calum fowler

8/18/2019 Calum Fowler

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Review of Composite Toroidal

,

and Development for On‐Board CNG

and Hydrogen Storage

– Melbourne, Australia

Supervisors:

Prof. Chun Wang – Primary supervisor – RMIT University

– –

Composites Australia and CRC – ACS Conference 2014

.

Dr. Stephen Daynes – Associate supervisor – RMIT University


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Personal Background• Graduated from Deakin University, Geelong in 2012

with Bachelor of Engineering (Mechanical)• Completed final year project on “Clamp load loss of

compos te o te o nts n con unct on w t Car on

Revolution• omp e e e ence ng neer ng n erns p rogram

with CRC‐ACS over summer of 2012/ 2013

–

“ ”

• Began PhD at RMIT in September 2013



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Project Overview• PhD Project

•

Sponsored by AutoCRC 2020 – Gaseous Fuels: “to address both technological and social

”

– Toroidal vessels for gaseous fuel storage previously studied

in AutoCRC Visionary Project (RMIT contributions)

• Begun in September 2013

• Aim: – To optimise the design of filament wound carbon fibre composite

toroidal vessels for high‐pressure CNG and hydrogen storage for

vehicular usa e



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Aims of this Presentation1. Briefly review the current “state‐of ‐the‐art” in

regar s o on‐ oar s orage o an y rogen

using composite pressure vessels (CPVs)

2. Review recent research on the design, optimisation

.further research and development of toroidal CPV



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CNG and H dro en Gas

• 3

– Stored in internally pressurised vessels

• Current CNG vessel standards allow u to 20 MPa

(200 bars) of internal pressure

• H dro en vessels are able to store as at u to 35‐40MPa (350‐400 bars)

• Cylindrical and spherical vessels are traditional

options due to constant/near‐constant curvature


Zheng et al, International Journal of Hydrogen Energy , 37(1), pp. 1048‐1057, 2012

ISO 11439:2013: Gas cylinders – High pressure cylinders for on‐board storage on natural gas as a fuel for automotive vehicles, 2013


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Limitations to Natural Gas Vehicle (NGV) Uptake• Storage tanks difficult to integrate into vehicles

• ‐

conventional retro‐fits• Stora e tank o eratin ressures and internal volumes

are too low

– Limited driving ranges

• Little current infrastructure

• Slow, inconvenient refuelling

Figure 1:Composite H2 storage tank used in a


.,Flynn, Energy Policy , vol. 30, pp. 613‐619, 2002

http://www.autocrc.com/activities/research/gaseous ‐fuels‐program, AutoCRC – Gaseous Fuels Program Overview, Accessed, 31/03/2014


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C lindrical Pressure Vessels• Disadvantages:

– Structural weaknesses due to use of end‐caps

(changes of curvature; differing wall thicknesses)

– L m te to c rcu ar cross‐sect ons

•

Deviations require additional wall thicknesses and

– Can be volumetrically inefficient in certain

situations

– Nozzles/valves protrude from cylinder ends


White et al., AutoCRC Visionary Project C2‐24: Volume Efficient High Pressure Storage Vessel – Internal AutoCRC Report , 2012


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Toroidal Tank Exam les in Industr(a) (c)

Figure

3:(a) Thiokol – toroidal tank liner

fabrication

o o – omp e e oro a

vessel (created by hand)

(c) San Diego Composites – FW

toroidal vessel (automatedmanufacture)

(d) San Diego Composites – RTM

mold and accompanying

toroidal vessel

(b) (d)

http://www.sdcomposites.com/Products/p_product1.html, San Diego Composites Website – Pressurant and Propellant Tanks Product

Overview, Accessed 31/03/2014


Delay & Roberts, Toroidal Tank Development for Upper Stages, in 5th Conference on Aerospace Materials, Processes and Environmental

Technology , 2003


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Toroidal Theory• An axisymmetric shell of revolution formed by

rotatin a 2D sha e 360 de rees about a central axis

(no intersection at axis)• A “donut” structure

• A bent, endless cylinder

• Advanta es:

– Fixed centre of mass

– No end‐caps

Figure

4:A toroidal structure with circular

cross‐section (Li & Cook, 2002)

– Able to protect valve/nozzle/pressure regulator

– Potential to innovate design (circular cross‐section,


un orm c ness are no op ma


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a

R/r = 1.25 R/r = 2.5 R/r = 5

(a) Toroids of various aspect ratio

(R/r), and (b) geometrical parameters

of a toroidal shell including major/circumferential radius (R) and minor/

(b)

cross‐sectional radius (r)

r

R


Vu, Structural and Multidisciplinary Optimization, vol. 42(3), pp. 351‐369, 2010


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Hoop stress distribution for various

toroidal aspect ratios around circular

cross section




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Blachut, 2005• Concluded that wall thickness variation was required

to provide uniform stress distribution

Figure 8:Side‐on view of metallic toroidal

shells before and after internal

pressurisation

Vu & Blachut, 2009•

specimens (location of maximum hoop stress)

(a) Shape of metallic toroidal shell

after burst and (b) burst failure

location of the toroidal shell


Blachut, Journal of Pressure Vessel Technology – Transactions of the ASME , vol. 127(2), pp. 151‐156, 2005

Vu & Blachut, Journal of Pressure Vessel Technology – Transactions of the ASME , vol. 131(5), p. 051203, 2009


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oro a amen n ng

a

(b)

(a) Overhead view of a FW toroidal vessel with some geometrical and winding parameters, and (b)

layout of a toroidal filament‐winder with an associated coordinate system


Zu, Zhang, Xu & Xiao, International Journal of Hydrogen Energy , vol. 37(1), pp. 1027‐1036, 2012


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Geometry

Figure 12:Isotensoid cross‐sections for

increasin volume outlined

Figure 11:Toroidal cross‐sections investigated by


by Zu et al., 2010,


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Steele, 1965• ons ere vo ume r c an mass e c enc es o c rcu ar an

elliptically cross‐sectioned toroidal PVs

• Deviations from circular cross‐sections caused large decreases in

structural performance

• Concluded, for practical purposes, circular cross‐sections produced

lowest mass for constant and variable wall thicknesses

Vu, 2010•

methods to design isotropic toroidal pressure vessels of minimum

weight

,• Circular cross‐sections with thickness variation were the best

balance between material saving and manufacturability


Steele, Journal of Spacecraft and Rockets, vol. 2(6), pp. 937‐943, 1965



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Z l. v ri • The majority of recent studies into optimal cross‐

sec ona geome ry an c ness o amen ‐woun

toroidal pressure vessels have involved Lei Zu: – “ ‐

filament‐wound toroidal pressure vessels,” in 17 th International

Conference of Composite Materials (ICCM‐17), Edinburgh, UK, 2009

– Zu, Koussios & Beukers, “Optimal cross sections of filament‐wound

toroidal hydrogen storage vessels based on continuum lamination theory,”

International Journal of Hydrogen Energy , vol. 35(19), pp. 10419‐10429,

2010

– Zu, Koussios & Beukers, “A novel design solution for improving the

performance of composite toroidal hydrogen storage tanks,” International

Journal of Hydrogen Energy , vol. 37(19), pp. 14343‐14350, 2012



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Zu et al., 2010• Optimal toroidal FWPVs had lower and wider profiles than

circular toroidal FWPVs of equal volume

Figure 13:(a) Optimal and circular profiles of

,

performance comparison of circular

and optimal toroidal and cylindrical

PVs

• Optimal toroids became circular at small internal volumes

– As internal volume increased, the optimal toroidal profile became

more non‐circular• Optimal toroids were lighter than circular equivalents at any

e ual volume


Zu, Koussios & Beukers, International Journal of Hydrogen Energy , vol. 35(19), pp. 10419‐10429, 2012


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• Optimal toroids produced lower stresses than geodesic

equivalents

– Due to winding angle decrease, not the change in cross‐sectional

shape

gure :Sectional views of (a) a circular‐shaped toroidal vessel, and (b) an isotensoidal, non‐geodesically

wound toroidal vessel obtained by Zu et al. (ρmin = 0.2, λ = 0.04), where λ is the friction coefficient

between the non‐geodesic fibres and he mandrel surface

(a) (b)




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the “Natural Thickening Effect”

Various wall thickness variations and cross‐sectional shapes of isotropic

toroidal PVs investigated by Vu, 2010



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• Performed thickness optimisation study on an

re oro a an us ng an a ec s

Logic

• Approximately 50% weight saving predicted

Figure 16:(a) Uniform thickness and (b)

th

iteration using Mattheck’s Logic


White et al., AutoCRC Visionary Project C2‐24: Volume Efficient High Pressure Storage Vessel (Internal report), 2012


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. , • The study then considered identical toroidal FW tanks that

had ex erienced natural thickenin

P a ]

Figure 17:Comparison of hoop stress distribution

between 80 litre toroidal FW tanks of o n a

l S t r e s s [

optimisations performed by White et al.

M e r i d i

Degrees around the toroidal meridian [˚]

• The naturally thickened toroidal vessel was found to be 27%

li hter com ared to one of uniform thickness

(0˚ at upper crest, clockwise direction)


White et al., AutoCRC Visionary Project C2‐24: Volume Efficient High Pressure Storage Vessel (Internal report), 2012


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, , Figure 18:(a) A comparison of equal volume cylindrical and toroidal vessels worn on a persons back and (b)

diagram of the toroidal breathing apparatus showing the natural thickening variation in the cross‐section

Maximum thickness

Minimum thickness

•

Natural thickness build‐up almost exactly accounted for hoopstress variation for the given example

– No eometrical dimensions or toroidal as ect ratio iven


Cook et al., in 19th International SAMPE Europe Conference, pp. 125‐138, 1998


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O timisation of Toroidal Windin Angles ([α/‐α]n)

Figure

20:Model depicting the geodesic helical winding of a

toroidal vessel (White et al, 2012)

Figure

19:Non‐geodesic winding pattern after 40 rotations of

mandrel using single helical winding (Zu et al., 2007)



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Zu et al, various dates

• Like toroidal geometry, the majority of recent studies into winding angle

optimisation of toroidal FWPVs has involved Lei Zu: – u, e an , attern es gn or non‐geo es c w n ng toro a pressure vesse s, n

International Conference on Composite Materials (ICCM‐16), Kyoto, Japan, 2007

– Zu, Koussios and Beukers, “Pattern design and optimization for filament‐wound toroidal pressure

vessels,” in 23rd Technical Conference of the American Society for Composites, Memphis, TN, USA,

– Zu, Koussios and Beukers, “Design of filament‐wound circular toroidal hydrogen storage vessels

based on non‐geodesic fiber trajectories,” International Journal of Hydrogen Energy , vol 35(2), pp.

660‐670, 2010

– Zu, Koussios and Beukers, “Minimum wei ht desi n of helicall and hoo wound toroidal h dro en

storage tanks with variable slippage coefficients,” Polymer Composites, vol. 33(12), pp. 2218‐2227,

2012

– Zu, Koussios and Beukers, “A novel design solution for improving the performance of composite

toroidal hydrogen storage tanks,” International Journal of Hydrogen Energy, vol. 37(19), pp. 14343‐

,

– Zu, Zhang, Xu and Xiao, “Integral design and simulation of composite toroidal hydrogen storage

tanks,” International Journal of Hydrogen Energy, vol 37(1), pp. 1027‐1036, 2012

– Zu, “Stability of fiber trajectories for winding toroidal pressure vessels,” Composite Structures, vol.


, . ‐ ,


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Zu et al., 2008• Created an optimisation algorithm to determine optimal

winding paths and thickness distributions of circular helical‐

and‐hoop wound toroidal PVs

– To obtain minimum weight while satisfying strength, non‐slippage and

non‐bridging criteria

• Toroidal PV example:R/r = 4.0

allowable sli a e coefficient = 0.3

pburst (burst pressure) = 70 Mpa

Xf (filament tensile strength) = 4.9 Gpa

– Optimal average thickness: 1.8 mm

– Optimal average winding angle: 50.83˚ Figure

21:Comparison of geodesic and optimal

non‐geodesic winding trajectories on

toroidal mandrel


Zu, Koussios and Beukers, in 23rd Technical Conference of the American Society for Composites, Memphis, TN, USA, 2008


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Zu et al., 2010• Extended previous work to include continuum theory

– Netting theory used in previous study

50˚‐56˚

•

Zu et al., 2012• se var a e s ppage coe c en s o crea e op ma

non‐geodesic minimum weight toroidal vessels

°.periphery to 55.12° at inner periphery



Zu, Koussios & Beukers, Polymer Composites, vol. 33(12), pp. 2218‐2227, 2012


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Zu et al., 2012• Determined optimal cross‐sectional shapes of non‐

geodesically wound, isotensoid toroidal PVs

• ye s ape oro resu e n w n ng ra ec or es

varying from 5° at outer periphery to approximately°

Zu, 2012•

helical and helical‐and‐hoop winding methods

• Toroidal FWPVs with aspect ratios less than 3 should avoid

netting‐based non‐geodesic winding – Should employ geodesic or semi‐geodesic winding



Zu, Composite Structures, vol. 94(5), pp. 1855‐1860, 2012


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Zu et al., 2012(a) (c)

Single Single

Figure 22:Optimal geodesic trajectories after 300

Helical

Winding

Helical

Winding

wound circuits of mandrel for:

(a) single helical winding, and

(b) symmetrically helical winding, and

Optimal non‐geodesic trajectories

(b) (d)

after 160 wound circuits of mandrel

for:

(c) single helical winding, and

(d) symmetrically helical winding

Symmetrical

Helical

Winding

Symmetrical

Helical

Winding

Geodesics Non‐geodesics


Zu et al., International Journal of Hydrogen Energy , vol. 37(1), pp. 1027‐1036, 2012


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Conclusions drawn from Literature• Majority of studies into toroidal FWPVs have been

urel numerical theoretical

–

Dedicated toroidal winding machinery is highly desirable – Experimental validation required

•

Uniform wall stress in toroidal FWPVs can beachieved by:

– Isotensoid cross‐sections

–

a t c ness var at ons – Optimal geodesic, semi‐ or non‐geodesic winding patterns



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Conclusions drawn from Literature• Circular cross‐sections with wall thickness variations

‐ ‐

weighting and manufacturability compared toelli tical isotensoid cross‐sections

– White et al. suggested further studies to determine if there

is an optimal toroidal aspect ratio (R/r) where naturalt ic ening ten s towar s geometry o unconstraine

thickness optimisations

• Utilising natural thickening would potentially simplify

the toroidal FWPV desi n and manufacturin rocess



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Conclusions drawn from Literature•

by Zu et al. should be utilised to maximise volumetricpotential of toroids

– Winding pattern optimisation is still needed for such ratios

• s u es re a ng o oro a s ave on y

considered flawless and pristine vessels

placement or impact damage) on design are required



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Research Questions

1. Are optimal winding angles ([α/‐α]n) of toroidal

FWPVs affected by the presence of holes and/or

impact damage?

– a c oa ng

– Fatigue loading?

2. Is there an optimal toroidal aspect ratio (R/r) where

natural wall thickenin tends towards the eometr

of unconstrained thickness optimisations?



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Li & Cook, Journal of Pressure Vessel Technology –

Transactions of the ASME , vol. 124(2), pp. 215‐222, 2002

I would like to thank AutoCRC, RMIT University and my supervisors for their on‐going support


o y o u .

calum fowler

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