1. Thermal Extraction System
Senior Design team from Utah State University for AFRL Challenge 2015
1

2. TES Solution2
Objective
Requirements
Design
Systems Weight 5.03 lbs
Estimated Run Time 4.5 hours
Thermal Test Watts Cooled
118F, 22% Humidity 127
95F, 50% Humidity 108
95F, 65% Humidity 75
95F, 80% Humidity 35

3. Soldier Diagram3
Undershirt
Cooling
Vest
Long sleeve
shirt
Bullet proof
vest

4. 4 Field Test
Range Of Motion
Stretching
Running
Jumping
Climbing
Prone
Crouch
Sitting
No More Restrictive Than Gear

5. Testing Chamber and Procedure
• Insulated 64 ft3 testing environment
• Drip line to simulate sweating
• 7 Thermistors to measure temp at
specific locations
• NI Mytemp and NI Mydaq for signal
processing
• 2 space heaters, 2 humidifiers to
control conditions
• Tobi (Test on body interface) filled
with water and preheated
• Heat transfer calculated using
change in temp of the water
• Maximum chamber conditions
• High temperature of 138℉
• High relative humidity of 88%
• Highest combined: 117℉ and 78%
5

6. Fan Decision Matrix
Fan Decision Matrix
Blower
(BFB1212EH)
Single Axial
(FFB0812SHE)
Double Axial
(2 x FFB0812SHE)
Heat Removed at
118 F 20-30% RH
160-170 60-70 120-140
Maximum flow rate
(CFM)
54.8 68.5 68.5
Current Draw
(Amps)
2.4 0.7 1.4
Weight
(oz)
9.8 6.0 12.0
Fan Dimensions
(mm)
120 x 120 x 32 80 x 80 x 38 80 x 80 x 76
Static Pressure Drop
(in. H2O)
3.5 0.6 1.2
Total run time
(hours)
2.6 9.1 4.5
6

7. Thermal Model7
For testing correlation
mannequin, the results
equate to a person with
fat and skin wall of 6
mm thick.
Rwater + Rplastic =0.035 K/W
Testing Set up
Human Set up
T Core

8. Thermal Testing Results8
-20
0
20
40
60
80
100
120
140
160
118 F 20% 95 F 50% 95 F 65% 95 F 80%
WattsRemoved
Environment Conditions
Measured Cooling Environment Cooling Effective System Cooling
Measured – Environment = System Effective

9. Evolution of the Vest
 The original selected foam was
changed for a weather-resistant
neoprene foam for safety in high
heat situations and for comfort
 Ripstock nylon was originally chosen
to minimize head loss. It had problems
with the channels coming together
and blocking flow so the vest was
switched to a spandex material that
added losses but kept the channels
open
 The channel design was changed to
add more surface area being cooled
9

10. Battery Placement
 Pelican Case
Attach to belt or MOLLE
 Ammo Pouch
 Already carried
 Attached to Fan Manifold
Fan and battery are one
Less wires
10

11. Fan Manifold Assembly
11
 Two axial fans
 Splitting function
 Battery holster
Velcro strap
 MOLLE connections
 3D printed

12. Expanded Usage
 Airman directing ground traffic on the tarmac
 Military personnel working on the planes and
other machines
 Road workers out under the brutal summer
sun
 Outdoor exercise during hot weather
12

13. TES Solution13
Objective
Requirements
Design
Systems Weight 5.03 lbs
Estimated Run Time 4.5 hours
Thermal Test Watts Cooled
118F, 22% Humidity 127
95F, 50% Humidity 108
95F, 65% Humidity 75
95F, 80% Humidity 35