Enclosure Design Sprint Pt. 2

Owned by Eric Zhao
Mar 09, 2023
4 min read

GOALS

We will split into two groups to create two PERFECTED designs to compare impounding in vehicle and impounding in impound box.

Whichever one is selected should be ready to start building and prototyping by the start of the next term.

Timeline + Deliverables

Due date: Apr 10, 2023 (1 month from now… i believe in us)

Weekly check-ins every Thursday 8:00pm EST until then, make and update a brief presentation (PowerPoint or Confluence page or whatever way you want to document your work) for each check-in :

Mar 16, 2023

  • Read through regulations, have good understanding of limitations on enclosure

  • Watch the impound video attached below

  • Read through the past designs in the past design sprint, jot down any possible solutions explored / inspo

  • Brainstormed mounting solutions, create CAD models for most viable solutions

    • Use past design sprint as inspiration

  • Goal is to decide on a single mounting solution by the end of this check-in, also get critique/ideas

 

Mar 23, 2023

  • More detailed CAD model of mounting solution and enclosure within the chassis

  • Incorporate cooling fans

  • More details to come after the check in before

 

Mar 30, 2023

  • Details TBD after the initial check-ins

 

Apr 6, 2023

  • Details TBD after initial check-ins

 

Apr 10, 2023

  • Present our finalized designs to the mech team, decide on which solution looks best for the car

Details

There are two options for our battery box enclosure, impound in vehicle (we would need to provide a locking solution that can lock out ANY possible access to the battery (close and shut off any openings into the enclosure) with a maximum of 3 lock, OR impound in an impound box (we would need to pull out the enclosure from the vehicle every night, and lock it in a box).

There are pros and cons for both options, you should read through the regulations here: https://uwmidsun.atlassian.net/wiki/spaces/MECH/pages/3188850810, and watch https://drive.google.com/file/d/1yhFEMxoY75Byicuy7MHLREKkFE9km-48/view?usp=sharing.

Read through our past design sprint slides here:

https://drive.google.com/drive/folders/1qMvW87Pui0EynrJgvJV-uTlVbMhs1Q3R?usp=sharing

Each group will design their enclosure based on the regulations that apply to their specific solution. Some previous designs can be found in https://workbench.grabcad.com/workbench/projects/gc-TDa3HlgF44RHTO8OUQAeTZF1S4ZfGW7LMpBwytT8QBR#/folder/12917722 (msg me if you don’t have access to our GrabCAD, you’ll probably be using this to collaborate on CAD designs for the enclosure).

The enclosure will be made out of fiberglass.

Some screenshots here (Note that these are old designs sitting in the old chassis, our new chassis is a little more limited on space for the enclosure, SEE: Reference dimensions) (Read through the design sprint slides linked above for a better idea of what the designs are):

erics idea for impound in box where you pull out the enclosure with those handles
erics last design for impounding in vehicle, note the possibility of adding some short chassis tube attachments to help with mounting stuff

READ THROUGH THE DESIGN SPRINT SLIDES (at least the LAST design sprint slides for each person), there’s a lot of feedback and inspo there

 

 

Reference Dimensions

Current chassis V10.4 dimensions for enclosure (check GrabCAD for better idea of how it looks): 408.25mm width x 743.25mm length x 393.25mm height

Fiberglass thickness (approx.): 7.46mm

We can attach things to the chassis (such as additional chassis tubing and mounting points).

Use Eric’s latest Rev 4 module design (https://workbench.grabcad.com/workbench/projects/gc-TDa3HlgF44RHTO8OUQAeTZF1S4ZfGW7LMpBwytT8QBR#/folder/13047713 WIP) as reference for the dimensions of the modules.

  • If for some reason the CAD for my module breaks lol, the dimensions should be:

    • 189.41mm length, 107mm width, ~100mm height

    • The total module configuration should be 378.82mm wide, 535mm long, ~100mm tall

    •  

Use Darton’s Aux Battery design for the dimensions of the auxiliary battery: https://workbench.grabcad.com/workbench/projects/gc-TDa3HlgF44RHTO8OUQAeTZF1S4ZfGW7LMpBwytT8QBR#/folder/13344725

  • You can use his design in your CAD model, probably better that way

Use these dimensions for the other boards REQUIRED in the enclosure for now (ignore the fans and the aux battery) (dimensions are estimates, tbd when hardware finishes):

Final comments

Lmk if I missed anything or you need any other dimensions or anything, I’ll update this page with that info and send the info to the group chat as well, thanks!