Case study of simulation driven designed components in use for a hydrogen-powered prototype vehicle
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The Hydro2Motion Team is a university project at the faculty 03 (general, car and aircraft engineering) at the University of Applied Sciences Munich. During the last years the students started to get more involved to the topic of Simulation. Developing and manufacturing a car in a very limited amount of time and working in a team of less than ten students, the Hydro2Motion team needed to come up with a process which consumes less time. At the very beginning simulation in the students project was very little used and if so, just as a validation tool. During the last years the members of Hydro2Motion shifted over to benefit from the simulation and the optimization as a help to find the ideal design for the various parts.
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Case study of simulation driven designed components in use for a hydrogen-powered prototype vehicle
- 1. Case study of simulation driven designed components in use for a hydrogen-powered prototype vehicle
- 2. Agenda • Aim: How we try to think before we build • Introduction Team • General Information • Composites • Topology Otimisation • Aerodynamics
- 3. The Team
- 4. The Mission 33,5 kg light Hydrogen fueled 603 km/m³Hydrogen => 1849 km/l gasoline => 3rd Place Shell Ecomarathon 2015 Continous development
- 5. Fuel Cell t r t Cooling Water Tank H2 Tank Radiator Air Pump 2 Water Pump Filter 1 Cut-Off Valve H2 Flow-Meter Fuellcell Air Pump 1 Temp. Sensor Temp. Sensor Rh Sensor t r Temp. Sensor Rh Sensor ∞ In In Out Out Manometer Manometer Pressure Reducer 2bar Pressure Reducer 250mbar V MOSFET Coil Voltmeter Voltmeter Ampere- meter A V CAP´s Air Hydrogen Humid AirHot Water t Temp. SensorBlowout Valve ECU Electric Motor Torque Air Air Hydrogen cold Water Elec. Current p p Heating Jack Heating Coil Bottle Valve Air ∞ Purge Valve Elec. Current
- 6. Live Telemetry • Live data stream • Preset options • Average speed • Visualisation online
- 7. Composites • Easy Part for experimentation • Hybrid: GFK Core CFK Cover Layer • Easy load step
- 8. Measuring • Eigenfrequenz analysis • Spring mounted in car
- 9. Topology Optimisation • Boundary conditions • Load and deformation requirements • Design follows topological optimization
- 10. Weight and stiffness • Designed parts result with concrete loadpaths • Inspiration for design process • Productionally by additive manufacturing
- 11. • CFD - Simulation 25 km/h – 30 km/h • Mutating the geometry Aerodynamics
- 12. Aerodynamics
- 13. Aerodynamics
- 14. Aerodynamics
- 15. Aerodynamics
- 16. Aerodynamics Summary • Status quo with covered front wheels c * Ax = 0.040 m² • New concept for completly covered front axle c * Ax = 0.065 m² • Conclusion: Why build a new car? Let‘s get rid of the problematic sections and build new wheel covers.
- 17. • Collaboration with more faculties • Comparision of different software tools • Composites manufacturing and testing Outlook