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
Slide 4
Schedule in Microsoft Excel Calendar in Yahoo! batterybox
groupYahoo! batterybox group Weekly team meetings Weekly and daily
status reports
Slide 5
Slide 6
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)
Slide 7
Hymotion Pros Compact Appearance Cons No analysis Stress &
Thermal No spare tire solution No fans
Slide 8
Jerrys Box Pros Cheap Compact Cons Weak Material No Analysis
Stress & Thermal Dangerous No fan
Slide 9
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
Slide 10
Slide 11
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
Slide 12
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
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
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
Slide 19
Boundary Fluent Boundary Type Parameter and Value Enclosure
wallWallAdiabetic (heat flux = 0) Battery module surface Wall
Constant heat flux 1000 W/m 2 (run 1) 50 W/m 2 (run 2) IntakeInlet
ventT air = 323 K OutletExhaust fanp = 3500 Pa Fluent model
boundary conditions
Slide 20
Fluent mesh
Slide 21
20C discharge rate
Slide 22
Velocity Streamlines
Slide 23
20C discharge rate
Slide 24
Aluminum GradeUltimate Strength (ksi) Price ($) Ksi 4'x12'
4'x8' 2014T670Unable to obtain unable to obtain
2024T358-63$170.95$114.54 7075T668-75 $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 of 2024T3 Aluminum 7075T6 chosen
Enclosing the battery pack safely, securely, and conveniently
Protection from accidental battery explosion Reduces customers
budget Safety concerns of Toyota Plug-in Hybrid customers Safety
concerns of Toyota manufacture
Slide 29
Satisfied the majority of our sponsors 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.
Slide 30
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 customers safety.
Slide 31
Explosion analysis with software Live demo Dynamic analysis
Ansys Analysis Limitation Explosion force simulation Computer
limitation Redesign of ventilation system Eliminate hot spots
Slide 32
Presentation on HPEV battery technology
http://enerdel.com/pdfs/EnerDelT echnicalPresentation.pdf
http://enerdel.com/pdfs/EnerDelT echnicalPresentation.pdf Lithium
Ion Battery http://electronics.howstuffworks.
com/lithium-ion-battery1.htm http://electronics.howstuffworks.
com/lithium-ion-battery1.htm Jerry's Battery Box Jerry's battery
box, used for competitive benchmarking
http://jerryrig.com/convert/step1 0.html
http://jerryrig.com/convert/step1 0.html Hymotion
http://www.hymotion.com/ http://www.hymotion.com/ Hymotion
Installed good view of installation http://www.hybridfest.com/image
s/26.jpg http://www.hybridfest.com/image s/26.jpg About explosions
by Aristatek equation for peak overpressure
http://www.aristatek.com/explosi ons.aspx
http://www.aristatek.com/explosi ons.aspx Blast Wrap
http://www.blastgardintl.com/pdf s/BLGA_AP_12805.pdf
http://www.blastgardintl.com/pdf s/BLGA_AP_12805.pdf Blast Wrap
specs http://www.blastgardintl.com/bp_ blastwrap.asp
http://www.blastgardintl.com/bp_ blastwrap.asp Calculating
overpressures from BLEVE (Boiling Liquid Expanding Vapor Explosion
http://dx.doi.org/10.1016/j.jlp.20 04.08.002
http://dx.doi.org/10.1016/j.jlp.20 04.08.002 Vapor Cloud Explosion
Estimates http://www.questconsult.com/99- spring.pdf
http://www.questconsult.com/99- spring.pdf Vapor Cloud Explosion
Estimates http://www.questconsult.com/99- spring.pdf
http://www.questconsult.com/99- spring.pdf
Slide 33
Dr. Hazim El-Mounayri Through out the whole project Dr. Sohel
Anwar Project Sponsor Jack Waddell Information of new product Blast
Wrap Dr. Erdal Yilmaz CFD Analysis TA. Rapeepan Promyoo Ansys
Modeling
