1. T.E.S.-001 Test
Procedure and Results
THERMAL EXTRACTION SYSTEM
Utah State University
Senior Design Test Team
Colton Remund, Zachery Pope, Logan Gumucio, Craig Hastings
Spring 2015
2. T.E.S.-001 Page2
Table Of Contents
Purpose 4
Goals From Testing 4
1. Building the Control Volume (CV) 4
1.1 Items Required 5
2. Controlling The Environment 5
2.1 Temperature 5
2.2 Humidity 5
2.3 Measuring Temperature
and Humidity within the Environment
5
3. Building the Test On Body
Interface (TOBI)
5
3.1 Items Required 5-6
3.2 Preparing the Test On
Body Interface (TOBI)
6
4. Performing Each Test 6-9
4.1 Safety 6
4.2 Surface Temperature
Sensors
6-7
4.3 Temperature Sensor
Locations
7
4.4 Setup 7-8
4.5 Test Parameters 8
4.6 Running Each Test 8-9
a) TOBI Dry-No Vest, No Power 8
b) Dead Test-Vest On, No Power 8-9
c) Total Power-Vest On, Power On 9
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5. Calculations 9-12
5.1 Measuring Total Heat Transfer 9-10
5.2 Measuring Heat Transfer Due to
Evaporation
10
5.3 Calculations for Model 11-12
6. Test Report 13-19
6.1 Descriptions of tests conducted 13-14
6.2 Results of Tests 14-17
6.3 Discussion on Results 17
6.4 Recommendations for Future Work 17-18
6.5 Conclusion of Testing Results 18
Appendix A: Matlab Code 19
Appendix B: Spec. Sheets and Product Specifications 20
4. T.E.S.-001 Page4
Purpose
The purpose of this procedure is to test the effectiveness of heat removal from the vest system, TES-001, designed by
Thermal Extraction Systems. To do this, testing will be done in various controlled environments to establish an
expected performance. The main variables being controlled within the testing environment will be the humidity and
temperature conditions. These in turn will highlight real world conditions that military personnel would operate in
while utilizing TES technology.
Description of System
The TES-001 is designed to remove excess heat away from the body of select Air Force Battlefield Airmen for the
duration of entire missions while they are performing their duties. In hot environments, soldiers are at risk of heat
stress and heat stroke. The TES-001 needs to be able to maintain a soldiers normal core body temperature in order to
reduce the risk of soldiers being adversely affected by overheating.
The TES-001 provides cooling through the means of evaporative and convective cooling. Airflow is created using two
axial fans in series that are mounted on the backpack of the soldier. The airflow passes through a manifold that splits
the airflow in two and routes it through two flexible tubes that connect the fans to the designed vest. The vest is
designed to be worn underneath the soldier’s armor and on top of a compression shirt. The vest utilizes a layout of
channels created by foam inserts. The air passes through these channels and over the compression shirt. This
enhances evaporation of the soldier’s perspiration and subsequently creates a cooling effect.
The AFRL has stated that the objective weight is less than 2 pounds. The threshold is 4 pounds but could be heavier if
the design works well enough to justify it. The TES-001 weighs in at 5 lbs. While keeping the system light, it is also
rugged. It has the ability to handle rough usage. During a mission, the system can handle bumping into other objects
and being oriented in different directions since the soldier could be moving in a variety of ways.
Goals From Testing
1. Measure the heat removed by TES-001
a. Compare to previous calculations from fall semester testing
b. Understand what changes may need to be made to increase performance
2. Measure the moisture evaporated by TES-001
a. Compare with previous calculations from fall semester testing
3. Ensure flow in all channels
4. Ensure comfort and mobility
1. Building the Control Volume (CV)
The environment will be controlled by building a 4’x 4’ x 4’ insulated control volume (CV). The CV may be accessed on
the top as well as one of the sides. The CV will be built using foam board insulation (4’ x 4’ x 4’) with a wood frame.
The wooden frame will be built to house the insulation and serve as support and ease of moving if needed. Edges
along the bottom and corner walls will be sealed using tape and glue to hold in humidity, temperature, as well as
solidifying the structure. The top of the CV will be sealed by a plastic sheet, as well as covered with a layer of
insulating foam board. One of the side foam boards will provide access to the inside of the CV, as it can be removed
from the wooden frame for ease of access and moving parts.
Space heaters and humidifiers will be placed within the CV to provide the needed temperature and humidity levels,
with power chords fed through a sealed hole in the CV wall. These heaters and humidifiers will sit on hardboard on
the floor of the CV for added stability and protection. A 120mm fan will be mounted on the back wall above the
heaters and humidifiers to create circulation. A small foam board will also be placed between the heating/humidifying
element and the Test On Body Interface (TOBI), in order to isolate TOBI from direct radiative contact. This spacer will
hold a wireless sensor which measures the ambient temperature and humidity within the CV and transmits it to an
outside display. Throughout each test, the temperature will be measured and logged every second.
5. T.E.S.-001 Page5
1.1 Items Required
● Foam Board Insulation ( 6 – 4’x4’ sizes)
● 2” x 4” (12-4’ lengths)
● Screws (AR)
● Humidifiers (2)
● Wireless Temp/Humidity sensor
● Radiative Space Heaters (2)
● Heater tape (AR)
● Gorilla Glue
● 5 mil thick plastic sheet (4’ x 4’)
● 120mm fan
● Wire Hanger
● Insulating Foam board spacer(36” x 24”) with leg risers(3-4” x 2”)
● Hard Board (2-2’ x 4’)
● Inline vent draft blocker (4” diameter)
2. Controlling The Environment
2.1 Temperature
Temperature will be provided by space heaters within the CV, while additional heat will be added to the CV from the
humidifiers and prototype. The top insulating foam board will be removed if temperature exceeds set parameters (+
5°F of set point). This will be done by sliding/lifting the insulating foam board off of the plastic sheet, allowing more
heat to leave the CV and maintain the target environment while maintaining humidity. The uncovered surface area of
the sheet will be determined by the level of temperature offset within the CV.
2.2 Humidity
Humidity shall be controlled by powering two humidifiers to reach a steady target level and then powering them off.
As it leaves the target level, the humidifiers will be re-activated to restore steady target levels. If the humidity
becomes too high the vent from the inline blocker, located on the lower rear wall of the CV, will be opened to allow
moisture to escape as required.
.
2.3 Measuring Temperature and Humidity within the Environment
Humidity and temperature within the environment will be measured using a Meade TM005-X Wireless
Thermo-Hygrometer. The wireless sensor will be mounted on the separation barrier inside the testing environment,
and will transmit readings to the outside receiver. By doing this, the temperature and humidity inside the
environment can be adjusted to the desired conditions.
3. Building the Test On Body Interface (TOBI)
To ensure that the TES-001 can remove heat, a test dummy was created, known as the Test On Body Interface (TOBI).
Because the TES-001 is dependent on evaporative cooling, TOBI will need to have a form of ‘sweating’. By using an
immersion heater within the water filled dummy, in conjunction with thermistors, the rate at which the TES-001 can
remove heat may be determined.
3.1 Items Required
● Mannequin Torso
● Immersion Heater
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● Acrylic
● Thermistors
● CAT 5 Cable
● Polyethylene tubing(3/8’’ x 1/4’’)
● Wicking/Compression Shirt
● Drum for “sweat” storage
● Fish Tank Pump
● Barbed Ball Flow Valve
● Water (as required)
● Medical Tape
3.2 Preparing the Test On Body Interface (TOBI)
TOBI will be prepared by filling the mannequin torso with water. An immersion heater will then be attached to an
acrylic board and placed into the water. This will provide needed separation between the immersion heater and
mannequin as it is heated. Small tubing will be oriented around the outside of TOBI’s surface, and secured into place
with a wicking/compression shirt, to also simulate sweating through clothing. The tubing will run from a drum full of
water outside the CV to the mannequin. The tubing will cover regions where the majority of ‘sweating’ is to occur and
will have small holes where water may drip out. The flow of water through these holes will be managed by placing a
flow valve at the end of the tubing. This will allow an increase/decrease in pressure and manage the water flow
through the holes.
Figure 1. Visual representation of testing setup within Control Volume (CV). The mannequin torso (TOBI) will be
placed within the chamber where heaters and humidifiers will control the temperature and humidity. The TOBI
sweating mechanism allows the inner layers of the compression shirt to remain moist, thus allowing continuous
testing of the system.
4. Performing Each Test
All thermal tests were performed in a controlled environment, using a 64 ft3
testing chamber. The testing
environment was insulated on all sides and sealed to keep the moisture inside the environment. The heat was
controlled using two space heaters, and the humidity was controlled using two humidifiers. A hollow mannequin
(TOBI) was filled with water and heated to a temperature of 102°F. Sweating was simulated by utilizing a pump and
drip line that wrapped around TOBI’s body. The flow rate through the pinholes of the drip line were controlled to
7. T.E.S.-001 Page7
match the amount of sweat produced by an individual in that area of the body. A compression shirt was then placed
over TOBI, and the vest was placed over the compression shirt. Power was supplied to the fan using a variable power
supply set at the voltage of the chosen battery for the system. Temperature data was measured using eight
independent thermocouples, connected to a NI Mytemp/MyDaq system, which then was plotted using a Labview
program.
4.1 Safety
● Ensure all pumps, heaters, and electrical equipment are properly grounded
● Ensure that all heaters and components do not exceed recommended temperatures
● Any water spills or leaks must be cleaned immediately to ensure safe work environment
● Ensure that space heater will not melt or cause damage to the CV or TOBI in any way while running
4.2 Surface Temperature Sensors
Thermistors will be used to monitor the internal and outer surface temperatures of various locations on TOBI. The
thermistors that will be used are Amphenol NTC Type MS Epoxy Coated thermistors. The thermistors will input data
into a NI MyTemp unit which is connected to a NI MyDaq. This signal will then be processed by a Labview virtual
instrument. Using the virtual instrument allows the surface temperature of various locations to be continuously
monitored and recorded.
4.3 Temperature Sensor Locations
A wireless temperature/humidity sensor will be located within the CV to measure conditions of the ambient
temperature ( ). Thermistors will be located within the water on the inside of TOBI, as well as various locations onTinf
TOBI’s surface area. The locations of the various thermistors are shown below in Figure 2.
Figure 2: Thermistor locations on the outside surface of TOBI. Back view left; one sensor each located on upper and
lower back. Front view right; two sensors located on chest, two sensors located under the armpits, and one sensor
located on lower abdomen.
4.4 Setup
● Boot up computer Labview program
● Initialize calibration of Thermistors
● Test wireless Temperature/Humidity sensor and Thermistors to ensure proper function.
● Fill the tank of water for “sweat” supply throughout testing.
8. T.E.S.-001 Page8
4.5 Test Parameters
The test parameters are given so that tests may be repeatable and informative.
● 110°F, 20% Humidity
● 90°F, 90% Humidity
● TOBI will be heated to Heat Stress levels (approx. 102°F)
4.6 Running Each Test
For each of the test parameters mentioned above in section 4.5, three experiments were tested. These different tests
were known as
● TOBI - No vest, No power
● Dead TES- Vest On, No power
● TES- Vest On, Power On
Detailed steps for each of these tests are as follows:
a) TOBI - No vest, No power
1. Check TOBI: make sure sensors and hydration line are securely in place.
2. Check the Labview temperature VI and verify all temperature sensors are responding.
3. Seal up the box.
4. Engage the CV fan, heaters, and humidifiers.
5. Monitor wireless sensor and thermistors for consistency in temperature readings.
6. As readings begin to reach target test parameters and steady state, turn off heaters and humidifiers.
7. Once steady, run Labview software, collecting data every second, for 20 minutes, and engage hydration line
as needed.
a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target
level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±
b. If temperature begins to descend too far below target level, reactivate heater until target level is
reached. Then deactivate heater. Threshold is 5 degrees.±
c. If humidity begins to rise too far above target level, open the inline vent draft blocker and expose
predefined plastic sheet flap on the roof above the vent until target level is reached. Then re-seal
the roof flap and insulation board.
d. If humidity begins to descend too far below target level, reactivate humidifier until target level is
reached. Then deactivate humidifier.
e. For ”sweating” cases, make sure the flow rate of the hydration line isn’t exceeding roughly 1 L/hr.
Adjust the flow valve as needed.
8. Upon completion, take saved data file and import into Matlab in order to plot and calculate heat transfer.
9. Note differences between thermistors and record any potential differences.
10. Analyze results and compare with original values.
b) Dead TES - Vest on, No power
1. Check TOBI: make sure sensors and hydration line are securely in place.
2. Check the Labview temperature VI and verify all temperature sensors are responding.
3. Put TES-001 on TOBI.
4. Make sure power on the vest is off.
5. Seal up the box.
6. Engage the CV fan, heaters, and humidifiers.
7. Monitor wireless sensor and thermistors for consistency in temperature and humidity readings.
8. As readings begin to reach target test parameter and steady state, turn off heaters and humidifiers.
9. Once steady, double check that TES-001 is off, and has no power. Engage hydration line as needed.
10. Run Labview software, collecting data every second, for 20 minutes.
9. T.E.S.-001 Page9
a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target
level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±
b. If temperature begins to descend too far below target level, reactivate heater until target level is
reached. Then deactivate heater. Threshold is 5 degrees.±
c. If humidity begins to rise too far above target level, open the inline vent draft blocker and expose
predefined plastic sheet flap on the roof above the vent until target level is reached. Then re-seal
the roof flap and insulation board.
d. If humidity begins to descend too far below target level, reactivate humidifier until target level is
reached. Then deactivate humidifier.
e. For ”sweating” cases, make sure the flow rate of the hydration line isn’t exceeding roughly 1 L/hr.
Adjust the flow valve as needed.
11. Upon completion, take saved data file and import into Matlab in order to plot and calculate heat transfer.
12. Note differences between thermistors and record any potential differences.
13. Analyze results and compare with original values.
c) TES - Vest on, Power on
1. Check TOBI: make sure sensors and hydration line are securely in place.
2. Check the Labview temperature VI and verify all temperature sensors are responding.
3. Put TES-001 on TOBI.
4. Make sure connections to power the vest are connected properly and secure.
5. Seal up the box.
6. Engage the CV fan, heaters, and humidifiers.
7. Monitor wireless sensor and thermistors for consistency in temperature and humidity readings.
8. As readings begin to reach target test parameter and steady state, turn off heaters and humidifiers.
9. Once steady, engage TES-001 and hydration line.
10. Run Labview software, collecting data every second, for 20 minutes.
a. If temperature begins to rise too far above target level, remove roof to bleed heat off until target
level is re-established. Then replace the roof on the CV. Threshold is 5 degrees.±
b. If temperature begins to descend too far below target level, reactivate heater until target level is
reached. Then deactivate heater. Threshold is 5 degrees.±
c. If humidity begins to rise too far above target level, open the inline vent draft blocker and expose
predefined plastic sheet flap on the roof above the vent until target level is reached. Then re-seal
the roof flap and insulation board.
d. If humidity begins to descend too far below target level, reactivate humidifier until target level is
reached. Then deactivate humidifier.
e. For ”sweating” cases, make sure the flow rate of the hydration line isn’t exceeding roughly 1 L/hr.
Adjust the flow valve as needed.
11. Upon completion, take saved data file and import into Matlab in order to plot and calculate heat transfer.
12. Note differences between thermistors and record any potential differences.
13. Analyze results and compare with original values.
5. Calculations
5.1 Measuring Total Heat Transfer
The goal of testing the effectiveness of the TES-001 is to see how large of a temperature difference from TOBI’s
starting and ending points can be obtained within the given environment parameters. Testing shall be done by first
reaching the desired humidity and temperature within the CV and TOBI. The TES-001 will then be turned on and the
temperature difference within TOBI will be measured. Temperature measurements will be taken every second for a
period of 20 minutes. The heat removed will be calculated using the equation derived from the resistance network
shown in Figure 3 below.
10. T.E.S.-001 Page10
Figure 3: The resistance network for the Testing apparatus. Starting at left with the internal water temperature within
TOBI, and moving to the right through the thermal resistance of TOBI’s thickness, TES-001 vest with convection and
conduction resistances, and then into the environmental chamber.
EQ.1
Where
= Total heat being removedQTotal
Tw= Temperature of the water inside TOBI
cp= Specific heat of water
m= Mass of water in TOBI
RT= Thermal resistance of TOBI
This equation can be used to determine the heat removed at each sensor location, as well as the absolute heat
removal for the entire system.
5.2 Measuring Heat Transfer Due to Evaporation
The heat transfer from evaporation will be measured by analyzing the change in weight of a wetted t-shirt. The
system will run with a pre-weighed wetted t-shirt. This shirt will be placed over TOBI and the TES-001 will be placed
over the shirt and be turned on. The test will run for a period of 20 minutes. The final weight of the t-shirt will be
weighed. With the following equation, the heat transfer due to an overall change in moisture will be calculated:
weight/ΔtimeQevap = Hvap * Δ EQ.2
Where
= Heat transfer of the system,Qevap
= Latent heat of vaporization,Hvap
= Change in weight over time of 20 minutes.weight/ΔtimeΔ
The overall heat transfer due to convection will be calculated and compared with fall testing results.
13. T.E.S.-001 Page13
6 Test Report
6.1 Description of Tests Conducted
The following tests were performed according to the procedures discussed in Section 4 of this report
1. Dry Testing (113°F, 20% humidity)
● The internal temperature of TOBI was 102°F at the beginning of the tests. The goal of this test was to get
results of heat transfer from TOBI to the environment without the aid of evaporation. The heat transfer was
determined by observing the change of TOBI’s internal temperature over a given period of time over 20
minutes.
● The drip line was turned off and the compression shirt kept dry.
2. Dry Testing with vest and fan on/fan off (115-118°F, 20-25% humidity)
● The purpose of this test was to determine the heat transfer of TOBI while the drip line was off and the vest
was on. The heat transfer was determined by observing the change of TOBI’s internal temperature over a
given period of time of 20 minutes.
● Two tests were ran: one with the fan on, and one with the fan off.
3. Wet testing (Dual axial fan, Blower fan {2.8 A Large, 3.8 A Large, 3.8 A compact}, 115-118°F, 20%
humidity)
● The wet testing was the standard test used for determining the heat transfer produced by the vest. These
tests were ran with the drip line running, the vest on, and the fan running. The heat transfer was determined
by observing the change of TOBI’s internal temperature over a given period of time of 20 minutes. This
multiplied by the specific heat and mass of the water inside of TOBI gave the amount of heat transferred
from TOBI.
● Two/Three tests were ran to check repeatability of results.
● The best performer of the above test moved on to additional testing at higher humidities and lower
temperature
4. Wet testing (Dual axial fan, 95°F, 50% humidity)
● Similar wet testing procedure performed as #3, except at 95°F and 50% humidity
● Two/Three tests were ran to check repeatability of results
6. Wet testing (Dual axial fan, 95°F, 65% humidity)
● Similar testing procedure performed as #3, except at 95°F and 65% humidity
● Two/Three tests were ran to check repeatability of results
6. Wet testing (Dual axial fan, 95°F, 80% humidity)
● Similar testing procedure performed as #3, except at 95°F and 80% humidity
● Two/Three tests were ran to check repeatability of results
7. Mobility Tests (Qualitative)
● Qualitative testing
○ Run Test
■ Vest was worn while the subject was running, areas of the body that were being cooled by
the vest were noted, range of motion and comfort were also noted
■ Unobstructed range of motion while running, and noticeable cooling were considered
passing
○ Rollover Test
14. T.E.S.-001 Page14
■ The vest was worn while the subject attempted to roll over. Comfort and range were
noted
■ Ability to roll over without damage to the fan assembly and/or disconnection of
components was considered passing
○ Side Lay Test
■ The vest was worn while the subject laid on both side to check for comfort, any range of
motion limitations and closing of air channels/tubing was noted
■ Discomfort is bearable is considered passing
○ Range of Motion testing
■ The vest was worn while various physical motions were performed by the subject. Any
limitations and comfort issues were noted
■ Full range of motion is considered passing
8. Destruction Tests
● Qualitative testing
○ Drop test
■ Drop Fan assembly from a five foot drop level. Repeat until 1 or both fans stop working or
visible damage to fan manifold
■ If Sample survives 10 drops without physical damage, and fans still operational is
considered passing
○ Water Spray Test
■ Mist fan assembly with water bottle until fan stops working or 4 hours have passed
○ Sand Tests
■ Funnel sand particles through fan assembly until fan assembly stops working or 4 hours
have passed
6.2 Results from Testing
Decision Matrix Summary
Table 1. Summary of fan decision matrix from testing
Importance Property Measured Blower: 2.8 A Single Axial Double Axial
Primary Heat Removed at 118°F 20-30% RH 160-170 60-70 120-140
Primary Maximum Flow Rate (CFM) 55 68 68
Primary Current Draw (Amps) 2.4 0.7 1.4
Secondary Weight (oz) 9.8 6.0 12.0
Secondary Fan Dimensions (mm) 120 x 120 x 32 80 x 80 x 38 80 x 80 x 76
Secondary Static Pressure Drop (in. H2O) 3.5 0.6 1.2
Secondary Total run time (hours) 2.6 9.1 4.5
15. T.E.S.-001 Page15
TOBI With Vest and No Power To Fan Dry
Table 2. Testing data for full suit up and dry
118°F and 20% 90°F and 50% 90°F and 80%
Change Water
Temperature (°F)
-0.1 0.2 0.3
Watts Cooled -4 7.9 8.9
Btu/hr Cooled -16 27 30
Table 3. Testing data for Dual Axial Fan Set-Up at 118°F and 20-25% humidity wet
118°F and 20% 90°F and 50% 90°F and 80%
Change Water Temperature
(°F)
0.1 1.0 1.2
Watts Cooled -14 34 29
Btu/hr Cooled -48 119 99
Blower Fan 2.8 Amp Large
Table 4. Testing data for 2.8 Amp blower Set-Up at 118°F and 20-25% humidity
Trial 1 Trial 2 Trial 3 Average
Change Water Temperature (°F) 5.6 4.9 3.5 4.7
Watts Cooled 190 167 116 160
Btu/hr Cooled 648 157 398 546
Blower Fan 3.8 Amp Large
Table 5. Testing data for 3.8 Amp Large blower Set-Up at 118°F and 20-25% humidity
Trial 1 Trail 2 Trial 3 Average
Change Water Temperature (°F) 3.7 3.9 Na 3.8
Watts Cooled 127 132 Na 129
Btu/hr Cooled 433 450 Na 442
Blower Fan 3.8 Amp Compact
Table 6. Testing data for 3.8 Amp Compact blower at 118°F and 20-25% humidity
Trial 1 Trail 2 Trial 3 Average
Change Water Temperature (°F) 2.4 2.6 NA 2.5
Watts Cooled 81 89 NA 85
Btu/hr Cooled 304 279 NA 290
16. T.E.S.-001 Page16
Single Axial
Table 7. Testing data for Single Axial Fan Set-Up at 118°F and 20-25% humidity
Trial 1 Trail 2 Trial 3 Average
Change Water Temperature (°F) 2.3 1.9 1.9 2
Watts Cooled 77.9 66.2 63 69
Btu/hr Cooled 266.1 226 215 236
Dual Axial
Table 8. Testing data for Dual Axial Fan Set-Up at 118°F and 20-25% humidity
Trial 1 Trail 2 Trial 3 Average
Change Water Temperature (°F) 3.6 4.1 3.6 3.8
Watts Cooled 122 138 122 127
Btu/hr Cooled 419 471 417 435
Table 9. Testing data for Dual Axial Fan Set-Up 95°F and 50% humidity
Trial 1 Trail 2 Trial 3 Average Net Cooling
Change Water Temperature (°F) 4.1 4.1 Na 4.1 3.2
Watts Cooled 139 137 Na 138 108
Btu/hr Cooled 470 477 Na 471 368
Table 10. Testing data for Dual Axial Fan Set-Up 95°F and 65% humidity
Trial 1 Trail 2 Trial 3 Average Net Cooling
Change Water Temperature (°F) 3.0 3.4 3.0 3.1 2.3
Watts Cooled 102 113 100 105 78
Btu/hr Cooled 351 385 341 357 266
Table 11. Testing data for Dual Axial Fan Set-Up 95°F and 80% humidity
Trial 1 Trail 2 Trial 3 Average Net Cooling
Change Water Temperature (°F) 2.1 1.7 Na 1.9 1.1
Watts Cooled 69 59 Na 64 35
Btu/hr Cooled 234 201 Na 218 120
Table 12. Mobility Tests of dual axial results (Qualitative)
Type of test Results
Range of Movement of Arms and
Legs
Full range of Motion Possible (PASS)
Side Lay test Feels similar to laying on a Mag Pouch, but Flow obstructed on that side
(PASS)
Run Test Unobstructed range of Motion. Maintained Cooling (PASS)
Rollover Test Equipment survived rollover test (PASS)
17. T.E.S.-001 Page17
Table 13. Destruction Tests
Type of test Results
Sand Fill Fan Test Not Completed
Water Spray Fan Test Not Completed
Repeating Drop Fan Test 15 Drops before visible damage on fan. Both fans still operational (PASS)
6.3 Discussion on Test Results
The amount of cooling produced by the vest was able to achieve the optimum goal of 200 BTU/hr (58.6 Watts) that
was set by the TES group. The vest was able to achieve 138 Watts of cooling with a dual axial fan configuration at 95°F
and 50% relative humidity. At 118°F and 20-25% relative humidity, the dual axial fan produced 127 Watts of cooling
and the 2.8 amp blower fan produced 160 Watts of cooling.
Humidity plays an important role in this vest design and as expected, the cooling rates drop as the relative humidity is
increased. Increasing the relative humidity from 25% to 50% decreased the cooling rate of the vest by 15% for the
dual axial configuration. In addition, increasing the relative humidity from 25% to 65% produced a 17% decrease in
cooling rate for the dual axial configuration.
With the dual axial fan set up, a run time of 100 minutes longer can be achieved over the blower. The blower fan
produced more cooling, but at the cost of run time. The ratio of Watts out to Watts in achieved for the two system
configurations was 6.0 for the dual axial fan, and 4.8 for the blower fan. Based on these numbers the dual axial fan
configuration was chosen for our system.
The results of the mobility tests were that the vest did not impede motion for nearly all of the physical motions
tested. The vest passed the running and walking motion tests. The vest also passed the side lay test because it was
determined that is was no less comfortable or impeding than rolling onto a mag pouch. The airflow in that portion of
the vest was restricted, but air continued to flow through the other side of the vest. The vest failed the rollover test
based on the fact that a subject could not rollover with the vest on without damaging the vest components. The vest
passed all other arm and leg motion that was performed during testing.
6.4 Recommendations for Future Work
● Shrink Wrap Wiring: It was decided that it would be best to shrink wrap the wire on just two parts of the
tubing: one over the wiring between the switch and the fuse, the other between the fuse and the module
connection. This will allow access to all the necessary parts, protect the main portion of wiring, and make
the build look a lot cleaner. A smoother, cleaner, and more efficient way to protect the wiring would need
to be found if this system were to be implemented in the field.
● New Fan and Battery Module: The biggest change that is required is further revision to the Fan and Battery
Module. Mainly the MOLLE attachment points and battery housing location. A large amount of time was
put into getting the module to connect with the ballistic vest securely. Once it was on, we really got a good
view of the now extended soldier profile due to the added battery housing. This was especially noticeable
when laying prone, and completely prevented the possibility of rolling over and sitting up against a surface
comfortably.
○ Required Modifications: In order to condense the module into a more compact/mobile friendly
device, the battery housing needs to be moved to the "roof"or top of the module. This would allow
the battery to run horizontally over the top, extending just over a small portion of the tube barbs.
In doing so, some modifications need to be done in order to properly house the battery in this new
location, as well as to provide a more secure connection to the Soldiers Gear.
■ A simple L-shaped housing will allow the Battery to maintain a snug fit, and be held in
place with velcro straps that run through slots built into the housing. The back of the
L-shape will be up against the soldiers body. The module now will just need to have the
18. T.E.S.-001 Page18
empty space created by the angle on that side filled in.This will provide a secure base for
the housing. The angle on the opposite side will stay.
■ On the back side of the L-shape housing, near its base, it will provide 1 of the 3 MOLLE
attachment points, being located just over the barbs.
■ The barbs might need to be moved slightly closer to the soldiers body and down (see
sketch) and will need to be located such that the Tubing has enough clearance between it
and the now slightly extended battery housing above it.
■ The 2nd MOLLE attachment point will need to be moved from off the old angled side and
placed where the vertical slots are now. The vertical slots are being entirely removed from
the design.
■ The 3rd MOLLE attachment point will be a separate piece entirely and will attach to the
module where the two fans are screwed together. It will bolt down on that same
connection, and span the back side where the fans are held together.
○ These changes/modifications will result in keeping the module closer to the Soldiers body,
eliminating an extended profile, and provide greater mobility for the soldier.
● Dehumidifier: Since TES-001’s effectiveness is humidity dependant, a future design would be to implement a
dehumidifying booster to the fan system. This booster would allow the air to pass through, while
dehumidifying the air. This would allow for more sweat to be pulled off of the soldier and extract more heat
from them.
6.5 Conclusion of Testing Results
The testing results allowed the team to verify the TES-001 design. From testing with the highest cooling potential of
120 Watts, it is expected the design will be able to cool the soldier effectively in hot and dry climates. It is also
expected that the TES-001 design to be able to cool the soldier in mid-level humidities. With mobility testing the
system is considered a feasible design for the solder and not be obstructed from his/her duties. From the completed
destruction testing, the system is expected to be able to survive the abusive environment of the soldier and still
perform as designed.
19. T.E.S.-001 Page19
Appendix A: Matlab Code
QCode to find total immersion cooling of system.
clc; close all; clear all;
%% code to import data from labview save file and save as a heat transfer
% import data from tab delimited text file
T=dlmread('118 20% overheat blower 2.8 amp');
seconds=length(T(:,1));
% calculate average surface temperature at each second
summ=0;
for i=1:seconds
Tavg(i)=mean(T(i,2:6));
s(i)=i;
end
% Plot Temperature Data
figure(1)
plot(s, T(:,1), 'm')
hold on
plot(s, T(:,2), 'k')
plot(s, T(:,3), 'g')
plot(s, T(:,4), '--')
plot(s, T(:,5),'r')
plot(s, T(:,6),'c')
plot(s, T(:,7),':')
plot(s, Tavg,'-.')
xlabel('Time (seconds)')
ylabel('Temperature (fahrenheit)')
title('Temperature Profile')
legend('T1','T2','T3','T4','T5', 'T6','T7')
%properties of water
mass_water=37.9 %10 gallons of water in kilograms
cp_water=4.186 %J/kg*k
%% Calculate overall heat transfer by immersion cooling
Immersion_Cool=mass_water*cp_water*(max(T(:,1))-min(T(:,1)))/seconds*1000*5/9
20. T.E.S.-001 Page20
Appendix B: Product Specifications and Spec. Sheets
● Meade TM005X-M wireless sensor: (Product Sheet and call to company. Sheet not downloadable)
○ Temperature Range and Resolution: -4 - 158 ℉, ± 1℉
○ Humidity Range: 5 - 99%, ± 3%
● Water Pump:
○ Flow rate accuracy: ± 3%
● TEK Power Model TP 1803D:
○ Current and Voltage accuracy are ± 2.5%
● Battery:
○ Battery Type: Lithium Polymer (LiPO Battery)
○ C Rate: 70C
○ Volts: 14.8 V
○ Capacity: 6300mAh
○ Cell Count: 4 S
○ Cell Configuration: 4S1P
○ Continuous Discharge: 70C (441A)
○ Max Burst Rate: 80C (504A)
○ Max Volts per Cell: 4.2 V
○ Max Volts per Pack: 16.8 V
○ Min Volts per Pack: 12 V
○ Charge Rate: 1C (6.3A)
○ Wire Gauge: 12 AWG Soft and Flexible Low Resistance Silicone Insulated Wire
○ Plug Type: Venom UNI Plug. Compatible with Traxxas Plug, Tamiya Plug, Deans Plug & EC3 Plug.
○ Dimensions: 137 x 46 x 46 mm / 5.4 x 1.8 x 1.8 in
○ Watt Hours: 93.24
○ Weight: 20.5 oz (580 g)
● Fan: (Spec. Sheet attached)
● RL0503-5820-97-MS Thermistors: (Spec. Sheet attached)
● NI myDAQ and myTEMP: (Spec. Sheet attached)
21.
22.
23.
24.
25.
26.
27. Descriptions:
1. Delta will not guarantee the performance of the products if the application condition falls
outside the parameters set forth in the specification.
2. A written request should be submitted to Delta prior to approval if deviation from this
specification is required.
3. Please exercise caution when handling fans. Damage may be caused when pressure is applied
to the impeller, if the fans are handled by the lead wires, or if the fans are hard-dropped to the
production floor.
4. Except as pertains to some special designs, there is no guarantee that the products will be free
from any such safety problems or failures as caused by the introduction of powder, droplets of
water or encroachment of insect into the hub.
5. The above-mentioned conditions are representative of some unique examples and viewed as the
first point of reference prior to all other information.
6. It is very important to establish the correct polarity before connecting the fan to the power
source. Positive (+) and Negative (-). Damage may be caused to the fans if connection is
with reverse polarity, as there is no foolproof method to protect against such error.
7. Delta fans are not suitable where any corrosive fluids are introduced to their environment.
8. Please ensure all fans are stored according to the storage temperature limits specified. Do not
store fans in a high humidity environment. We highly recommend performance testing is
conducted before shipping, if the fans have been stored over 6 months.
9. Not all fans are provided with the Lock Rotor Protection feature. If you impair the rotation of
the impeller for the fans that do not have this function, the performance of those fans will lead
to failure.
10.Please be cautious when mounting the fan. Incorrect mounting of fans may cause excess
resonance, vibration and subsequent noise.
11.It is important to consider safety when testing the fans. A suitable fan guard should be fitted to
the fan to guard against any potential for personal injury.
12.Except where specifically stated, all tests are carried out at relative (ambient) temperature and
humidity conditions of 25o
C, 65%. The test value is only for fan performance itself.
13.Be certain to connect an “over 4.7µF” capacitor to the fan externally when the application calls
for using multiple fans in parallel, to avoid any unstable power.
28.
29.
30. SPECIFICATIONS
NI myDAQ
Analog Input
Number of channels..........................................2 differential or 1 stereo audio input
ADC resolution.................................................16 bits
Maximum sampling rate...................................200 kS/s
Timing accuracy ...............................................100 ppm of sample rate
Timing resolution..............................................10 ns
Range
Analog input .............................................±10 V, ±2 V, DC-coupled
Audio input...............................................±2 V, AC-coupled
Passband (-3 dB)
Analog input .............................................DC to 400 kHz
Audio input...............................................1.5 Hz to 400 kHz
Connector type
Analog input .............................................Screw terminals
Audio input...............................................3.5 mm stereo jack
Input type (audio input) ....................................Line-in or microphone
Microphone excitation (audio input) ................5.25 V through 10 kΩ
Absolute accuracy
Nominal Range
Typical at 23 °C (mV) Maximum (18 to 28 °C) (mV)
Positive
Full Scale
Negative
Full Scale
10 -10 22.8 38.9
2 -2 4.9 8.6
33. 4 | ni.com | NI myDAQ specifications
Connector type
Analog output ...........................................Screw terminals
Audio output .............................................3.5 mm stereo jack
AC-coupling high-pass frequency
(audio output with 32 Ω load)...........................48 Hz
Absolute accuracy
Slew rate ...........................................................4 V/μs
Timing accuracy................................................100 ppm of sample rate
Timing resolution..............................................10 ns
Overdrive protection.........................................±16 V to AGND
Maximum power-on voltage1 ...........................±110 mV
Output FIFO size ..............................................8,191 samples, shared among channels used
Digital I/O
Number of lines ................................................8; DIO <0..7>
Direction control...............................................Each line individually programmable as input or
output
Update mode.....................................................Software-timed
Pull-down resistor.............................................75 kΩ
Logic level ........................................................5 V compatible LVTTL input; 3.3 V LVTTL
output
VIH min .............................................................2.0 V
VIL max.............................................................0.8 V
Maximum output current per line2....................4 mA
Nominal Range
Typical at 23 °C (mV) Maximum (18 to 28 °C) (mV)
Positive
Full Scale
Negative
Full Scale
10 -10 19.6 42.8
2 -2 5.4 8.8
1 When powered on, the analog output signal is not defined until after USB configuration is complete.
2 The total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW
(typical)/100 mW (minimum). Refer to the Calculating Power Consumption section for information on
calculating the total power consumption of the components of your system.
35. 6 | ni.com | NI myDAQ specifications
Note All AC voltage accuracy specifications apply to signal amplitudes greater
than 5% of range.
Accuracy
Input impedance................................................10 MΩ
Current Measurement
DC ranges .........................................................20 mA, 200 mA, 1 A
AC ranges .........................................................20 mArms, 200 mArms, 1 Arms
Note All AC accuracy specifications within 20 mA and 200 mA ranges apply to
signal amplitudes greater than 5% of range. All AC accuracy specifications within
the 1 A range apply to signal amplitudes greater than 10% of range.
Function Range Resolution
Accuracy
± ([% of Reading] + Offset)
DC Volts 200.0 mV 0.1 mV 0.5% + 0.2 mV
2.000 V 0.001 V 0.5% + 2 mV
20.00 V 0.01 V 0.5% + 20 mV
60.0 V 0.1 V 0.5% + 200 mV
40 to 400 Hz 400 to 2,000 Hz
AC Volts 200.0 mV 0.1 mV 1.4% + 0.6 mV* —
2.000 V 0.001 V 1.4% + 0.005 V 5.4% + 0.005 V
20.00 V 0.01 V 1.5% + 0.05 V 5.5% + 0.05 V
* The accuracy for AC Volts 200.0 mV range is in the frequency range of 40 Hz to 100 Hz. For example,
for a 10 V using the DC Volts function in the 20.00 V range, calculate the accuracy using the following
equation:
10 V × 0.5% + 20 mV = 0.07 V
37. 8 | ni.com | NI myDAQ specifications
Power Supplies
Caution Do not mix power from NI myDAQ with power from external power
sources. When using external power, remove any connections to the power supply
terminals on NI myDAQ.
+15V Supply
Output voltage
Typical (no load).......................................15.0 V
Maximum voltage with no load................15.3 V
Minimum voltage with full load ...............14.0 V
Maximum output current1.................................32 mA
Maximum load capacitance ..............................470 μF
-15V Supply
Output voltage
Typical (no load).......................................-15.0 V
Maximum voltage with no load................-15.3 V
Minimum voltage with full load ...............-14.0 V
Maximum output current1.................................32 mA
Maximum load capacitance ..............................470 μF
+5V Supply
Output voltage
Typical (no load).......................................4.9 V
Maximum voltage with no load................5.2 V
Minimum voltage with full load ...............4.0 V
Maximum output current1.................................100 mA
Maximum load capacitance ..............................33 μF
Calculating Power Consumption
The total power available for the power supplies, analog outputs, and digital outputs is limited
to 500 mW (typical)/100 mW (minimum). To calculate the total power consumption of the
power supplies, multiply the output voltage by the load current for each voltage rail and sum
them together. For digital output power consumption, multiply 3.3 V by the load current. For
1 The total power available for the power supplies, analog outputs, and digital outputs is limited to 500 mW
(typical)/100 mW (minimum). Refer to the Calculating Power Consumption section for information on
calculating the total power consumption of the components of your system.
39. 10 | ni.com | NI myDAQ specifications
Environmental
Operating temperature
(IEC 60068-2-1 and IEC 60068-2-2)................0 to 45 °C
Storage temperature
(IEC 60068-2-1 and IEC 60068-2-2)................-20 to 70 °C
Operating humidity
(IEC 60068-2-56)..............................................10 to 90% RH, noncondensing
Storage humidity
(IEC 60068-2-56)..............................................10 to 90% RH, noncondensing
Maximum altitude.............................................2,000 m (at 25 °C ambient temperature)
Pollution Degree (IEC 60664) ..........................2
Indoor use only.
Safety
Safety Voltages
Measurement Category I1 is for measurements performed on circuits not directly connected to
the electrical distribution system referred to as MAINS voltage. MAINS is a hazardous live
electrical supply system that powers equipment. This category is for measurements of voltages
from specially protected secondary circuits. Such voltage measurements include signal levels,
special equipment, limited-energy parts of equipment, circuits powered by regulated
low-voltage sources, and electronics.
Caution Do not use this module for connection to signals or for measurements
within Measurement Categories II, III, or IV.
Safety Standards
This product is designed to meet the requirements of the following standards of safety for
electrical equipment for measurement, control, and laboratory use:
• IEC 61010-1, EN 61010-1
• UL 61010-1, CSA 61010-1
Note For UL and other safety certifications, refer to the product label or the Online
Product Certification section.
Caution Using the NI myDAQ in a manner not described in this document may
impair the protection the NI myDAQ provides.
1 Measurement Categories CAT I and CAT O are equivalent. These test and measurement circuits are not
intended for direct connection to the MAINS building installations of Measurement Categories CAT II,
CAT III, or CAT IV.
