FSAE Polytechnique Montreal 23

For the 2023 season, my role as a member of the battery subgroup was to deisgn the casing. I worked with two other student in order to properly integrate the segments and electrical components.

During manufacturing, a lot of problems arose which we had to fix. We received the casing with a lot of warped panels due to the welding. The segments also had some less that ideal assembly features that which we did did not think of earlier. The battery was functionnal but not easy to work with and the final build quality was not the best.

The casing below is the assemlby that I was responsable for. It is made from 2.3 and 3.2 mm 5052 Aluminium Sheet metal. It containts over 35 laser cut and machined parts that are welded together.

The goal of the casing was to protect the segments from impacts and water ingress, house the BMS, relays and resistor as well as being rigid for performance. It was also important that in was compliant with the SES.

Overall, the 2023 battery was a great learning experience as it allowed be to understand a lot of the mistakes that can be made and that through hardwork and perseverance they can be fixed.