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Jahutussüsteemi projekteerimine formula student võistlusautole Fest15

Juhan, Viik (2015) Jahutussüsteemi projekteerimine formula student võistlusautole Fest15. [thesis] [en] Design of Fest15 Cooling System.

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Abstract

Antud töös projekteeriti jahutussüsteem FS Team Tallinn esimesele neljaveolisele elektrivormelile. Selleks toodi välja põhimõttelised erinevused FEST15 ja varasemate elektrivormelite ehituse vahel Peamisteks erinevusteks on jõuülekande edasiarendus neljaveoliseks ja toruraami asendamine süsinikmonokokk-kerega. Punktid, mis mõlemad mõjutavad jahutissüsteemi projekteerimist. Esiteks, muutub jahutusring oluliselt pikemaks, et tagada kõikide mootorite võrdne jahutus. Teiseks, peab detailide paigutamine autole olema varasemat veel rohkem läbimõeldud, sest enamik kinnitustest peavad olema projekteeritud kerevormi sisse. Lähteülesande analüüsis tehti valik erinevate jahutusskeemide vahel ja arvutati maksimaalne pumba võimsus, milleks on 72W. Et leida vajalik süsteemi jahutusvõimsus arvutati eralduv soojuskogus, ligikaudne vajalik pumba tootlikus, mis on vastavakt 20l/min ja 175 000W/m2. Kasutades saadud andmeid teostati voolavusanalüüsid, et leida parim jahutusärgi geomeetria ja optimeerida vajaliku pumba tootlikkust. Lisaks kasutati simulatsioonidest saadud väljund temperatuure radiaatori jahutuspindala arvutamiseks, milleks leti 2,4m2. Kasutati arvutitarkvara, et leida mootori veesärgi optimaalne kuju jäädes vajalike temperatuuride piirkonda. Lõplike tulemustena saadi vooluhulgaks 10l/min ja kaks radiaatorit mis, kinnituvad kummalegi auto küljele, gabariitmõõtmetega 195x162x32 mm Järgnevalt koostati kogusüsteemist 3D mudel. Kus vooluskeem paigutati autole, mille abil leiti täpsed voolikute pikkused, vajalikud liitmike kohad ja kinnitus elemendid mis on vajalikud jahutusringi koostamiseks. Kõikide voolikute kogu pikkuseks on 9,6m. Liitmikena Metal Work R-seeria push-in ühendusi, mis tagavad süsteemi kiire ühendamise ja lihtsa hoolduse. Viimaks eelarvestati auto vastavalt Formula Student võistlusreeglitele, kus loetleti üles kõik autol olevad detailid, vajalikud materjalid ja ostutooted, koostamise kulud ja kinnitus elemendid andes neile maksumuse. Auto kogumaksumuseks tuli 233€ (265$), mis on kallim kui, eelnev elektrivormel oma pikema vooluskeemi ja eraldi projekteeritud jahutussärkide tõttu. Kuna tegemist on tootearendus projektina pakun välja tulevasi edasiarendusi. Olles saadud juba reaalseid andmeid test ja võistlus perioodis, võib proovida siduda pump mootori pöörlemiskiirusega vältides seeläbi pumba liigset tööd ja teiseks radiaatorite pindala optimeerimine vastavalt testtulemustele.

Abstract [en]

The goal of this thesis is to design and manufacture the necessary parts for 2015 FS Team Tallinn electric formula car cooling system. Firstly differences between the previous electric cars and FEST15 are brought out. There are two big developments changing the drivetrain form 2WD to 4WD and secondly building a monocoque chassis compared to the previous car tubular space frame. These concepts make the design of the cooling system more complicated by making the cooling circuit considerably longer and the attachment of components has to more thoroughly thought through. For cooling system, base parameters were analyzed by comparing different possible cooling assemblies, calculated the maximum pump power and heat dissipation. The circuit schematics were developed consisting of two radiators attached to each side of the car. The developed cooling system is designed with one circulation pump connected with coolant hoses and fittings From there calculations were made to find out the heat generation at the motors, form what the outlet temperatures were found using Computational fluid dynamics analyses at the same time compering different cooling jacket geometries. Using the results from the analyzes pumping power was optimized. Resulting in ø10 polytetrafluoroethylene hoses connected with Metal Work R-series “push in” fittings that make the connecting and maintenance of the system simple. 3D printed cooling jacket with spirally running cooling channels are fitted to all 4 motors. The optimal cooling temperature is achieved by running a circulation pump 14 W pumping power of 15 l/min. In the last chapter the cost of the assembly was made complying with the Formula Student Cost Report rules. Where all parts, material, process and fasteners are listed and priced. The cost on FEST15 cooling assembly is 233€ (265$) being more expensive compared to previous cars because of the long cooling circuit need to cool four separate motors. For future developments I suggest connecting the pumping speed and the wheel rotational speed to avoid unnessesary pumping where heat is not generated. Also after gathering the results from the testing period to further optimize the radiator size.

Item Type: thesis
Advisor: Tavo Kangru
Co-advisor: Margus Villau
Subjects: Mechanical Engineering > Production Development > CAD Systems
Mechanical Engineering > Production Engineering and Technology > Hydraulic and Pneumatic Equipment
Mechanical Engineering > Production Development > Industrial Design
Mechanical Engineering > Production Engineering and Technology
Mechanical Engineering > Production Development
Divisions: Institute of Engineering > Machine Building
Depositing User: Juhan Viik
Date Deposited: 08 Jun 2015 07:27
Last Modified: 08 Jun 2015 07:27
URI: http://eprints.tktk.ee/id/eprint/1197

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