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Thermal Extraction System Senior Design team from Utah State University for AFRL Challenge 2015 1

USU AFRL Presentation usu local present

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Page 1: USU AFRL Presentation usu local present

1

Thermal Extraction SystemSenior Design team from Utah State University for AFRL Challenge 2015

Page 2: USU AFRL Presentation usu local present

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

Page 3: USU AFRL Presentation usu local present

3 Soldier Diagram

UndershirtCooling Vest

Long sleeve shirt

Bullet proof vest

Page 4: USU AFRL Presentation usu local present

4 Field TestRange Of Motion

StretchingRunningJumpingClimbing

ProneCrouchSitting

No More Restrictive Than Gear

Page 5: USU AFRL Presentation usu local present

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%

Page 6: USU AFRL Presentation usu local present

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

Page 7: USU AFRL Presentation usu local present

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

Page 8: USU AFRL Presentation usu local present

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

Page 9: USU AFRL Presentation usu local present

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

Page 10: USU AFRL Presentation usu local present

10Battery Placement

Pelican Case Attach to belt or MOLLE

Ammo Pouch Already carried

Attached to Fan Manifold Fan and battery are one Less wires

Page 11: USU AFRL Presentation usu local present

11Fan Manifold Assembly

Two axial fans Splitting function Battery holster

Velcro strap MOLLE connections 3D printed

Page 12: USU AFRL Presentation usu local present

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

Page 13: USU AFRL Presentation usu local present

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