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
 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
 Schedule in Microsoft Excel
 Calendar in Yahoo! batterybox group
 Weekly team meetings
ME462 Project Plan

 Weekly and daily status reports

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

Alum 2014T6 Alum 2024T3 Alum 7075T6

0.01 0.033554634 0.030199171 0.035951394

0.1 3.338898164 3.005008347 3.57739089

0.2 13.28273245 11.9544592 14.23149905

0.25  20.69781195 18.62803075 22.17622708

0.3 29.72399151 26.75159236 31.84713376

0.4 52.55748475 47.30173627 56.3115908

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

 c
 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
 Fluent model boundary conditions

Boundary Fluent Parameter and Value

Boundary
Type
Enclosure Wall Adiabetic (heat flux = 0)
wall
Battery Wall Constant heat flux
module 1000 W/m2 (run 1)
surface 50 W/m2 (run 2)
Intake Inlet vent T­air = 323 K
Outlet Exhaust fan Δp = 3500 Pa
 Fluent mesh
 20C discharge rate
 Velocity
Streamlines
 20C discharge rate
Aluminum      
Price ($)
Grade Ultimate Strength (ksi)  
  Ksi 4'x12' 4'x8'
2014T6 70 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
Purchasing
Item Information Unit Quantity Price Total

Aluminum Sheet
(t = 0.025") Grade = 7075T6 4'x8' sheet 1 $117.95 $117.95

Aluminum Sheet
(t = 0.025") Grade = 7075T6 4'x4' sheet 1 $51.27 $51.27
BlastWrap (t =
1.0")   sqft 16 $16.00 $256.00

Toggle Clamp CL-500-PA piece 2 $64.00 $128.00

Fan  SF-90  piece 2 $2.50 $5.00
Vent   piece 1 $3.99 $3.99

Metal Feet
Attachment   piece 4 $18.20 $72.80

Retractable Cord
Apparatus 5000-30GF  piece 1 $33.00 $33.00
Total $668.01
 Enclosing the battery pack safely,
securely, and conveniently

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/EnerDelTe
chnicalPresentation.pdf
 Lithium Ion Battery
http://electronics.howstuffworks.c
om/lithium-ion-battery1.htm
 Jerry's Battery Box
Jerry's battery box, used for
competitive benchmarking
http://jerryrig.com/convert/step10
.html
 Hymotion
http://www.hymotion.com/
 Hymotion Installed
good view of installation
http://www.hybridfest.com/images
/26.jpg
 About explosions by Aristatek
equation for peak overpressure
http://www.aristatek.com/explosio
ns.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/99-
spring.pdf
 Vapor Cloud Explosion Estimates
http://www.questconsult.com/99-
spring.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