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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
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
.,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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 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,
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
Vu, Structural and Multidisciplinary Optimization, vol. 42(3), pp. 351‐369, 2010
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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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
Steele, Journal of Spacecraft and Rockets, vol. 2(6), pp. 937‐943, 1965
Vu, Structural and Multidisciplinary Optimization, vol. 42(3), pp. 351‐369, 2010
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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
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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)
Composites Australia and CRC – ACS Conference 2014
Zu, Koussios & Beukers, International Journal of Hydrogen Energy , vol. 37(19), pp. 14343‐14350, 2012
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the “Natural Thickening Effect”
Various wall thickness variations and cross‐sectional shapes of isotropic
toroidal PVs investigated by Vu, 2010
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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)
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
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)
Composites Australia and CRC – ACS Conference 2014
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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.
Composites Australia and CRC – ACS Conference 2014
, . ‐ ,
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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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
Zu, Koussios & Beukers, International Journal of Hydrogen Energy , vol. 35(2), pp. 660‐670, 2010
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
Composites Australia and CRC – ACS Conference 2014
Zu, Koussios & Beukers, International Journal of Hydrogen Energy , vol. 37(19), pp. 14343‐14350, 2012
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
Composites Australia and CRC – ACS Conference 2014
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
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
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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?
Composites Australia and CRC – ACS Conference 2014
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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
Composites Australia and CRC – ACS Conference 2014
o y o u .
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