and allows immediate preventive actions, including automatic cooling and vehicle shutdown, thereby reducing the risk of thermal runaway and fire hazards. Additionally, the incorporation of Thermoelectric Generator (TEG) modules provides an innovative approach to utilizing waste heat energy. The system effectively converts excess battery heat into electrical energy, which can be stored and reused, contributing to improved energy efficiency and extended vehicle range. The results demonstrate that the system is reliable, responsive, and capable of enhancing overall EV performance. Its compact design and low maintenance requirements make it suitable for practical implementation. Overall, this project contributes to the development of safer, smarter, and more sustainable electric vehicles, supporting the future of green transportation.

References

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Copyright

Copyright © 2026 Prof. S. P. Johle, Ms. Samiksha Khobragade, Ms. Diya Madavi, Mr. Hardik V. Bodele. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.