Overview
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Objective
Design solution to mount battery box (enclosure) to vehicle
Background
Battery Box Design
Based on prior discussion (2017-01-14 Battery Box Size), the current battery box weight and dimensions can be summarized as follows:
- We will be using 2 boxes, each housing 18 of the 36 modules
- Rough Dimensions: 24" x 18" x 5" (L x W x H)
- Approx weight of 40 kg per box, based on 80 kg estimate for both boxes (see Weight Budget)
Battery Placement in Chassis
*Regarding the pontoon hull, the current proposal would be to split the two battery boxes between the hulls as per above.
Previous Discussion
Previous documentation relating to the Battery Box mounting solution can be found here: Battery Box Mount
Design Considerations
| Requirements | Constraints |
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*Regarding the configurability of mounting solutions, having this option would allow for better weight distribution depending on the number of battery modules used (per different regulations for maximum battery capacity) by allowing for the repositioning of the battery/batteries in the vehicle. This would also be the case for adjusting when racing with a driver + passenger vs. driver only.
Sub-Functions
Based on the above requirements and constraints, the function of the battery box mounting system can be broken down into the following sub-functions:
- Guide system (what will actually hold battery box, provide support in "x","y" direction)
- Mounting to chassis
- Locking mechanism (what will secure box in place, support in "z" direction)
- Vibration dampening
Design Selection & Analysis
Solutions to these sub-functions can be analyzed in a morphological chart:
Morphological Chart
| Sub-Function | Option 1 | Option 2 | Option 3 | Option 4 | Option 5 | Option 6 |
|---|---|---|---|---|---|---|
| Guide System | Tracks (low friction) | Tracks (wheels) | Enclosure (box) | Enclosure (skeletonized) | Enclosure (C-channel) | Webbing |
| Mount to Chassis | Weld | Bolt Into | Fasten Around | Adhesive | ||
| Locking Mechanism | Pin | Straps | Arm | Ratchet | ||
| Vibration Dampening | Foam | Springs | Tight fitting guide | Tightening guide |
Proposed Solutions
| Design | Sub-function Solutions | Sketch |
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| Option A (Datum) |
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| Option B | ||
| Option C |
Selection
The above proposed solutions can then be ranked based on the following criteria. The ranking scheme used will compare designs against a datum design (Option A) ranking them with either: +1 (better), -1 (worse), or 0 (equal).
Ranking Criteria:
- Securely hold battery box in place
- Robustness
- Easy removal of battery box
- Minimize vibrations
- Configurability
- Manufacturability
- Securely mount to chassis
Design Selection Chart
| Criteria | Option A (Datum) | Option B | Option C |
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| +0 | |||
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| Total | 0 |
Discussion
Believe that Design ______ is best because of _____________
Some issues that still need to be addressed are ____________ which can be further addressed by doing __________ to this design
All in all, we believe that this design is the best possible option for mounting the battery box to the vehicle chassis based on the aforementioned requirements and constraints.
Moving Forward
- Go over possible design solutions with Graydon McDonnell (Deactivated) (Monday, January 22?)
- Go over proposed solution with Devon Copeland (TBD)
- Begin refining solution