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FINAL PRESENTATIONPurdue University
Andrea Vacca4/20/2017
Team Introduction
Zhengpu Chen Yizhou Mao
Zhuangying Xu Chenxi Li
Gianluca Marinaro 2
Team Advisor
Andrea VaccaTeam Advisor
PhD, Associate ProfessorMaha Fluid Power Research CenterPurdue University
3
Problem Statement and Project Objective
• Light
• Efficient
• Safe
• Human Interactive
Purdue Tracer 4
5
Hydraulic System - Layout
A3
A2
A1
HPP
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 accumulatorNV needle valve
DG dog gear
RP regener. pumpCV# check valves
CV1
RP
CV2
NV
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 DesignPedaling Mode
NV
A3
A2
A1HP
P
CV1
RV
V1
M RP
V2NV
CV2
A
DG
A
Hydraulic System DesignCharging Mode
Control Outputs
Sensor Input 7
V1 V2
Activated Activated
A3
A2
A1
HPP
CV1
RV
V1
M RP
V2NV
CV2
A
DG
Hydraulic System DesignBoost Mode
Control Outputs
Sensor Input 8
V1 V2
Not activated Activated
A3
HPP
CV1
RV
V1
M RP
V2NV
CV2
DG
A1
A2
AA
Hydraulic System DesignRegeneration Mode
9
V1 V2
Activated Activated
Control Outputs
Sensor Input
10
A3
A2
A1
HPP
CV1
RV
V1
M RP
V2NV
CV2
A
DG
Control Outputs
Sensor Input
Hydraulic System Design - Sizing
𝑇𝑚 = F · r
𝐹 = 𝑀𝑔𝑠𝑖𝑛(𝜃) +𝑀𝑔𝑓𝑐𝑜𝑠(𝜃)
Vm=20𝜋 · 𝑇𝑚𝛥𝑝 · 𝜂ℎ𝑚,𝑚
Q =𝑉𝑚 · 𝑛
1000 · η𝑣,𝑚
Vp =𝑄 · 1000
𝑛 · 𝜂ℎ𝑚,𝑝
11
Hydraulic System Design - Sizing
Vehicle linear velocity
Efficiency function 𝑊 ∗ 𝐿
𝑝 ∗ 𝑉
Accumulator pressure
12
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
13
Hydraulic System Design - SizingNumerical 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 ✔
Velocity ✔
Torque IN (Human Constraint) 25 Nm
Given data:
• Cadence = 70 rpm• Acc. volume = 2 L• Acc. Max press.= 180bar• Vehicle parameters
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
14
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%
14
Boost Mode
Max speed 5.21 m/s
Efficiency Function 51.12
Distance covered 221 m
Hydraulic System Design– SizingPerformance – Pedaling & Boost modes
15
Hydraulic System Design– SizingPerformance – 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
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 %
16
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%
16
Boost Mode (Best Design)
Max speed 5.21 m/s
Efficiency Function 51.12
Distance covered 221 m
17
Hydraulic System Design– SizingNumerical 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 ✔
18
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– SizingPerformance – Regeneration mode
Purdue Tracer
19
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
20
Frame – Reservoir
– Tank Full – Accumulator Full – No oil
21
Frame FEA
22
Front Gear Box
Front Gear Box Technical Specifications
Gear and Shaft Material Stainless Steel
Number of Gear Stages 1
Gear Ratio 120/19
23
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
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
Electronic SystemPurpose:
• 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 HubGear Ratio
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
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
System ControlClick
NC Valve
Circuit Close
VCC
END
Signal
12 V battery
Connected
Relay
Low voltage signal
Normally disconnected
System ControlClick
BOOST MODE:NC Valve
Circuit Close
Pressure sensor -
Accumulator
Hall rpm sensor
Hall rpm sensor
Pressure Sensor -
Main line
Heart rate sensor
Data Collection
Regeneration Mode
Proportional Button Relief ValveMicro Processor
Press the Button: Voltage ⬆ Process the signal Voltage ⬇ ------ Pressure ⬆
Accumulator Save
Energy!
Reference: http://www.sunhydraulics.com/model/RBAN/XAN912N
33
Actual Test Data Compared to AnalysisExperimental 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 = 𝑊 · 𝐿
𝑝 · 𝑉
W = 127 kg (rider+bike)V = 2 liters
20
30
40
50
60
70
20 30 40 50 60
effi
cien
cy f
un
ctio
n
accumulator precharge [bar]
34
0
50
100
150
200
0 10 20 30 40 50 60 70 80 90
Acc
um
ula
tor
Pre
ssu
re [
ba
r]
Actual Test Data Compared to AnalysisModel validation
0
10
20
30
0 10 20 30 40 50 60 70 80 90Veh
icle
lin
ear
velo
city
[k
m/h
]
Time [s]
Experimental Model
Actual Test Data Compared to AnalysisReoptimization (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;
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: $ 6314.79Prototype Cost with Donation: $ 4237.14
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
Lessons Learned
• Time Management
• Team Cooperation
• Theoretical Knowledge Learning
• Practical Problem Solving
38
Conclusion
39
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