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To validate the compression design, we decided to build a prototype of 3 modules in series. Our goal was to:

  • Verify electrical conductivity
  • Identify pain point in manufacturing
  • Size materials appropriately

Retrospective  

Participants: Adam MarchandTitus Chow

  • Overall: Relatively simple to manufacture, used 4mm threaded rod
  • The copper plates we built weren't quite up to spec, but still seemed to work well - very tolerant to error!
    • Didn't actually sit flush in the grid, so they were a little annoying to align
    • We just did vertical strips for ease of manufacturing which worked, but was annoying to align (didn't sit flush in the plastic)
  • Try avoiding handling to copper and/or electroplate it - picked up a lot of grime really easily
  • Foam + backing plates could probably be thinner
    • Backing plate cracked - add torque specs?
  • Copper could be thinner and reduced in width
    • 3D print caps to isolate the copper
    • Add top plate to support busbars and hold modules in place
  • We should deburr the plastic holders when we drill holes - they caught on the heatshrink of the threaded rod
    • Heatshrink is very annoying to deal with - recommend coating rod with silicone or something
    • The heatshrink may have caused the pressure to be distributed unevenly, probably want a bit of play or at least make it easier to slide
  • Batteries + plastic holders are extremely rigid - don't need to worry about batteries coming out, especially with the threaded rod
  • Remember to use fujilocks for all the battery-related fasteners!
  • Remember to use a non-flammable material for the backing plates!
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