Battery package design for Formula E racing
Problem statement
Wisconsin Racing, a subsidiary of the University of Wisconsin-Madison, needs an accumulator that is capable of outputting 60 kW continuously while maintaining an internal temperature below 60°C for the Formula SAE Electric competition. The competition, set to take place in June of 2021, includes an endurance event that has proven to be what sets teams apart from one another. The Energus modules previously utilized by the team had an internal resistance that dissipated too much heat to maintain temperatures below the competition limit. The power output of the accumulator was therefore limited to 20kW. Following this result, the Wisconsin Racing Formula E team set out on a ground-up redesign of the accumulator. New modules from Melasta were found to have a significantly smaller internal resistance, allowing the accumulator to maintain a lower internal temperature. With the past design team having completed approximately 80% of the accumulator design, we aim to validate the design through the assembly process and integration into the vehicle. As a team, we will focus on utilizing cell performance data and modeling to validate the current design, the documentation and solution of any issues that arise during assembly, and a competition-ready accumulator design for Wisconsin Racing.
Team members
John Wander – leader
Zachary James Miller – communicator
Krey Matthew Hacker – accountant
Dajun Tao – admin