Battery Enclosure Presentation
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Transcript of Battery Enclosure Presentation
Members
Brian AlanoJae Shin Korkut OzuyenerChristopher SheltonMatt Zwiesler
Introduction Planning Design Specification Competitive Benchmark Concept Design Product Evaluation Impact Statement Conclusion Recommendation
462 Capstone design Design of battery enclosure for
Toyota Prius Used with existing Hybrid technology
to further improve car performance Plug-in technology used to double
overall vehicle performance
Schedule in Microsoft Excel Calendar in Yahoo! batterybox group Weekly team meetings Weekly and daily status reports
ME462 Project Plan
Assigned To
Man-Hours
hours complete
% complete Inputs Deliverables Deadline
Currently Projected Completion
Actual Completion
Specification Definition 0% approved PDP approved QFD 01-31 01-30
Jae 1 0 0%ME462 Project Handout who on QFD 01-24
Jae 4 0 0%
sponsor, ME462 Project Handout, who on QFD what on QFD 01-24
Weigh customer requirements Jae 0.5 0 0%
research, ME462 Project Handout, what on QFD what on QFD 01-24
Matt 12 0 0%research, what on QFD
Now v. What on QFD (benchmarks v. requirements) 01-27
Matt 6 0 0% now, what on QFDWhat v. how & how v. how on QFD 01-28
Matt 4 0 0% now, how on QFD
Now v. How on QFD (benchmarks v. specifications) 01-28
Set targets Jae 6 0 0%now, what, how on QFD
how v. how much and now v. how much on 01-29
QFD approval Team 5 0 0% QFD approved QFD 01-30
Task
Evaluate competition against cust. requirements
Evaluate competition against engr. specifications
Generate engineering specifications
Description of customers
Generate customers requirements
38.5
Maintenance cost ($/year) Total cost of prototype Trunk space after installation (sq. in) Number of battery modules that fit (#) Max internal temp at max power draw
(deg. C) Explosive force experienced without
fragmenting (kg TNT)
HymotionPros
CompactAppearance
ConsNo analysis
Stress & ThermalNo spare tire
solutionNo fans
Jerry’s BoxPros
Cheap Compact
ConsWeak MaterialNo Analysis
Stress & ThermalDangerousNo fan
Latch High Strength
MaterialSS + Rugged Alloy
Steel High Holding Capacity
7500 lbs Easy to use Simple design Adjustable
Constraints Interference check
with trunk interior
Potential energy contained by batteries equal to 25.2 MJ
Laws of thermodynamics- pressure that results from complete release of energy equal to 21.58 ksi 9.6” thick Al-7075T6 necessary
BlastWrap data indicates it can absorb 4.9 MJ Leaves energy that could result in pressure of
17.38 ksi 8.4” thick Al-7075T6 necessary
This is worst case scenario, and disregards any ventilation also
Rectangular pressure vessel calculations from ASME Boiler and Pressure Codes
1/4” thick Al-7075T6 can handle 22.17 psi.
This equals about 25.82 kJ. Added to energy absorbed by BlastWrap
results in total energy designed enclosure can handle= 4.9258 MJ
Thickness (in) Pressure (psi)
Alum 2014T6 Alum 2024T3 Alum 7075T6
0.01 0.033554634 0.030199171 0.035951394
0.1 3.338898164 3.005008347 3.57739089
0.2 13.28273245 11.9544592 14.23149905
0.25 20.69781195 18.62803075 22.17622708
0.3 29.72399151 26.75159236 31.84713376
0.4 52.55748475 47.30173627 56.3115908
0.5 81.68028005 73.51225204 87.51458576
Hand calculated allowable pressure used
Bottom of enclosure used as it would experience largest moments
Symmetry- Forces applied to two sides
Static Pressure Analysis Von Mises Failure
Criteria Max stress=60.33 ksi
Ansys Stress AnalysisSolid Brick 8 Node
45Aluminum 7075T61/10th Scale ModelBoundary ConditionSymmetry
GeometryApplied Pressure =
22.176 Psi
Ansys Model
Free Meshing Deformation
VonMises Stress
c
Maximum Stress
Conclusion
Maximum stress: 21226 psiMax ultimate strength of material: >
75000 psiThe selected battery enclosure can
withstand the calculated explosion force: 22.176 psi
Boundary Fluent Boundary Type
Parameter and Value
Enclosure wall
Wall Adiabetic (heat flux = 0)
Battery module surface
Wall Constant heat flux1000 W/m2 (run 1)50 W/m2 (run 2)
Intake Inlet vent T air = 323 K
Outlet Exhaust fan Δp = 3500 Pa
Fluent model boundary conditions
Fluent mesh
20C discharge rate
Velocity Streamlines
20C discharge rate
Aluminum
Grade Ultimate Strength (ksi)Price ($)
Ksi 4'x12' 4'x8'
2014T6 70 Unable to obtain unable to obtain
2024T3 58-63 $170.95 $114.54
7075T6 68-75 $153.95 $117.95
Al-2014T6 much rarer than expected Al-7075T6 is the strongest, then 2014T6, and then
2024T3. even with a higher ultimate strength, the price of
7075T6 cheaper than that of 2024T3 Aluminum 7075T6 chosen
Bill of Materials
ItemPurchasing Information Unit Quantity Price Total
Aluminum Sheet (t = 0.025") Grade = 7075T6 4'x8' sheet 1 $117.95 $117.95
Aluminum Sheet (t = 0.025") Grade = 7075T6 4'x4' sheet 1 $51.27 $51.27
BlastWrap (t = 1.0") sqft 16 $16.00 $256.00
Toggle Clamp CL-500-PA piece 2 $64.00 $128.00 Fan SF-90 piece 2 $2.50 $5.00 Vent piece 1 $3.99 $3.99
Metal Feet Attachment piece 4 $18.20 $72.80
Retractable Cord Apparatus 5000-30GF piece 1 $33.00 $33.00
Total $668.01
Enclosing the battery pack safely, securely, and conveniently
Protection from accidental battery explosion
Reduces customer’s budgetSafety concerns of Toyota Plug-in Hybrid
customersSafety concerns of Toyota manufacture
Satisfied the majority of our sponsor’s requirementsFit in the trunk space and hold two battery
modules inside safely and securely Analysis
Hand calculations, Pro-Engineer analysis, Ansys analysis, and CFD analysis gave the team more confidence
Satisfied the cost requirement will help the future product to be
completed satisfactorily.
BlastWrap is such a new material, even they do not have many solid data points on their material Design and conduct small scale tests, utilizing the
BlastWrap during explosions Compare results to other scaled explosion tests that
do not utilize the BlastWrap. Possibility to prove its efficiency and more
Different material could be chosen for the outside of the enclosure.
Cheaper, lighter weight If tests show BlastWrap not
as efficient Choose stronger, heavier,
more expensive material Ensure customer’s safety.
Explosion analysis with softwareLive demoDynamic analysis
Ansys Analysis LimitationExplosion force simulationComputer limitation
Redesign of ventilation systemEliminate hot spots
Presentation on HPEV battery technology http://enerdel.com/pdfs/EnerDelTechnicalPresentation.pdf
Lithium Ion Battery http://electronics.howstuffworks.com/lithium-ion-battery1.htm
Jerry's Battery Box Jerry's battery box, used for competitive benchmarking http://jerryrig.com/convert/step10.html
Hymotion http://www.hymotion.com/
Hymotion Installed good view of installation http://www.hybridfest.com/images/26.jpg
About explosions by Aristatek equation for peak overpressure http://www.aristatek.com/explosions.aspx
Blast Wrap http://www.blastgardintl.com/pdfs/BLGA_AP_12805.pdf
Blast Wrap specs http://www.blastgardintl.com/bp_blastwrap.asp
Calculating overpressures from BLEVE (Boiling Liquid Expanding Vapor Explosion http://dx.doi.org/10.1016/j.jlp.2004.08.002
Vapor Cloud Explosion Estimates http://www.questconsult.com/99-spring.pdf
Vapor Cloud Explosion Estimates http://www.questconsult.com/99-spring.pdf
Dr. Hazim El-MounayriThrough out the whole project
Dr. Sohel AnwarProject Sponsor
Jack WaddellInformation of new product – Blast Wrap
Dr. Erdal YilmazCFD Analysis
TA. Rapeepan PromyooAnsys Modeling