Battery Box Meeting Notes [MSXV]

Summary: Got bodied but tight deadlines before manufacturing can proceed

Module

• add ribs to the L bracket of the module holder

• Make into one part

• Vertical mounts - make sure there is enough space/strong for heat insert

• Test the module to module connections

• Shift the hole to eliminate divet in plate

Cell Holder

• ABS → look into printing services (Micheal, WatIMake)

Busbars

• Only have sigma clad for module to module connections

  • Nickel to nickel for parallel + series connections

  • Due to spot-welding limitations

• Conduct resistivity test of connections

Module to Enclosure Design

• Hex caps MAY interfere with one another

• M3 may be too weak

• Find hardware to fit

Module to AFE

• Highest temp will be in the center

• Change number of thermistors to 24 → change layout

Manufacturing

• Test material resistivity

• No thermal test

• Need a way to measure ambient temperature (post manufacturing)

  • Strat will need this data

Electrical Connections

• Figure out a way, low prio, copper bar works for now

• Chaos

• New members starting to integrate (assigned to projects on Sat)

Production Module Testing (4.5.3)

• keysight: not feasible too long

• two paralle

possible solutions for worst case:

• ask other people? not done yet

• ask profs

• maybe past documentation

• ask teerstra

• ask lab in waterloo

• talk other design teams

• ask prof for battery challenge

Current assessment of module manufacturing & testing

• all modules to be completely manufactured: dec 8th

• will have to check with testing the first module

• do we have prototype module testing goals?

  • draw for 30min and check temperature

  • asc does not outline anything specific

Prototype module testing:

• depends on what we say

  • will say it was first one made (of the production run)

• documentation needed? no but yes (for future etc)

• keep prototype deadline same on pvdr but aim for end of nov

• continue to test for production

Pack & battery systems validation

• different equipment?

  • either use motor or power resistors

  • have a completed plan before jan 2024 (check-in mid-dec)

Actionables:

• module manufacturing timeline done for 06-11 (will check with donna)

• working on on validation plan - check monday 05-11 and review (check with owen)

• jenna will start prototype testing this week, feasibility test (check-in end of week)

  • just draw current 58.2 A and 3.6V with module

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

Open

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)