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title05 November 2023 - Enclosure Manufacturing

why are baffles being redesigned?

  • bc safety wire

  • too much wire around the box

  • not checked

  • will not push to git, keep to safety wire

Design change

  • one extra cutout need for molex connector

  • air duct been designed?

    • cad changed for fan folders to accommodate for air duct (completed)

    • will be stuck with tape

    • once air duct connector cad done will check with jenna

Machining

  • only a few extra inches to the order

  • jenna will assign to experienced machining people to get it done

3d prints

  • fan holders (problem with heat set)

    • two seem viable from prototype, will be used for module

  • Hydrophobic mesh for inlet will look into it now -shem will do

  • enclosure feet: petg

    • will might need to modify according to weld bead

    • can we print right now? yes can print, but might need to modify to fit bolts to chassis

    • air baffles and diagonal supports can print right now

Electrical integration

  • wires who will buy?

  • so far know:

    • can use hardware money (can check confluence page)

    • all connectors for wiring in and out of box

  • deliverable: have a list of everything in battery box in electrical that is not module in enclosure (for saturday working session 11-11) will confirm with jonathan/forest

    • fans, connectors, etc

jigs

  • crossbar is good

  • chassis is good

mdf

  • jenna will let nicole know when done to check

welding

  • what happens if it sucks?

    • if too small use 1/8 inch board

    • if too big: need to redo or grind down bars

summary of deliverables:
shem:

  • list of electrical components/stuff in enclosure (everything but the modules) for 11-11-2023

  • assign 3d printing to new members on sat 11-11 (enclosure feet, air baffles & diagonal supports)

  • send update about asc email 05-11

  • Hydrophobic mesh for inlet 11-11

nicole:

  • jigging as soon as everything is done

  • machining to be done?

jenna:

  • will cut mdf (will be checked by nicole for wed)

  • modify aux bat for securing m4 for 10-11

  • air duct will confirm with micheal there is 2

  • assign machining as soon as gotten

update: email from asc securing method can be done with pack itself

  • sealing required for impounding

  • can secure another method post-assembly for during race (ie. fishing wire through modules)

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title13 December 2023 - W2023 Plans, Elec Integration, and Enclosure Assembly

Meeting Notes for December 13, 2023 MeetingMeeting Topics
Things we to talk about Wednesday:

  • Elec Integration plan for battery next term

  • What has to be done?

  • Who will be involved?

  • When will we be able to get it done?

  • Assembly plan

  • General overview

  • New check-in & project tracking structure

  • Trello & Confluence

  • Individual project updates

  • Avoiding past mistakes

Meeting Notes:Elec Integration plan for battery W2024:What has to be done?

  • Competition in July, we dont know where Owen’s gonna be

  • Battery pack with everything assembled by end of next term

  • Figure out where all electrical components are going to be placed (confirm positioning with Hardware)

  • Figure out wire lengths

  • LV can be over-speced, HV can’t because insulation is so thick (can’t bend easily)

  • Need custom busbars for main battery pack

  • ex. end busbar for pack terminals need to be bent backwards, L shaped

  • need to build up all the busbars

  • Rear busbars can be built now, others can’t because positioning not confirmed.

  • Need plates to place PCBs & solar relay & everything else

  • Make sure all the modules fit properly, might need changes if things go wrong. Including baffles, fans and all.

  • Terminals and solar relays are the same (from MSXII)

Who will be involved for elec integration?

  • Hardware: Jonathon, Forest

  • Battery: After enclosure is finished do modules, manufacturing spare modules, electrical integration.

  • Doesn’t hurt to talk to other teams in the SDC. Sit-down meeting with questions prepared would be useful.

Endgoal of W2024 for elec integration

  • Full pack complete with all boards & components connected

  • Assuming BMS is complete, check Hardware’s timeline

Module Testing Side Tangent

  • One has been tested, Forest says its good

  • Placed a thermistor in the middle of module: 10C change (20-30mins run time @ 10Amps)

  • Testing plan is there, work with Forest on it next term

  • Goal is to make all modules, then test W2024

  • Modules with weak busbar potting. Tried reapplying potting onto top cell plate, didn’t turn out well. Didn’t seem to stick.

  • Is potting necessary? Just to hold sigmaclad in place. Tight spacing between modules, moving around w/ vehicle moving, good to have potting. Potting will be done after testing.

  • Potting cells after testing (potting material poured over welded connections), potting busbars is necessary. We have to figure out how to redo, if top cell plates can’t be reused, might have to rip them out for new ones.

  • Potting process is fine, procedure just weren’t followed correctly.

  • Owen says we should do internal resistance test on all finished modules (won’t take long, just multimeter to read resistance)

  • Will do both individual module test and full pack test for thermals w/ BMS hooked.

Enclosure Assembly Plan

  • Nicole has a plan (rough outline)

  • Goal is to print baffles and everything using leftover ABS

  • Nicole will print

  • Owen’s friend can print some things

  • Nicole will put together a sheet of who’s printing what

  • Vaibhav will update the Enclosure BOM, put everything small and ez to lose in Enclosure Plastic Bag

  • Hydrophobic mesh is pricy ($30), hose clamp ($4). Push things we don't need immediately for next term to buy with WEEF/ENGSOC money.

  • Finish assembly before start of W2024

  • Need to 3d print validation device to ensure boards sit where they’re supposed to sit. Will look like modified version of the baffles. Design in the works. Nicole is working on it.

  • Validation for feet onto chassis

New check-in & project tracking structure

  • Bring back trello, with projects updated by only core members (and roping new members in if the consistently are coming in).

  • Updates should be made as soon as something is done, not just during check-ins.

  • Fall term check-ins (Jericho’s perspective)

  • Not so bad, because of going directly to ppl working on projects

  • Confluence gets convoluted & outdated, Trello is more readable

  • Clearer structure of parameters would’ve been helpful. What materials to use, how many parts to use. Stricter idea of what it should’ve been.

  • Trello:

  • Active updating, journal entry updates

  • Confluence:

  • Wiki, ctrl c + ctrl v stuff on trello

  • Project specific meetings:

  • Have specific meetings for each project (elec integration w/ Hardware & module manufacturing)

  • Make sure ppl online aren’t in the dark

  • Check-Ins

  • General overview of what’s going on in the subteam

  • Owen runs

  • Have something similar to Summer, not just done after work term. We won’t have as much time to dedicate to onboarding. Check-ins were good way to know whats going on and what projects are available. If it’s right after working session, ppl just left cus they were tired after the work session.

  • Check-ins ideally done day after a working session

Meeting times:

Winter Onboarding Side Tangent:

  • Maybe 5-10 new members peak in the beginning

  • Not spend a lot of time on it

  • If not a lot of ppl leads/lead in training can assign project to new member

  • No module spec’ing or make your own module