Team 04032 Delphi Corporation Solid Oxide Fuel Cell

Team 04032 Delphi Corporation Solid Oxide Fuel Cell Durability Test Stand Mechanical Engineers • John Bagby Electrical Engineers • Wai Meng Ng • Michael Scholl • Richard Yang • Joshua Gannon • Gregory Tyminski • David White Faculty Mentor • Margaret Bailey, Ph. D. , PE Delphi Contact • Chris Mergler Friday, May 14, 2004 SOFC Durability Test Stand 1

Subgroup Structures Friday, May 14, 2004 SOFC Durability Test Stand 2

Stand §Preliminary Design §Final Decisions § 1. 5” x 1. 5” 80/20 extruded aluminum built 36” tall § 2” x 2” 80/20 extruded aluminum used due to in-stock supply §Double Anchor Bolt Fasteners for assembly § 80/20 corner brackets and joining plates used for assembly due to in-stock supply § 32” height of stand § 4 lengths 80/20 top rails supporting top plate §Top rail elimination §Post PDR Suggestions § 32” height of stand §Elimination of 4 supporting 80/20 top rails Friday, May 14, 2004 SOFC Durability Test Stand 3

Stand FEA • Maximum Deflection under 700 lb Load: 0. 003 in Friday, May 14, 2004 SOFC Durability Test Stand 4

Enclosure §Post PDR Suggestions §Preliminary Design § 80 / 20 Extruded Aluminum, 1” x 1” Cross Section §Supporting Structure §Cast Acrylic Plexiglas §Toggle Clamp Attachment for enclosure removal §Excellent Clarity § 150 degree F tolerance §Firewall § 1850 degree F tolerance §Rubber Seal §Fulfills airtight requirement §Aluminum Plate §Due to high temperature requirement at exhaust outlet Friday, May 14, 2004 §Hinges for enclosure opening §Reduces manual lift of enclosure to supporting position on the stand base §Top Exhaust for CO startup leak §Extra air draw through enclosure to reduce CO emissions into the room §Movable position of top plate within enclosure §Gives better inline positional placement of exhaust of SOFC to enclosure exhaust opening SOFC Durability Test Stand 5

Enclosure § Final Decisions § § § Hinges are to be used to open enclosure with support braces for a propped position on stand No Top Exhaust addition § Relay on sensors and Labview within enclosure to shutdown stand if necessary Movable plate within enclosure § Top plate is anchored at its vertical position § Enclosure hood is vertically movable • Manual disassembly and reassembly of supporting 80/20 for vertical movement of enclosure • Enclosure movement provides robust placement of SOFC in comparison to hood exhaust outlet Friday, May 14, 2004 SOFC Durability Test Stand 6

Fuel Delivery System Fuel Supply Delivery System § System supplies natural gas/diesel/gasoline fuels to SOFC. § Refueling is accomplished without interrupting the fuel flow to the SOFC. § Fuel Pump supplies liquid fuel at 500 k. Pa to fuel injector. § Redundant Automatic shutdown safety feature. Friday, May 14, 2004 SOFC Durability Test Stand 7

Fuel Delivery System §Swagelok Components §Warren Rupp Sandpiper II Diaphragm Pump §Mc. Master-Carr High Pressure Fuel Tanks Friday, May 14, 2004 SOFC Durability Test Stand 8

Controls Component Interface §Labview 6. 1 §The main view of the controls were already developed by Delphi. Our task was to integrate what we had with the given components. §Enclosure data, fuel pump enable and enclosure warnings. §E-stop is to be tied in with the e-stop sequence for SOFC unit. Friday, May 14, 2004 SOFC Durability Test Stand 9

Data Acquisition §Data collection for enclosure’s thermocouples and gas sensors. §Detection of warning & e-stop violations. §Data logging writes to a new file each day. §Stand DAQ VI can be incorporated into Main VI as a sub VI with one input and two outputs. §Input for initialization §Two outputs for data values and warning signals. Friday, May 14, 2004 SOFC Durability Test Stand 10

Financial Summary Components Removed From Budget By Delphi Corporation • Many Swagelok, exhaust and computer components, stocked in house • Field Point Modules $4. 2 K • $12 K Load Bank Replaces $17 K Load Bank • Gas Sensor System $4. 5 K Friday, May 14, 2004 SOFC Durability Test Stand 11

Tasks Outstanding § Finalize and debug Controls & DAQ Virtual Interface § Full installation into Laboratory environment: Plumb Air, NG, Exhaust lines Friday, May 14, 2004 SOFC Durability Test Stand 12

Thank You: R·I·T Delphi Corporation §Margaret Bailey, Ph. D. , P. E. §Mr. Chris Mergler §Alan Nye, Ph. D. §Mr. Chris De. Minco §Mr. Anthony De. Rose §Mr. Kristian Whitehouse Friday, May 14, 2004 SOFC Durability Test Stand 13

Questions Friday, May 14, 2004 SOFC Durability Test Stand 14