Enclosure Lid Redesign Sprint - Tutorial Session

Owned by Nicole Choe
Last updated: Oct 10, 2023 by Jenna Kong
3 min read

During this tutorial question, we went over:

  • How to solve the first on-boarding question

  • Answering questions about CADING your modules

  • Introducing the enclosure design sprint

Onboarding - CADING Module

Some things to think about:

  • Sketching your design with basic measurements may help

  • cell placement (straight line or hex pattern? Any reasons as to why)

  • adding fillets + chamfers to your design (reduce any sharp corners)

  • tolerancing - In the real world, the measurements of your 3D printed module are not perfect. To account for this, tolerancing is required

Enclosure Lid Design Sprint

Meetings will happen on September 20th, 23rd, 27th, and 30th during the first hour of our working sessions (both online and in the bay)

The Problems:

  1. Our current design for the enclosure lid is too wide and thus interferes with the steel flats on the side of our box. This makes our lid very difficult to take out

  1. Right now, there is a lot of space on top of the battery modules in our enclosure. This is an issue because the air flowing into our box will take the path with least resistance, and thus our modules will not be cooled at all. A solution is required to optimize the lid to make airflow go through the modules instead of the open space.

 

Side View of Enclosure:

We do not want this - with too much space, the air will not flow through the modules

Top View of Enclosure:

 

Your Task: To think of a solution to adjust our enclosure lid in order to make it more easily removable and optimize airflow inside of the box.

Present your ideas by sketching or CADING, but most importantly, you have to be able to justify WHY these ideas should work : )

Skills Developed:

  • Critical thinking

  • CAD skills

  • Teamwork

Some Solutions Tossed Around:

  1. Sliding mechanism - a good idea, but may be too complicated to manufacture. Be sure to answer the question HOW will this work?

  2. Adjusting the lid of the box to make it smaller - a GREAT idea

  3. “Picnic Basket” lid idea - make sure the dimensions of the lid are optimal

  4. Pins idea - something I didn’t think about during our meeting was the vibrational force of the car. If this idea isn’t implemented perfectly, the enclosure wouldn’t be fixed. We could possibly put pins into our lid, but we would need then to change the dimensions of the lid to make it thicker (which is totally possible, just something to think about)