FSAE Cooling Battery
Formula SAE 2020-2021
Olin College of Engineering
Pictured above: an exploded view of the pack, cells, and tabs to connect the cells
Intro
Engineering Requirements
Engineering Requirements
Engineering Requirements
Design a battery pack that can power the cooling system of our electric racing vehicle for one hour conforming to a series of electrical requirements
My Role
Engineering Requirements
Engineering Requirements
I completed all elements of this project individually.
Background
The Olin Electric Motorsports (OEM) Mk. 5 vehicle has a central battery called the accumulator. This battery generates heat, which must be removed for efficient function. To remove this heat, there are a series of fans and a cooling pump integrated into the pack.
The cooling battery is designed to power the cooling system continuously for one hour.
This project will evaluate/investigate the
- Choice to use cylindrical cells
- Arrangement of cells within the cooling pack
- Overall cooling pack design
- Position of the cooling battery assembly on the car
High-Level Design Goals
Pack will:
- Meet the electrical requirements outlined below
- Be accessible on the car when at a standstill
- Be serviceable in case of failure
This pack conforms to a series of requirements
Design Specifications
- Voltage: 12 volts
- Current: 20 amps
- Time: 1 hour
- Power: 240 watts (12V * 20A)
- Energy: 240 Whr (240 watts * 1 hr)
- Capacity: 20Ah (20 amps * 1 hr)
Below are images of the OEM vehicle
Process
This six-week project followed the following timeline
Week 1: System Spec
- Reviewed electrical specifications
- Defined project requirements
- Set high-level goals
Week 2: Cell Choices + Configurations
- Researched cell types
- Learned and applied cell configurations
- Looked into mechanical stability of example assemblies
Week 3: Thermal Analysis
- Performed power dissipation calculations: energy to change in temperature
- Reviewed basic decision-making matrix for design tradeoffs
Week 4: Linkage + Enclosure
- Learned about thermal management systems and heat sinks
- Bus bars, current, and thermal dissipation
Week 5: Enclosure + Integration
- Designed enclosure in CAD
- Incorporated preliminary feedback for assembly
Week 6: System Design Review
- Presented design to senior engineers on team
- Noted feedback about bus bars and manufacturability
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