archetype final presentation
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Team Archetype First Semester final presentation, enjoy!TRANSCRIPT
A r c h e t yp e2
Hydrogen Fuel Cell Vehicle
Final PresentationFall 2013
Cole BoothKurtis CalkinsScott DavisBenjamin Johnson
Jeremy JohnsonJohn McGee
Alfredo SarachoAlysha Yinger
IntroductionFuel Cell Technology
OverviewHorizon H-1000XP
Fuel Cell SystemDrivetrainMotor
Motor analysisSteering System
Front axle Suspension
WheelBraking System
Analysis on Incline Analysis on Wheel
Frame Analysis Fabrication
Summary Path ForwardReferences Acknowledgements
OVERVIEW
Shell Eco-Marathon Americas Competition Prototype Fuel Cell Apr 24th – 27th 2014
Design Goals Total weight: 80 lb 1000+ mpg-e Competition compliant
INTRODUCTION
Battery Energy storage device
Energy is stored within battery itself
Ceases to produce energy when reactants are consumed (discharged)
Fuel Cell Energy conversion device
Fuel and oxidant are supplied continuously
Produces power as long as fuel is supplied
FUEL CELL TECHNOLOGY OVERVIEW
Energy Exchange Diagram (Proton Motor)
FUEL CELL TECHNOLOGY OVERVIEW
Unit Cell Forms the core of the fuel cell Converts chemical energy
contained in reactants into electrical energy
Consists of an electrolyte layer in contact with an anode and a cathode
Fuel Cell Stacking Unit cells are combined in a
cell stack to achieve the voltage and power output required for desired application
Stacking means connecting multiple unit cells in series via electrically inductive connections
Fuel Cell Diagram (site)
Developed for the Shell Eco-Marathon
12 V battery required for start up, self suffi cient afterwards
Weight Stack: 4.9 kg (10.8 lbs) Entire system: 6.8 kg (15
lbs) Peak Power: 1100 W Rated Current: 0-33 A @ 30
VDC Fuel (Reactants): Hydrogen
and ambient air (Oxygen)
HORIZON H-1000XP FUEL CELL SYSTEM
Horizon H1000-XP Fuel Cell Stack (Horizon)
HYDROGEN FLOW DIAGRAM
Key:
H2 Flow
ELECTRICAL FLOW DIAGRAM
Key:
Electrical Flow
5 . 6 2 : 1 S c a l e m o d e l
C ro s s - s e c t i o n a l a re a o f 0 . 0 1 2 8 m ²
Rey n o l d s n u m b e r ra n g e 1 0 1 , 0 0 0 -3 4 0 , 0 0 0
D ra g c o e f f i c i e n t o f 0 . 2 7 9
At 1 5 m p h , D ra g f o rc e = 2 . 3 5 N ( 0 . 5 l b f )
At 2 0 m p h , D ra g f o rc e = 4 . 3 N ( 0 . 9 7 l b f )
AERODYNAMICS
S A E S t a n d a r d J 2 2 6 3
E s t a b l i s h e s p r o c e d u r e f o r d e t e r m i n a t i o n o f v e h i c l e r o a d l o a d f o r c e f o r s p e e d s b e t w e e n 7 1 . 5 a n d 9 . 3 m p h ( 1 1 5 a n d 1 5 k m / h r ) .
F i n a l r e s u l t d e l i v e r s a m o d e l o f t h e r o a d l o a d f o r c e , a s a f u n c t i o n o f s p e e d , d u r i n g o p e r a t i o n .
• Powe r s u p p l i e d by f u e l - ce l l to e l e c t r i c mo to r
• Ch ai n d r ive wi t h f re e wh e e l h u b
• P l an e t ar y g e ar s e t f o r i n te r me d i a te g e ar re d u c t i o n
• F i n al d r ive wi t h b i ke s p ro cke t s
• G e a r rat i o o f 11. 07: 1
DRIVETRAIN
To accelerate the 90.7 kg (200 lb) vehicle at 0.14 m/s 2 a propulsion force at the rear wheel was calculated from Newton’s Second Law.
ΣFx:max=FPr op u l s i on-2F r es i s t , f-F r es i s t , r-Fd r ag
Propulsion force = 18.3 N (4.11 lb) Corresponding torque of wheel is 4.65 N-m (3.4 lb-ft) The acceleration of 0.14 m/s 2 allows the vehicle to accelerate to
required average velocity of 6.7 m/s (15 mph) in 48 seconds.
ACCELERATION ANALYSIS
Permanent magnet DC motor
200 W @ 48 VDC input
Torque: 0.420 N-m (.31 lb-ft)
Effi ciency: 88%
Max speed: 4620 rpm
Current Rating: 4.58 A
Weight: 1.1 kg (2.4 lb)
MOTOR
Clean and lubricated chain is 98% effi cient
Maximum tension occurs when accelerating from rest
83.07 N (18.67 lb) Under dynamic tension
Fatigue safety factors of; KV=1.2, KC=1.34,
KS=1.3
173.6 N (39.03 lb) Light weight bicycle chain (ANSI 41)
has max permissible working load of 1.2 kN (269.7 lb)
Vehicle application the chain has a safety factor of 6.9
CHAIN ANALYSIS
PLANETARY GEAR SET
Used for intermediate gear reduction
Gear ratio 5.0:1 Max bending
fatigue stress 587.88 psi
Max surface fatigue stress 104.2 ksi
Requires case
(surface) hardened
or fully hardened
steel for gears. Assembly weight of
1.1 lbs
Sun gear is keyed to motor shaft
Stationary ring gear
Planetary gears drive the sprocket
MOTOR MOUNT
Machined from quarter inch
6061 aluminum
Motor mounts at the face
Cradles motor to resist torque
on face and body
Weight of 0.62 lbs
Mounts to the body of the
vehicle
FEA on part
STEERING AND SUSPENSION
Steering Wheel:• Brakes• LCD display
U-JointSuspension System • Manitou Air Shock
Wheels• Low rolling resistance tires
Rack and Pinion
STEERING SYSTEM
Where:
Outer turning angle Inner turning angleL = Wheel base
R = Turning Radius
t = track width
SUSPENSION
Purposes of a Suspension System:
1. Reduce the effect of shock forces
2. Keep the tires in contact with
the road (reduce scrubbing)
3. Obtain Responsive handling
4. Support vehicle weight
5. Control the vehicle’s direction of
travel
Upper Arm
Lower A-Arm
Manitou Air Shock Axle
Knuckle
Body Mount
ANALYSIS
FEA ran on spindle during cornering. Lateral Force 437NNormal Force 359NMaterial: Aluminum 6061-T6
ANALYSIS
FEA analysis on Upper Arm and Lower A-Arm:
Upper Arm:Normal Force 359 N
Lower A-Arm:Normal Force 359 N Lateral Force 437N
Material: Aluminum 6061-T6
WHEELS
Rear wheel will utilize a chain driven freehub for increased efficiency over 2013’s hub motor design
20 in. rims have been selected to be compatible with Michelin low rolling resistance tires supplied by Shell Eco-Marathon for added efficiency
Front hubs will feature solid 15 mm through axles for added strength in order to withstand cantilever forces
Rear hub will feature solid 12 mm through axle
Design Parameters Front and rear systems
must be independently controlled by one controller each
Front and rear systems must be capable of immobilizing the vehicle independently from each other when placed on a 20% incline
Lightweight Inexpensive Hydraulic disc brakes are
recommended for stopping power
BRAKING SYSTEM
Shimano XT Hydraulic Mountain Bike Disc Brakes
Custom designed caliper mount Aluminum 6061 T6
Lightweight Strong
Material removed at strategic locations to reduce weight
Attach to spindle via carriage through bolts Easy vertical adjustment
BRAKE CALIPER MOUNTING
h-adaptive FEAFrictional force required to stop vehicle from 20 mph in 30 feet
Local yielding at corner of caliper – mount interface
Local yielding does not cause failure of assembly
CALIPER MOUNT ASSEMBLY STRESS ANALYSIS
BRAKING ANALYSIS ON INCLINE
Incline Safety Requirements Front and rear
independent actuation
Track Performance Stopping distance @ 25 mph ≤ 30 ft
Required static braking torque for competition:
78 N-m (57.5 lb-ft) 156 N-m (115.0 lb-ft)
Stopping distance (with reaction time):
16.8 m (55 ft)
BRAKING ANALYSIS FOR WHEEL
Considerations weight performance manufacturing
FRAME DESIGN
Carbon Fiber Monocoque Body
polymer honeycomb 37x increase in stiffness 9.2x increase in flexural strength 1.06x increase in weight
embedded inserts provides strong and precise
mounting
FABRICATION
Monocoque multiple female mold
CNC milled insulating foam PVA sealant sanding
hand lay-up j ig for location-dependent
inserts joining pieces
Rear Arms milled aluminum 6061-T6 takes advantage of motor
mounting lightweight
Windshield Lexan heat lamp
draping
FRAME ANALYSIS
Material Weight FOS
Displacement Stress
Al 6061-T6
0.53 kg (1.17 lb)
2.84
2.18 mm (0.008 in.)
96.9 MPa (14.1 ksi)
Al 7075-T6
0.55 kg (1.21 lb)
5.21
2.09 mm (0.008 in.)
96.9 MPa (14.1 ksi)
Finite element analysison rear arms
Analysis
550 NFinite element analysis on front wheel
mount
Practice lay-up on small-scale mold Fabricate full mold and body Purchase raw material and components Begin EdgeCam work for machined parts
PATH FORWARD
1. EG&G Technical Services, Inc. (2004, November). Fuel Cell Handbook (Seventh Edition). Morgantown, West Virginia, USA.
2. Fuel Cells: Working Principle . (n.d.). Retrieved September 11, 2013, from Fuel Cell Technology: http://www.fuelcelltechnology.info/
3. Horizon. (2013). Retrieved October 4, 2013, from Horizon Fuel Cell Technologies: http://www.horizonfuelcell .com
4. Shell Global. (n.d.). Shell Eco-Marathon . Retrieved September 11, 2013, from http://www.shell .com/global/environment-society/ecomarathon.html
5. Proton Motor . Cutting-Edge in Fuel Cell Technology . 2012: http://www.proton-motor.de
6. Shenzen Unite Industries Co. (2011). BLDC Motor BM1412ZXF 1000W . From
http://www.cn-dcmotors.com/en/ProductShow.asp?id=1927. Tsubakimoto Chain Co. (2006). The Complete Guide to Chain . from jkjhttp://chain-guide.com/toc.html8. Wong, J.Y. Theory of Ground Vehicles (Fourth Edition). 2008. John Wiley & kkSons, INC. Hoboken, NJ.
REFERENCES
Bellco Credit UnionMerrick & Co.H2 Eco-Challenger Team Joseph Cullen, MSRonald Rorrer, PhDDouglas GallagherChris Yakacki, PhDMark HadenFriends and Family
ACKNOWLEDGEMENTS
QUESTIONS
DID WE DO THIS RIGHT?
QUESTIONS