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Battery Enclosure Presentation. Members Brian Alano Jae Shin Korkut Ozuyener Christopher Shelton Matt Zwiesler. Outline. Introduction Planning Design Specification Competitive Benchmark Concept Design Product Evaluation Impact Statement Conclusion Recommendation. Introduction.

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battery enclosure presentation
Battery Enclosure Presentation

Members

Brian Alano

Jae Shin

KorkutOzuyener

Christopher Shelton

Matt Zwiesler

outline
Outline
  • Introduction
  • Planning
  • Design Specification
  • Competitive Benchmark
  • Concept Design
  • Product Evaluation
  • Impact Statement
  • Conclusion
  • Recommendation
introduction
Introduction
  • 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
planning
Planning
  • Schedule in Microsoft Excel
  • Calendar in Yahoo! batterybox group
  • Weekly team meetings
  • Weekly and daily status reports
design specification
Design Specification
  • 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)
competitive benchmark
Competitive Benchmark
  • Hymotion
    • Pros
      • Compact
      • Appearance
    • Cons
      • No analysis
        • Stress & Thermal
      • No spare tire solution
      • No fans
competitive benchmark1
Competitive Benchmark
  • Jerry’s Box
    • Pros
      • Cheap
      • Compact
    • Cons
      • Weak Material
      • No Analysis
        • Stress & Thermal
      • Dangerous
      • No fan
concept evaluation
Concept Evaluation
  • Latch
    • High Strength Material
      • SS + Rugged Alloy Steel
    • High Holding Capacity
      • 7500 lbs
    • Easy to use
    • Simple design
    • Adjustable
  • Constraints
    • Interference check with trunk interior
product evaluation hand calculations
Product Evaluation: Hand Calculations
  • 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
product evaluation hand calculations1
Product Evaluation: Hand Calculations
  • 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
product evaluation pro e mechanica
Product Evaluation: Pro-E Mechanica
  • 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
product evaluation
Product Evaluation
  • Ansys Stress Analysis
    • Solid Brick 8 Node 45
    • Aluminum 7075T6
    • 1/10th Scale Model
    • Boundary Condition
    • Symmetry Geometry
    • Applied Pressure = 22.176 Psi
  • Ansys Model
ansys analysis
Ansys Analysis
  • Free Meshing
  • Deformation
ansys analysis1
Ansys Analysis
  • VonMises Stress
  • c
  • Maximum Stress
ansys analysis2
Ansys Analysis
  • Conclusion
    • Maximum stress: 21226 psi
    • Max ultimate strength of material: > 75000 psi
    • The selected battery enclosure can withstand the calculated explosion force: 22.176 psi
cfd analysis
CFD Analysis
  • Fluent mesh
cfd analysis1
CFD Analysis
  • 20C discharge rate
cfd analysis2
CFD Analysis
  • Velocity Streamlines
cfd analysis3
CFD Analysis
  • 20C discharge rate
cost analysis
Cost Analysis
  • 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
impact statement
Impact Statement
  • Enclosing the battery pack safely, securely, and conveniently
    • Protection from accidental battery explosion
    • Reduces customer’s budget
    • Safety concerns of Toyota Plug-in Hybrid customers
    • Safety concerns of Toyota manufacture
conclusion
Conclusion
  • Satisfied the majority of our sponsor’s requirements
    • Fit 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.
recommendations
Recommendations
  • 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.
recommendations1
Recommendations
  • Explosion analysis with software
    • Live demo
    • Dynamic analysis
  • Ansys Analysis Limitation
    • Explosion force simulation
    • Computer limitation
  • Redesign of ventilation system
    • Eliminate hot spots
references
References
  • 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 Aristatekequation 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
special thanks
Special Thanks
  • Dr. Hazim El-Mounayri
    • Through out the whole project
  • Dr. Sohel Anwar
    • Project Sponsor
  • Jack Waddell
    • Information of new product – Blast Wrap
  • Dr. ErdalYilmaz
    • CFD Analysis
  • TA. RapeepanPromyoo
    • Ansys Modeling
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