Battery WorkForce Challenge

Designed Battery Disconnect Unit(BDU) using SolidWorks, following Design For Manufacturing principles. The BDU is a critical safety component that allows for the rapid disconnection of the battery in the event of an emergency, preventing potential hazards such as fires or electric shocks. *Note that this project is currently ongoing, so more details and pictures will be added as the project progresses.*

Ran Finite Element Analysis, busbar and bolt torque and pressure tests, and impact and drop simulations using Ansys. Researched busbar materials, dimensions and design to optimize performance and manufacturability. Designed custom enclosure for the BDU, prioritizing durability and functionality in harsh environments, serviceability, and manufacturability. Created detailed drawings to aid in manufacturing and assembly. Worked closely with the manufacturing team to ensure designs were feasible and cost-effective. Completed entire BDU design a week ahead of schedule and aheaed of other subteams.