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

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


IN 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

MilestoneOwnerDeadlineStatusNotes
Decide on spot welder to purchase

 

COMPLETE


Purchase battery cells for testing
 COMPLETE
Research module mounting solutions
COMPLETEMachine pins out of acetal plastic, use epoxy to glue down
Decide on cell connection and purchase accordingly 
 COMPLETEHave decided to move forward with EMS material
Get rough power requirements from Elec Team

 

COMPLETEVery critical for battery box team
Module design initial concept (rev. 1)
 IN PROGRESS

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

Module design (rev. 2)
 NOT STARTED
Module design (rev. 3)
 NOT STARTED
Module final design 
 NOT STARTED
Cell TestingMicah Black NOT STARTED
Module Manufacturing Eric Chiang NOT STARTED
Enclosure integration with Chassis

NOT STARTEDNeed to wait for chassis design to start

Timelines

Design Journal 

DateJournal EntryStakeholders Involved
 


Reference materials

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