FINAL PRESENTATION Purdue University Andrea Vacca 4/20/2017 Team - - PowerPoint PPT Presentation

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FINAL PRESENTATION Purdue University Andrea Vacca 4/20/2017 Team - - PowerPoint PPT Presentation

Oct 10, 2022 118 likes β€’518 views

FINAL PRESENTATION Purdue University Andrea Vacca 4/20/2017 Team Introduction Chenxi Li Zhuangying Xu Zhengpu Chen Yizhou Mao Gianluca Marinaro 2 Team Advisor Andrea Vacca Team Advisor PhD , Associate Professor Maha Fluid Power

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SLIDE 1

FINAL PRESENTATION Purdue University Andrea Vacca 4/20/2017

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SLIDE 2

Team Introduction

Zhengpu Chen Yizhou Mao Zhuangying Xu Chenxi Li Gianluca Marinaro

2

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SLIDE 3

Team Advisor

Andrea Vacca

Team Advisor PhD, Associate Professor Maha Fluid Power Research Center Purdue University

3

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SLIDE 4

Problem Statement and Project Objective

  • Light
  • Efficient
  • Safe
  • Human Interactive

Purdue Tracer

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SLIDE 5

5

Hydraulic System - Layout

A3 A2 A1

HP P RV V1 M V2 A DG Control Outputs Sensor Input HP hand pump P main pump RV inverse relief valve M motor V1 On-Off, NO, poppet V2 On-Off, NC, poppet A accumulator NV needle valve DG dog gear RP regener. pump CV# check valves CV1 RP CV2 NV

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SLIDE 6

CV2 A V2

6

A3 A1

P RV V1 M RP CV2 DG CV1 Control Outputs Sensor Input

V1 V2 Not activated Not activated

A2

Hydraulic System Design

Pedaling Mode

NV

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SLIDE 7

A3 A2 A1

HP P CV1 RV V1 M RP V2 NV CV2 A DG A

Hydraulic System Design

Charging Mode

Control Outputs Sensor Input

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V1 V2 Activated Activated

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SLIDE 8

A3 A2 A1

HP P CV1 RV V1 M RP V2 NV CV2 A DG

Hydraulic System Design

Boost Mode

Control Outputs Sensor Input

8

V1 V2 Not activated Activated

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SLIDE 9

A3

HP P CV1 RV V1 M RP V2 NV CV2 DG

A1 A2

AA

Hydraulic System Design

Regeneration Mode

9

V1 V2 Activated Activated

Control Outputs Sensor Input

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SLIDE 10

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A3 A2 A1

HP P CV1 RV V1 M RP V2 NV CV2 A DG Control Outputs Sensor Input

Hydraulic System Design - Sizing

π‘ˆπ‘› = F Β· r 𝐺 = π‘π‘•π‘‘π‘—π‘œ(πœ„) + 𝑁𝑕𝑔𝑑𝑝𝑑(πœ„)

Vm =

20𝜌 Β· π‘ˆπ‘› π›¦π‘ž Β· πœƒβ„Žπ‘›,𝑛

Q =

π‘Šπ‘›Β· π‘œ 1000 Β· η𝑀,𝑛

Vp = 𝑅 Β· 1000

π‘œ Β· πœƒβ„Žπ‘›,π‘ž

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SLIDE 11

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Hydraulic System Design - Sizing

Vehicle linear velocity Efficiency function 𝑋 βˆ— 𝑀 π‘ž βˆ— π‘Š Accumulator pressure

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SLIDE 12

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Hydraulic System Design - Sizing

Implementation of the model with maps of pump/motor efficiency

Volumetric efficiency for an external gear pump Mechanical efficiency for an external gear pump

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SLIDE 13

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Hydraulic System Design - Sizing

Numerical Optimization – Pedaling & Boost modes

NLPQL - INPUTS Lower Bound Upper Bound Pump Displacement 1 cc/rev 9 cc/rev Motor Displacement 1 cc/rev 9 cc/rev Accumulator Pre-charge Gas 20 bar 45 bar Front Gear Ratio 5 9 Rear Gear Ratio

  • 8
  • 1

NLPQL - OUTPUTS Objective Upper Bound Efficiency βœ” Velocity βœ” Torque IN (Human Constraint) 25 Nm Given data:

  • Cadence = 70 rpm
  • Acc. volume = 2 L
  • Acc. Max press.= 180bar
  • Vehicle parameters
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SLIDE 14

Best Design* Pump Displacement 4.52 cc/rev Motor Displacement 2.13 cc/rev Accumulator Volume 2.00 L

  • Acc. Pre-charge Gas Pressure

25 bar Front Gear Ratio 1/5.68 Rear Gear Ratio 4.47

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Pedaling Mode Power 183 W Torque IN (Human) 25 Nm Pump shaft 435 rpm Bike speed 5.10 m/s Main line pressure 46 bar Main line flow rate 1.81 L/min Pump vol. Efficiency 88.91 % Pump mec. Efficiency 86.76 % Motor vol. Efficiency 94.62 % Motor mec. Efficiency 85.55 % Overall Efficiency 62.44%

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Boost Mode Max speed 5.21 m/s Efficiency Function 51.12 Distance covered 221 m

Hydraulic System Design– Sizing

Performance – Pedaling & Boost modes

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SLIDE 15

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Hydraulic System Design– Sizing

Performance – Pedaling & Boost modes

Best Design Pump Displacement 4.52 cc/rev Motor Displacement 2.13 cc/rev Accumulator Volume 2.00 L

  • Acc. Pre-charge Gas Pressure

25 bar Front Gear Ratio 1/6.48 Rear Gear Ratio 4.00 Selected Components Pump CASAPPA PLP 10-4 4.27 cc/rev Motor CASAPPA PLM 10-2 2.13 cc/rev Accumulator STEEL HEAD COMPOSITES MicroForce 2.00 L

  • Acc. Pre-charge Gas

Pressure 25 bar Front Gear Ratio (MISUMI) 19/120 1/6.32 Rear Gear Ratio (MISUMI) 100/25 4.00

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SLIDE 16

Pedaling Mode (Selected components) Power 223 W Torque IN (Human) 30 Nm Pump shaft 442 rpm Bike speed 5.87 m/s Main line pressure 64.59 bar Main line flow rate 1.64 L/min Pump vol. Efficiency 86.36 % Pump mec. Efficiency 90.85 % Motor vol. Efficiency 90.81 % Motor mec. Efficiency 90.43 % Overall Efficiency 64.44 %

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Hydraulic System Design - Sizing

Boost Mode (Selected components) Max speed 4.87 m/s Efficiency Function 50.55 Distance covered 214 m Pedaling Mode (Best Design) Power 183 W Torque IN (Human) 25 Nm Pump shaft 435 rpm Bike speed 5.10 m/s Main line pressure 46 bar Main line flow rate 1.81 L/min Pump vol. Efficiency 88.91 % Pump mec. Efficiency 86.76 % Motor vol. Efficiency 94.62 % Motor mec. Efficiency 85.55 % Overall Efficiency 62.44%

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Boost Mode (Best Design) Max speed 5.21 m/s Efficiency Function 51.12 Distance covered 221 m

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SLIDE 17

17

Hydraulic System Design– Sizing

Numerical Optimization – Regeneration mode

NLPQL - INPUTS Lower bound Upper Bound Regeneration Pump Displacement 1 cc/rev 10 cc/rev Regeneration Gear Ratio

  • 50
  • 1

NLPQL - OUTPUTS Objective Accumulator Pressure βœ”

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SLIDE 18

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Best Design* Regeneration Pump Displacement 4.23 cc/rev Regeneration Gear Ratio 17.82

*V0 = 8.00 mph (3.58 m/s)

Selected components Casappa PLP 10-4 4.27 cc/rev Regeneration Gear Ratio 16.80 Best Design Performance* Accumulator Press. Increase 3.81 bar Breaking 5.29 m / 3.05 s Max breaking torque 52 Nm Max deceleration 1.2 m/s2 Selected comp.Performance Accumulator Press. increase 3.80 bar Breaking 5.56 m / 3.16 s Max breaking torque 49 Nm Max deceleration 1.2 m/s2

Hydraulic System Design– Sizing

Performance – Regeneration mode

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SLIDE 19

Purdue Tracer

19

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SLIDE 20

Frame Features

  • Internal Oil Reservoir

– 3.7 Liters Total Volume – Space & Budget Saved

  • Recommended Angle for Cycling

– 74 Deg Seat Tube Angle

  • Weight Optimization

– Minimum Weight (Aluminum) – Weight Distribution

  • Perfect Workmanship

http://www.trinewbies.com/tno_cycling/tno_cyclearticle_02.asp

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SLIDE 21

Frame – Reservoir

– Tank Full

– AccumulatorFull

– No oil

21

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SLIDE 22

Frame FEA

22

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SLIDE 23

Front Gear Box

Front Gear Box Technical Specifications Gear and Shaft Material Stainless Steel Number of Gear Stages 1 Gear Ratio 120/19

23

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SLIDE 24

Motor Gear Box

Motor Gear Box Technical Specifications Gear and Shaft Material Stainless Steel Number of Gear Stages 1 Gear Ratio 100/17 Shimano Gear Hub Reduction 0.5/1 – 1.6/1

24

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SLIDE 25

Regeneration Gear Box

Regeneration Gear Box Specifications Gear and Shaft Material Steel Number of Gear Stages 2 Primary Gear Ratio 120/20 Secondary Gear Ratio 56/20 Total Gear Ratio 16.8/1

25

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SLIDE 26

Electronic System

Purpose:

  • Maximize interaction

Electrical Improvements:

  • Safe
  • Intelligent

Arduino - Microcontroller Cellphone - App Bluetooth Module Sensors - Get data Valves:open/close (Change Modes)

  • Modern
  • Commercial value

Shimano Gear Hub Gear Ratio

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SLIDE 27

Application Design

Bicycle Application Bicycle control Mode Control Gear Ratio Control Data Display Bicycle Mode Data Velocity Main Line Pressure Accumulator Pressure Flow Rate Pump Torque Pump Power Human Mode Data Velocity Heart Rate Human Torque Human Power Cadence Supplementary functions Geolocation Weather Indication Contact section FAQ Contact Page Company Information

Click Gear Decrease Gear Add

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SLIDE 28

Application Design

Bicycle Application Bicycle control Mode Control Gear Ratio Control Data Display Bicycle Mode Data Velocity Main Line Pressure Accumulator Pressure Flow Rate Pump Torque Pump Power Human Mode Data Velocity Heart Rate Human Torque Human Power Cadence Supplementary functions Geolocation Weather Indication Contact section FAQ Contact Page Company Information

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SLIDE 29

System Control

Click

NC Valve

Circuit Close VCC END Signal 12 V battery Connected Relay Low voltage signal Normally disconnected

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SLIDE 30

System Control

Click BOOST MODE:

NC Valve

Circuit Close

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SLIDE 31

Pressure sensor - Accumulator Hall rpm sensor Hall rpm sensor Pressure Sensor - Main line Heart rate sensor

Data Collection

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SLIDE 32

Regeneration Mode

Proportional Button Relief Valve Micro Processor Press the Button: Voltage ⬆ Process the signal Voltage ⬇ ------ Pressure ⬆ Accumulator Save Energy!

Reference: http://www.sunhydraulics.com/model/RBAN/XAN912N

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SLIDE 33

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Actual Test Data Compared to Analysis

Experimental results

Pre-charge [bar] Distance covered [m] Efficiency function 60 315 32.1971 40 310 48.2957 30 280 58.1632 25 240 59.7417

Boost mode: Efficiency Fuction = 𝑋 Β· 𝑀

π‘ž Β· π‘Š

W = 127 kg (rider+bike) V = 2 liters

20 30 40 50 60 70 20 30 40 50 60 efficiency function accumulator precharge [bar]

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SLIDE 34

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50 100 150 200 10 20 30 40 50 60 70 80 90 Accumulator Pressure [bar]

Actual Test Data Compared to Analysis

Model validation

10 20 30 10 20 30 40 50 60 70 80 90 Vehicle linear velocity [km/h] Time [s] Experimental Model

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SLIDE 35

Actual Test Data Compared to Analysis

Reoptimization (future work)

  • The new model could be used next year.
  • Due the constraints of the competition, the team does not have

time to rebuild the prototype based on this new information;

  • After refining the model, a new AMESim optimization function

must be used to determine a new set of optimally sized hydraulic components;

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SLIDE 36

Cost Analysis

Frame $ 703.00 Front Gearbox $ 393.96 Other Bicycle Parts $ 478.17 Electronics $ 1379.00 Hydraulic Circuit $ 2299.44 Regeneration Gearbox $ 542.35 Motor Gearbox $ 518.87 Donated Parts $ 2077.65 Prototype Cost: $ 6314.79 Prototype Cost with Donation: $ 4237.14

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SLIDE 37

PurdueTracer Lite PurdueTracer Royal PurdueTracer Luxury Cost: $ 1977.42 Cost: $ 2966.87 Cost: $ 3404.97

Cost Analysis

  • Shimano Alfine 8 Speed
  • Shimano Alfine 8 Speed
  • Electronic Control System
  • Energy Storage System
  • Shimano Alfine 11 Speed
  • Electronic Control System
  • Regeneration System
  • Energy Storage System
  • Customized Painting
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SLIDE 38

Lessons Learned

  • Time Management
  • Team Cooperation
  • Theoretical Knowledge Learning
  • Practical Problem Solving

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SLIDE 39

Conclusion

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