1 / 34

Battery Enclosure Presentation

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.

kirti
Download Presentation

Battery Enclosure Presentation

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Battery Enclosure Presentation Members Brian Alano Jae Shin KorkutOzuyener Christopher Shelton Matt Zwiesler

  2. Outline • Introduction • Planning • Design Specification • Competitive Benchmark • Concept Design • Product Evaluation • Impact Statement • Conclusion • Recommendation

  3. 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

  4. Planning • Schedule in Microsoft Excel • Calendar in Yahoo! batterybox group • Weekly team meetings • Weekly and daily status reports

  5. Planning

  6. 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)

  7. Competitive Benchmark • Hymotion • Pros • Compact • Appearance • Cons • No analysis • Stress & Thermal • No spare tire solution • No fans

  8. Competitive Benchmark • Jerry’s Box • Pros • Cheap • Compact • Cons • Weak Material • No Analysis • Stress & Thermal • Dangerous • No fan

  9. 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

  10. Latch Design

  11. 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

  12. 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

  13. Aluminum Grade Analysis

  14. 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

  15. 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

  16. Ansys Analysis • Free Meshing • Deformation

  17. Ansys Analysis • VonMises Stress • c • Maximum Stress

  18. 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

  19. Fluent model boundary conditions

  20. CFD Analysis • Fluent mesh

  21. CFD Analysis • 20C discharge rate

  22. CFD Analysis • Velocity Streamlines

  23. CFD Analysis • 20C discharge rate

  24. 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

  25. Final Design

  26. Final Design

  27. 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

  28. 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.

  29. 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.

  30. Recommendations • Explosion analysis with software • Live demo • Dynamic analysis • Ansys Analysis Limitation • Explosion force simulation • Computer limitation • Redesign of ventilation system • Eliminate hot spots

  31. 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

  32. 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

  33. Questions

More Related