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Ailan Jiang (Unlicensed)

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nameMS Battery Pack Schedule S2019 AJ.xlsx
height250

LeadMembersReviewersStatus
Micah BlackMicah Black, Robin Pearce, Raj Kumar, Leif Blake

Micah Black, Robin Pearce, Raj Kumar, Leif Blake, Ailan Jiang (Unlicensed)


Status
colourYellow
titleIn Progress


Problem

Problem Statement

Create the battery pack which will supply the power requirements of MSXIV, and create the enclosure which houses the battery pack. Also assist electrical team in designing housing for circuit boards.

Goals 

To create a safe and lightweight battery pack which fulfills the car's energy  requirements under different driving conditions. The battery pack is one of the heaviest component of MSXIV. Streamlining the weight of the battery box will lead to less energy usage.

Constraints Regulations 
  • Provide MSXIV with its energy requirements (TBD)
  • Must perform within cell operating temperature (0~60 ℃)
  • Meet any safety regulations 
Criteria 
  • Significant weight reduction from MSXII
  • Lowered manufacturing time
  • Minimal cost


Scope


Activity
Must have
  • Research
    • Cell connections
    • Battery pack configuration
    • Chassis Integration
  •  Purchasing
    • Battery Cells
    • Spot Welder
    • Cell Connectors 
    • Battery Holders
  • Design Components
    • Circuit board enclosures
    • Battery module
    • Battery Pack enclosure
    • Enclosure mounts
  • Manufacturing
    • Module Assembly
    • Battery Pack Assembly
    • Enclosure
    • Module/Enclosure mounting
    • Electrical Wiring
Nice to have
  • MATLAB thermal simulation of the battery box based on cell spacing, power draw, and airflow.
Detailed Materials Needed

Prototype 1:

  • Acetal Plastic
  • Bus Bars 
  • Bolts to secure modules together
  • Fibre spacers - keep in mind, may need them if design changes

Prototype 2:

  • Polycarbonate 
  • Plastic guard to align modules
  • Alignment pins

Final Module: 

  • Thermal epoxy kaptone tape-high temp resistant tape
  • 22 gauge wire
  • AFE Connectors
  • Cable sleeve
  • 11 gauge interconnected copper sheets

Materials for Battery Box Enclosure - needed for later in Fall 2019 term:

  • Board mounting hardware
  • Resin
  • Foam core
  • Aluminum frame - tbc
  • Anderson (high current) connectors
  • Threaded inserts for composite panels
  • Fuses, contactors, 2 gauge crimp terminals
  • Cable management (3D printed)
  • DP 420-structural epoxy
  • PVC/module spacers
  • Vibration dampening foam (maybe polyurethane)
  • MDF for battery box


Milestones and deadlines

MilestoneOwnerDeadlineStatusNotesDecide on spot welder to purchase

 

StatuscolourGreentitleCOMPLETEPurchase battery cells for testing  StatuscolourGreentitleCOMPLETEResearch module mounting solutions StatuscolourGreentitleCOMPLETEMachine pins out of acetal plastic, use epoxy to glue downDecide on cell connection and purchase accordingly   StatuscolourGreentitlecompleteHave decided to move forward with EMS materialGet rough power requirements from Elec Team

 

StatuscolourGreentitlecompleteVery critical for battery box teamModule design initial concept (rev. 1)  StatuscolourYellowtitlein progress

First time laser cutting acetal plastic - fingers crossed everything will work according to plan

Module design (rev. 2)  StatuscolourRedtitleNot StartedModule design (rev. 3)  StatuscolourRedtitleNot StartedModule final design   StatuscolourRedtitleNot StartedCell TestingMicah Black  StatuscolourRedtitleNot StartedModule Manufacturing Eric Chiang  StatuscolourRedtitleNot StartedEnclosure integration with Chassis StatuscolourRedtitleNot StartedNeed to wait for chassis design to start

Timelines

600
Gdriveconnector
dummy1562782986131
filenameS19 - Battery Box Timeline
width1000
mimeTypeapplication/vnd.google-apps.spreadsheet
fileId18HK26cr-APtvNtXCRbtp-h_Oz75tVmZAzU76eparIFY
height
Google drive sheets
urlhttps://docs.google.com/spreadsheets/d/13FyB62JNlwkbRkpEBZQN5cizZeEfzXHxrzqeRntyogc/edit#gid=1115838130



Timelines


Design Journal 

DateJournal EntryStakeholders Involved
 



Reference materials