Project Overview

The Battery Disconnect Unit (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. More details and pictures will be added as the project progresses.*

On the BDU team, I:

• Led the design of the BDU
  • Led a small team of designers to meet all mechanical, electrical, and integration requirements
  • Managed communication within the team and with other subteams and stakeholders
• Used SolidWorks throughout the process, following Design For Manufacturing principles
• Ran Finite Element Analysis, busbar and bolt torque and pressure tests, and impact and drop simulations using Ansys
• Researched busbar materials, dimensions and designs to optimize performance and manufacturability
• Designed busbar layouts to optimize for electrical performance, manufacturability, and serviceability
• Designed custom enclosure for the BDU while:
  • adhering to strict spatial constraints
  • prioritizing manufacturability, durability, and serviceability
• Created detailed technical drawings to aid in manufacturing and assembly
• Worked closely with manufacturing team to ensure:
  • designs were feasible
  • the procurement and use of correct materials and components