final presentation purdue university andrea vacca 4/20/2017 · final presentation purdue university...

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


Vehicle linear velocity

Efficiency function 𝑊 ∗ 𝐿

𝑝 ∗ 𝑉

Accumulator pressure

12


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


Pump shaft 442 rpm

Bike speed 5.87 m/s

Main line pressure 64.59 bar






Overall Efficiency 64.44 %

16


Boost Mode (Selected components)

Max speed 4.87 m/s



Pedaling Mode (Best Design)

Power 183 W


Pump shaft 435 rpm

Bike speed 5.10 m/s

Main line pressure 46 bar






Overall Efficiency 62.44%

16

Boost Mode (Best Design)

Max speed 5.21 m/s



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


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


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

final presentation purdue university andrea vacca 4/20/2017 · final presentation purdue university...

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