400 V

Max Voltage

100 Km/hr

Top Speed

70,000

Cost (USD)

Role: Battery System Lead

  1. Battery system design, manufacture, assembly.

  2. Battery Management System algorithm design.

  3. Document and pass down experience.

Skills

  1. Implement the algorithm in Arduino to control cells' voltage balance.

  2. Module design and integration

  3. Circuit Board design and layout

Tool

  1. Solidworks

  2. Autodesk - Eagle

  3. Power Point, Word, Excel

Design Specification

  1. High voltage battery 400 V (6 modules in series).

  2. Monitoring battery cell's voltage and temperature.

  3. Battery Managment System(BMS) with passive voltage balancing.

Designed Protection Mechanism

  1. Insulation Monitor Device to detect leakage.

  2. Main Fuse protect over current.

  3. Main Relay to disconnect current path.

  4. Pre-charge circuit, protect over current while turning on the system.

  5. Discharge circuit, discharge energy after turning off the system

  6. BMS to control the system at a safe temperature range.


Design Phase

Battery System Architecture

Designing the battery system architecture.

Battery System Assembly

Designing the layout and placement of the battery system.

Powertrain System

Make sure the battery container and the wiring layout fit in the race car.

Manufacturing Phase

Battery Managment System

Battery management PCB with fuses protection, voltage sensing lead, and temperature sensor.

Battery Connecting

Connecting battery cells in series with copper busbar, total 58V per module.

Programming

Developed the algorithm to monitor each cell's voltage, and control the cell balancing current.

Assembling Phase

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

The high-voltage battery comprises six modules connected in series, reaching a total voltage of about 350V when fully charged.

Battery System

Assemble the battery system, including electric leakage detection, main relays, fuse protection, current sensor, pre-charging circuit etc.

Result