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Team 04032 Delphi Corporation Solid Oxide Fuel Cell Durability Test Stand

The Solid Oxide Fuel Cell Durability Test Stand project by Team 04032 at Delphi Corporation focused on enhancing the stand's mechanical and electrical components. The team, comprising mechanical and electrical engineers, along with a faculty mentor, upgraded the structures, enclosure, fuel delivery system, controls interface, and data acquisition components to improve the overall performance and accuracy. They optimized the test stand structure with 80/20 extruded aluminum, increased the enclosure's functionality and safety features, refined the fuel delivery system for efficiency, integrated Labview controls, and enhanced data acquisition capabilities for precise monitoring. The project achieved a maximum deflection of 0.003in under a 700lb load, ensuring durability and reliability. The team successfully addressed design challenges and budget constraints, leading to a comprehensive and efficient SOFC durability test stand. Kudos to the team and stakeholders for their dedication and collaboration.

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Team 04032 Delphi Corporation Solid Oxide Fuel Cell Durability Test Stand

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  1. Team 04032Delphi CorporationSolid Oxide Fuel Cell Durability Test Stand Mechanical Engineers Electrical Engineers • Wai Meng Ng • Richard Yang • John Bagby • Joshua Gannon • Michael Scholl • Gregory Tyminski • David White Faculty Mentor • Margaret Bailey, Ph.D., PE Delphi Contact • Chris Mergler SOFC Durability Test Stand

  2. Subgroup Structures SOFC Durability Test Stand

  3. Stand • Preliminary Design • 1.5” x 1.5” 80/20 extruded aluminum built 36” tall • Double Anchor Bolt Fasteners for assembly • 4 lengths 80/20 top rails supporting top plate • Post PDR Suggestions • 32” height of stand • Elimination of 4 supporting 80/20 top rails • Final Decisions • 2” x 2” 80/20 extruded aluminum used due to in-stock supply • 80/20 corner brackets and joining plates used for assembly due to in-stock supply • 32” height of stand • Top rail elimination SOFC Durability Test Stand

  4. Stand and FEA • Maximum Deflection under 700lb Load: 0.003in SOFC Durability Test Stand

  5. Enclosure • Preliminary Design • 80 / 20 Extruded Aluminum, 1” x 1” Cross Section • Supporting Structure • Cast Acrylic Plexiglas • Toggle Clamp Attachment for enclosure removal • Excellent Clarity • 150 degree F tolerance • Firewall • 1850 degree F tolerance • Rubber Seal • Fulfills airtight requirement • Aluminum Plate • Due to high temperature requirement at exhaust outlet • Post PDR Suggestions • Hinges for enclosure opening • Reduces manual lift of enclosure to supporting position on the stand base • Top Exhaust for CO startup leak • Extra air draw through enclosure to reduce CO emissions into the room • Movable position of top plate within enclosure • Gives better inline positional placement of exhaust of SOFC to enclosure exhaust opening SOFC Durability Test Stand

  6. Enclosure • Final Decisions • Hinges are to be used to open enclosure with support braces for a propped position on stand • No Top Exhaust addition • Relay on sensors and Labview within enclosure to shutdown stand if necessary • Movable plate within enclosure • Top plate is anchored at its vertical position • Enclosure hood is vertically movable • Manual disassembly and reassembly of supporting 80/20 for vertical movement of enclosure • Enclosure movement provides robust placement of SOFC in comparison to hood exhaust outlet SOFC Durability Test Stand

  7. FuelDelivery System Fuel Supply Delivery System • System supplies natural gas/diesel/gasoline fuels to SOFC. • Refueling is accomplished without interrupting the fuel flow to the SOFC. • Fuel Pump supplies liquid fuel at 500kPa to fuel injector. • Redundant Automatic shutdown safety feature. SOFC Durability Test Stand

  8. FuelDelivery System • Swagelok Components • Warren Rupp Sandpiper II Diaphragm Pump • McMaster-Carr High Pressure Fuel Tanks SOFC Durability Test Stand

  9. ControlsComponent Interface • Labview 6.1 • The main view of the controls were already developed by Delphi. Our task was to integrate what we had with the given components. • Enclosure data, fuel pump enable and enclosure warnings. • E-stop is to be tied in with the e-stop sequence for SOFC unit. SOFC Durability Test Stand

  10. Data Acquisition • Data collection for enclosure’s thermocouples and gas sensors. • Detection of warning & e-stop violations. • Data logging writes to a new file each day. • Stand DAQ VI can be incorporated into Main VI as a sub VI with one input and two outputs. • Input for initialization • Two outputs for data values and warning signals. SOFC Durability Test Stand

  11. Financial Summary • Components Removed From Budget By Delphi Corporation • Many Swagelok, exhaust and computer components, stocked in house • Field Point Modules $4.2K • $12K Load Bank Replaces $17K Load Bank • Gas Sensor System $4.5K SOFC Durability Test Stand

  12. Tasks Outstanding • Finalize and debug Controls & DAQ Virtual Interface • Full installation into Laboratory environment: Plumb Air, NG, Exhaust lines SOFC Durability Test Stand

  13. Thank You: R·I·T • Margaret Bailey, Ph.D., P.E. • Alan Nye, Ph.D. • Delphi Corporation • Mr. Chris Mergler • Mr. Chris DeMinco • Mr. Anthony DeRose • Mr. Kristian Whitehouse SOFC Durability Test Stand

  14. Questions SOFC Durability Test Stand

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