Embedded Files
Max Voltage
100 Km/hr
Top Speed
70,000
Cost (USD)
Role: Battery System Lead
Role: Battery System Lead
Battery system design, manufacture, assembly.
Battery Management System algorithm design.
Document and pass down experience.
Skills
Skills
Implement the algorithm in Arduino to control cells' voltage balance.
Module design and integration
Circuit Board design and layout
Tool
Tool
Solidworks
Autodesk - Eagle
Power Point, Word, Excel
Design Specification
Design Specification
High voltage battery 400 V (6 modules in series).
Monitoring battery cell's voltage and temperature.
Battery Managment System(BMS) with passive voltage balancing.
Designed Protection Mechanism
Designed Protection Mechanism
Insulation Monitor Device to detect leakage.
Main Fuse protect over current.
Main Relay to disconnect current path.
Pre-charge circuit, protect over current while turning on the system.
Discharge circuit, discharge energy after turning off the system
BMS to control the system at a safe temperature range.
Design Phase
Design Phase
Battery System Architecture
Battery System Architecture
Designing the battery system architecture.
Battery System Assembly
Battery System Assembly
Designing the layout and placement of the battery system.
Powertrain System
Powertrain System
Make sure the battery container and the wiring layout fit in the race car.
Manufacturing Phase
Manufacturing Phase
Battery Managment System
Battery Managment System
Battery management PCB with fuses protection, voltage sensing lead, and temperature sensor.
Battery Connecting
Battery Connecting
Connecting battery cells in series with copper busbar, total 58V per module.
Programming
Programming
Developed the algorithm to monitor each cell's voltage, and control the cell balancing current.
Assembling Phase
Assembling Phase
Battery Module
Battery Module
Each battery module has an independent BMS to monitor the voltage and temperature. Iron shell boxes with insulating material in the inner wall protect cells from impact.
Battery Assembly
Battery Assembly
The high-voltage battery comprises six modules connected in series, reaching a total voltage of about 350V when fully charged.
Battery System
Battery System
Assemble the battery system, including electric leakage detection, main relays, fuse protection, current sensor, pre-charging circuit etc.
Result
Result
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