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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