Development of hydrogen storage tank used for Fuel Cell Electric Vehicle (FCEV) by numerical analysis

Transcription

1 EVS28 KINTEX, Koea, May 3-6, 2015 Development of hydogen stoage tank used fo Fuel Cell Electic Vehicle (FCEV) y numeical analysis Dongsun Lee 1, Jaehan Jung 2, Jungik Kim 2, Chulho Im 2 1, 2 Fuel cell vehicle team, HYUNDAI MOTOR GROUP, 17-5, Mauk-o #240,yongin-si, kyeonggi-do, , Koea, dongsun2@hyundai.com

2 Contents I. Intoduction -Backgound and ojectives of study II. Reseach pocedues III. Development of engineeing design technique - Development of FE modeling tool on winding pattening - Development of estimating method on the oss thickness of composite - The manne of optimizing on the filament winding patten IV. Results and Discussions - The estimation of oss thickness afte filament winding - Bust test - Main expected effect of optimized model 2

3 I. Intoduction Backgound and ojective What is the coe technology on FCEV and the method of weight eduction? Item Gas mileage Weight pecent Wold 1 st mass poduced Fuel Cell Vehicle ( 13/2) 415 km 4.4 wt% Pice 77,000$ 1,100 KRW/1$ Component of hydogen tank Potion of the pice on component Aluminum Plastic : Gas seals and withstanding winding foce of caon fie CFRP : Withstanding high pessue of hydogen - % - % 0 - % - % - % - % 18% - % Hydogen stoage system Cost down and weight eduction y optimization on the laminate design of caon fie which is aout 85% of CFRP 3

4 II. Reseach pocedues Appoach Design optimization of winding patten y development oth stuctual modeling and analysis technique on hydogen tank Development of optimization technique Designing of winding patten y Revese Engineeing Poduct development y tial and eo Design Poduction Evaluation Need fo designing / analysis technique Development of modeling technique - Impoving pilot pogam (W/SIMULIA South) - Standad satisfaction (2.5times of chaging pessue) Poposition of equation on the evised design egading eal shape Estimating oss thickness y poposed equation FE modeling of winding angle and thickness of CFRP Poduction and evaluation Design/analysis of winding patten Evaluation of optimal patten Bust test Compaison analysis/expeiment Factue at cylinde a Bust pessue: 1,729a 1,798a 4

5 III. Development of engineeing design technique Development of FE modeling tool on winding pattening Development of modeling technique on the vaiale winding angle and thickness with vaiale dome cuvatue 1 1 Impoving pilot pogam defining mateial popeties (w/simulia South) 2 Dome Chaacteistics - Geneation of mateial popety with winding angle - Defining composite thickness with vaiale dome cuvatue - Calculation of stain and stess in the fie diection Tie condition (Al6061 & DPE) Contact condition (line & composite) 3 Cylinde 2 3 Symmety condition 5

6 III. Development of engineeing design technique Development of estimating method on the oss thickness of composite Poposition of equation that is ale to estimate the thickness of composite nea oss Aluminum Composite The method of Classical equation estimating composite thickness Estimation of composite thickness nea oss It is had to estimate the composite thickness nea oss (The angle is 90 degee) 1 Dome n pat composite ( ) sin tl Thickness of oss Eq.6 Thickness 0 of composite Plastic Cylinde pat Fig.2 Fig.1 의 1 구역확대그림 Fig.1 Illustation of H 2 tank model Magnification of 1 in Fig.1 t t tl cos( tl ) tl cos( ) 2 BW tl tl 4 t tl = Thickness at tangential line Θ tl = Angle at tangential line, Θ = Winding angle tl = Radious at at tangential line in dome 0 = Radious at helical end tip BW= Bandwidth Eq.7 6

7 III. Development of engineeing design technique Development of estimating method on the oss thickness of composite Aluminum 1 Plastic Composite Composite and Poposition of equation that is ale to estimate the thickness of composite nea oss Dome pat Cylinde pat Thickness of oss Thickness of composite composite Fig.2 Fig.1 의 1 구역확대그림 Fig.1 Illustation of H 2 tank model Magnification of 1 in Fig.1 * 6 ovelapping egion of composite laye Outside diamete of oss 1 The equation of estimating thickness on composite The method of Classical equation estimating composite thickness t N Estimation h of composite pthickness h nea oss Eq.8 It is had to estimate the composite thickness 90/(360/(( ) / BW ))) nea oss (The angle l is 90 degee) Eq.9 oss p ( t /(1 )) 2N N ( BW ) 2 N p n N ( BW ( ) ) sin 2 N p tl N 0 if, 1 Numenclatue ttl cos( ) t tl tl oss = The thickness of oss η α = Rduction cos( ate ) of and width t h = Initial thickness of helical 2 BWlaye 4 N p α = A nume of ovelapping on helical tl and t tl = at Thickness winding angle at tangential α line N h Θ α tl = A Angle nume at tangential of helical line, laye Θwith = Winding winding angle α l tl = = Full Radious diamete at at of tangential plastic line in dome 0 = Full Radious diamete at helical of aluminum end tip oss BW BW= = Bandwhidth Bandwidth tl p if, p Eq Eq.7 Illustation of ovelapping composite laye nea oss 7

8 Max. Pinc. Stess [MPa] Fie diectional Stess [MPa] III. Development of engineeing design technique The manne of optimizing on the filament winding patten The estimation of optimal winding patten y stess/stain tend line and ust limit condition Stess vaiation with winding angle Stess vaiation with thickness of composite layes st_hoop 2nd_hoop 3d_hoop 1st_tue helical nd_tue helical Inside tue helical Outside in Tansition egion Inside in tansition egion Inside hoop Winding angle [ ] Nume of helical layes [EA] 3d_tue helical Helical_23D Helical_12D Helical_10D - Investigation of minimum stess condition with winding angle - Investigation of minimum stess condition with thickness of composite layes - Investigation on the hoop stess with vaiale helical thickness 8

9 IV. Results and Discussions Poduction of hydogen stoage tank Poduction of hydogen stoage tank y filament winding method Winding condition - Tension of fie: 9.8~14.7 N - Moto pm: 60 pm - Caiage speed: 500mm/sec a Resin Bath (HDPE) Composite (Al6061) Cuing condition - 60 (2h) 85 (2h) ai-cooling (10h) Moving diection of caiage Rotation c (HDPE) Helical Hoop (Al6061) Caiage Moto Composite a,: Winding appatus c: Aluminum/HDPE line 9

10 IV. Results and Discussions The estimation of oss thickness afte filament winding Poduction of the hydogen tank and estimation the thickness of composite nea oss within 4% eo The esults of evaluation on the estimated equation Thickness of oss Thickness of composite composite 1 Tank Estimating Poducing Eo Pass/ No. thickness [mm] Thickness [mm] [%] fail # Fail Without equation # Pass # Pass With equation # Pass Fig.2 Fig.1의 1 구역확대그림 #2 #3 #4 10

11 IV. Results and Discussions Bust test Test sample #3: Eo 3.9% (Anal.: 1,729 a, Exp.: 1,798 a) Test sample #4: Eo 2.1% (Anal.: 1,755 a, Exp.: 1,792 a) The esult of ust test of sample #3 The esult of ust test of sample #4 Factue at cylinde a Factue at cylinde a Bust pessue: 1,729a Bust pessue: (Pedict 1,729a value) (Pedict value) 1,798a 2 nd stain egion % c Bust pessue: Bust 1,755a pessue: 1,755a (Pedict value) (Pedict value) 2 nd stain egion % c 1,792a C c Max stain egion % C c Max stain egion % 11

12 IV. Results and Discussions Main expected effect of optimized model The effect of optimal hydogen tank model weight of caon fie 8.5% / weight efficiency of H % Tank sample The weight of hydogen tank The weight of caon fie Weight efficiency of hydogen Commecial poduct 90.0 kg (standad) 52.0 kg (standad) 4.4 wt% (standad) Optimal sample 82.5 kg (8.3% ) 47.6 kg (8.5% ) 5.0 wt% (13.6% ) 12

13 Conclusion 1 Development of modeling technique on hydogen stoage tank The eliaility etween analysis and expeiment was appoximately 3% 2 Poposition of equation on the evised design egading eal shape Estimating eo on the composite thickness nea oss 4% was appoximately 4% 3 Effect of the optimal design on the weight eduction and efficiency Weight efficiency of hydogen 13.6%, The weight of caon fie 8.5% 13