Members
Brian Alano
Jae Shin
Korkut Ozuyener
Christopher Shelton
Matt Zwiesler

 Introduction
 Planning
 Design Specification
 Competitive Benchmark
 Concept Design
 Product Evaluation
 Impact Statement
 Conclusion
 Recommendation










ME462 Project Plan
Task To
Man-
Hours hours complete
% complete Inputs Deliverables
Specification Definition 38.5
approved QFD
Description of customers
Generate customers requirements
Jae
Jae
Weigh customer requirements Jae
1
4
0.5
0% approved PDP
ME462 Project
0 0% Handout sponsor, ME462
0 0%
Project Handout, who on QFD research, ME462
Project Handout,
0 0% what on QFD who on QFD what on QFD
Evaluate competition against cust. requirements
Generate engineering specifications
Evaluate competition against engr. specifications
Set targets
QFD approval
Matt
Matt
Matt
Jae
Team
12
6
4
6
5
0 0% research, what on
QFD
0 0% now, what on QFD
0 0% now, how on QFD now, what, how on
0 0% QFD
0 0% QFD what on QFD
Now v. What on QFD
(benchmarks v. requirements)
What v. how & how v. how on QFD
Now v. How on QFD
(benchmarks v. specifications) how v. how much and now v. how much on approved QFD
Deadline
01-31
Currently
Projected
Completion
Actual
Completion
01-30
01-24
01-24
01-24
01-27
01-28
01-28
01-29
01-30

 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)

 Hymotion

Pros

Compact

Appearance

Cons

No analysis

Stress & Thermal

No spare tire solution

No fans

 Jerry’s Box

Pros

Cheap

Compact

Cons

Weak Material

No Analysis

Stress & Thermal

Dangerous

No fan

 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

 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

 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

Thickness (in)
0.01
0.1
0.2
0.25
0.3
0.4
0.5
Pressure (psi)
Alum 2014T6 Alum 2024T3 Alum 7075T6
0.033554634 0.030199171 0.035951394
3.338898164 3.005008347
3.57739089
13.28273245
11.9544592 14.23149905
20.69781195 18.62803075 22.17622708
29.72399151 26.75159236 31.84713376
52.55748475 47.30173627
56.3115908
81.68028005 73.51225204 87.51458576

 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

 Ansys Stress
Analysis

Solid Brick 8 Node
45


Aluminum 7075T6
1/10 th Scale Model


Boundary Condition
Symmetry
Geometry

Applied Pressure =
22.176 Psi
 Ansys Model

 Free Meshing  Deformation

 VonMises Stress  Maximum Stress
 c



Maximum stress: 21226 psi

Max ultimate strength of material: >
75000 psi

The selected battery enclosure can withstand the calculated explosion force: 22.176 psi

Boundary
Fluent model boundary conditions
Fluent
Boundary
Type
Enclosure wall Wall
Parameter and Value
Adiabetic (heat flux = 0)
Battery module surface
Intake
Outlet
Wall Constant heat flux
1000 W/m 2 (run 1)
50 W/m 2 (run 2)
Inlet vent T air
= 323 K
Exhaust fan Δp = 3500 Pa



 20C discharge rate

 Velocity
Streamlines



Aluminum
Price ($)
Grade
2014T6
Ultimate Strength (ksi)
Ksi
70
4'x12' 4'x8'
Unable to obtain unable to obtain
2024T3 58-63 $170.95
$114.54
7075T6 68-75 $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

Bill of Materials
Item
Purchasing
Information
Aluminum Sheet
(t = 0.025") Grade = 7075T6
Aluminum Sheet
(t = 0.025")
BlastWrap (t =
1.0")
Grade = 7075T6
Toggle Clamp
Fan
Vent
Metal Feet
Attachment
CL-500-PA
SF-90
Retractable Cord
Apparatus 5000-30GF
Unit
4'x8' sheet
4'x4' sheet sqft piece piece piece piece piece
Quantity
1
4
1
1
16
2
2
1
Price
$117.95
Total
$33.00
$51.27
$16.00
$64.00
$2.50
$3.99
$18.20
Total
$117.95
$51.27
$256.00
$128.00
$5.00
$3.99
$72.80
$33.00
$668.01



Protection from accidental battery explosion

Reduces customer’s budget

Safety concerns of Toyota Plug-in Hybrid customers

Safety concerns of Toyota manufacture

 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.

 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.

 Explosion analysis with software


Live demo
Dynamic analysis
 Ansys Analysis Limitation


Explosion force simulation
Computer limitation
 Redesign of ventilation system

Eliminate hot spots

 Presentation on HPEV battery technology http://enerdel.com/pdfs/EnerDelT echnicalPresentation.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/step1
0.html
 Hymotion http://www.hymotion.com/
 Hymotion Installed good view of installation http://www.hybridfest.com/image s/26.jpg
 About explosions by Aristatek equation for peak overpressure http://www.aristatek.com/explosi ons.aspx
 Blast Wrap http://www.blastgardintl.com/pdf s/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.20
04.08.002
 Vapor Cloud Explosion Estimates http://www.questconsult.com/99spring.pdf
 Vapor Cloud Explosion Estimates http://www.questconsult.com/99spring.pdf

 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