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1
Thermal Extraction SystemSenior Design team from Utah State University for AFRL Challenge 2015
2 TES SolutionObjective Requirements
Design
Systems Weight 5.03 lbsEstimated Run Time 4.5 hours
Thermal Test Watts Cooled118F, 22% Humidity 127
95F, 50% Humidity 108
95F, 65% Humidity 75
95F, 80% Humidity 35
3 Soldier Diagram
UndershirtCooling Vest
Long sleeve shirt
Bullet proof vest
4 Field TestRange Of Motion
StretchingRunningJumpingClimbing
ProneCrouchSitting
No More Restrictive Than Gear
5 Testing Chamber and Procedure• Insulated 64 ft3 testing environment• Drip line to simulate sweating• 7 Thermistors to measure temp at
specific locations• NI Mytemp and NI Mydaq for signal
processing• 2 space heaters, 2 humidifiers to
control conditions• Tobi (Test on body interface) filled
with water and preheated• Heat transfer calculated using
change in temp of the water• Maximum chamber conditions
• High temperature of 138℉• High relative humidity of 88%• Highest combined: 117℉ and 78%
6 Fan Decision MatrixFan Decision Matrix Blower
(BFB1212EH)Single Axial
(FFB0812SHE)Double Axial
(2 x FFB0812SHE)
Heat Removed at 118 F 20-30% RH 160-170 60-70 120-140
Maximum flow rate (CFM) 54.8 68.5 68.5
Current Draw (Amps) 2.4 0.7 1.4
Weight (oz) 9.8 6.0 12.0
Fan Dimensions (mm) 120 x 120 x 32 80 x 80 x 38 80 x 80 x 76
Static Pressure Drop (in. H2O) 3.5 0.6 1.2
Total run time (hours) 2.6 9.1 4.5
7 Thermal Model
For testing correlation mannequin, the results equate to a person with fat and skin wall of 6 mm thick.
Rwater + Rplastic =0.035 K/W
Testing Set up Human Set up
T Core
8 Thermal Testing Results
118 F 20% 95 F 50% 95 F 65% 95 F 80%-20
0
20
40
60
80
100
120
140
160
Measured Cooling Environment Cooling Effective System Cooling
Environment Conditions
Wat
ts R
emov
ed
Measured – Environment = System Effective
9 Evolution of the Vest The original selected foam was
changed for a weather-resistant neoprene foam for safety in high heat situations and for comfort
Ripstock nylon was originally chosen to minimize head loss. It had problems with the channels coming together and blocking flow so the vest was switched to a spandex material that added losses but kept the channels open
The channel design was changed to add more surface area being cooled
10Battery Placement
Pelican Case Attach to belt or MOLLE
Ammo Pouch Already carried
Attached to Fan Manifold Fan and battery are one Less wires
11Fan Manifold Assembly
Two axial fans Splitting function Battery holster
Velcro strap MOLLE connections 3D printed
12 Expanded Usage
Airman directing ground traffic on the tarmac
Military personnel working on the planes and other machines
Road workers out under the brutal summer sun
Outdoor exercise during hot weather
13 TES SolutionObjective Requirements
Design
Systems Weight 5.03 lbsEstimated Run Time 4.5 hours
Thermal Test Watts Cooled118F, 22% Humidity 127
95F, 50% Humidity 108
95F, 65% Humidity 75
95F, 80% Humidity 35