Battery Enclosure
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Transcript of Battery Enclosure
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Members
Brian AlanoJae ShinKorkut OzuyenerChristopher SheltonMatt Zwiesler
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IntroductionPlanningDesign Specification
Competitive BenchmarkConcept DesignProduct EvaluationImpact StatementConclusionRecommendation
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462 Capstone design
Design of battery enclosure for
Toyota PriusUsed with existing Hybrid technology
to further improve car performance
Plug-in technology used to doubleoverall vehicle performance
b1
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Slide 3
b1 Thought this was a good photo to introduce our sponsor and the space into which our enclosure goes.balano, 4/28/2008
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Schedule in Microsoft Excel
Calendar in Yahoo! batterybox group
Weekly team meetingsWeekly 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 QFD
What 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
b2
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Slide 4
b2 Jae, I dropped in images you might use. Please make it pretty.balano, 4/28/2008
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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 withoutfragmenting (kg TNT)
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Hymotion
Pros
Compact
Appearance
Cons
No analysis
Stress & Thermal
No spare tiresolution
No fans
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Jerrys Box
Pros
Cheap
Compact
Cons
Weak Material
No Analysis
Stress & Thermal
Dangerous
No fan
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LatchHigh Strength
MaterialSS + Rugged Alloy
Steel
High Holding Capacity7500 lbs
Easy to useSimple designAdjustable
Constraints Interference check
with trunk interior
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Potential energy contained by batteries equal to25.2 MJ
Laws of thermodynamics- pressure that resultsfrom complete release of energy equal to 21.58
ksi 9.6 thick Al-7075T6 necessary
BlastWrap data indicates it can absorb 4.9 MJLeaves energy that could result in pressure of
17.38 ksi
8.4 thick Al-7075T6 necessaryThis is worst case scenario, and disregards any
ventilation also
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Rectangular pressurevessel calculations fromASME Boiler and
Pressure Codes1/4 thick Al-7075T6
can handle 22.17 psi.
This equals about 25.82 kJ.
Added to energy absorbed by BlastWrapresults in total energy designed enclosurecan handle= 4.9258 MJ
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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
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Hand calculatedallowable pressureused
Bottom of enclosure
used as it wouldexperience largestmoments
Symmetry- Forcesapplied to two sides
Static Pressure
Analysis Von Mises Failure
CriteriaMax stress=60.33 ksi
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Ansys StressAnalysisSolid Brick 8 Node
45
Aluminum 7075T6
1/10th Scale Model
Boundary Condition
Symmetry
GeometryApplied Pressure =
22.176 Psi
Ansys Model
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Free Meshing Deformation
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VonMises Stress
c
Maximum Stress
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Conclusion
Maximum stress: 21226 psiMax ultimate strength of material: >
75000 psi
The selected battery enclosure can
withstand the calculated explosionforce: 22.176 psi
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Boundary Fluent
Boundary
Type
Parameter and Value
Enclosure wall Wall Adiabetic (heat flux = 0)
Battery
module
surface
Wall Constant heat flux
1000 W/m2 (run 1)
50 W/m2 (run 2)Intake Inlet vent T-air = 323 K
Outlet Exhaust fan p = 3500 Pa
Fluent model boundary conditions
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Fluent mesh
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20C discharge rate
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VelocityStreamlines
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20C discharge rate
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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 of2024T3 Aluminum 7075T6 chosen
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Bill of Materials
Item
Purchasing
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
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Enclosing the battery pack safely,securely, and conveniently
Protection from accidental batteryexplosion
Reduces customers budget
Safety concerns of Toyota Plug-in Hybridcustomers
Safety concerns of Toyota manufacture
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Satisfied the majority of our sponsorsrequirementsFit in the trunk space and hold two battery
modules inside safely and securely
AnalysisHand calculations, Pro-Engineer analysis,
Ansys analysis, and CFD analysis gave theteam more confidence
Satisfied the cost requirementwill help the future product to be
completed satisfactorily.
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BlastWrap is such a new material, even they do nothave 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 ofthe enclosure.Cheaper, lighter weight
If tests show BlastWrap not
as efficient Choose stronger, heavier,
more expensive material Ensure customers safety.
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Explosion analysis with softwareLive demoDynamic analysis
Ansys Analysis LimitationExplosion force simulationComputer limitation
Redesign of ventilation systemEliminate hot spots
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Presentation on HPEV batterytechnologyhttp://enerdel.com/pdfs/EnerDelTechnicalPresentation.pdf
Lithium Ion Batteryhttp://electronics.howstuffworks.com/lithium-ion-battery1.htm
Jerry's Battery BoxJerry's battery box, used forcompetitive benchmarkinghttp://jerryrig.com/convert/step10.html
Hymotionhttp://www.hymotion.com/
Hymotion Installed
good view of installationhttp://www.hybridfest.com/images/26.jpg
About explosions by Aristatekequation for peak overpressurehttp://www.aristatek.com/explosions.aspx
Blast Wraphttp://www.blastgardintl.com/pdfs/BLGA_AP_12805.pdf
Blast Wrap specshttp://www.blastgardintl.com/bp_blastwrap.asp
Calculating overpressures fromBLEVE(Boiling Liquid Expanding VaporExplosionhttp://dx.doi.org/10.1016/j.jlp.2004.08.002
Vapor Cloud Explosion Estimateshttp://www.questconsult.com/99-spring.pdf
Vapor Cloud Explosion Estimateshttp://www.questconsult.com/99-spring.pdf
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Dr. Hazim El-MounayriThrough out the whole project
Dr. Sohel Anwar
Project SponsorJack WaddellInformation of new product Blast Wrap
Dr. Erdal Yilmaz
CFD AnalysisTA. Rapeepan PromyooAnsys Modeling
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