MKVI Service Section

This was my first project on Olin's Formula one team. I was mentored by Markus Leschley, Karen Hinh, and Andrew Phillips. When deciding which project to work on, I chose the service section since it was the intersection of the mechanical and electrical parts of the team. As a result, I learned alot about working within constraints (rules, regulations, and space), design for manufacturing and assembly, iteration, cross-team communication, and the electrical side of the car.

Left to Right: Original layout, original assembly, final assembly

Through multiple design reviews the service section evolved from the layout on the left to the assembly on the right. As my understanding of the electrical components improved, I shifted them around to efficiently use the space, fit the service section within the chassis, and to make assembly easier. The geometry of the enclosure changed to not interfere with the motor controller. Taking into account the expected pack current we determined the cross-sectional geometry of the bus bars. The overall geometry of the busbars was influenced by how easy they would be to manufacture.

Waterjet layout for busbars

When assembling the service section I had to order the correct fasteners, understand lead times to hit deadlines, and learn how to ground fasteners. The correct bolt lengths and distorted thread nuts in place of Nylock nuts for positive retention and heat resistance were needed. Ordering the fasteners and other components, waterjetting the busbars, working with other subteams, and more had to be taken into account to hit deadlines on time. To keep the service section safe and rule abiding, I used copper tape to ground external fasteners. Ultimately, working on this project taught me more about the engineering design process, mechanical engineering, interdisciplinary work, and project communication.