Power Electronics
Overview
This project focuses on designing and building a safe, high-performance lithium-ion battery pack for demanding applications. The pack combines mechanical protection, electrical safety systems, and thermal management to ensure reliable operation.
The design emphasizes ruggedness for real-world use while implementing comprehensive safety features.
Technical Implementation
- Structural Design: 3D-printed housing with five internal X-braces between parallel cell groups for impact protection
- Cell Configuration: Spot-welded nickel strips connecting cells in series-parallel configuration
- Safety Systems: In-line glass fuses and BMS taps for over-current protection
- Monitoring: Thermistor sensors at four locations for temperature monitoring
- Power Interface: XT-60 connector with 12 AWG wire for high-current applications
- BMS Development: Custom battery management system in Altium for over-voltage and over-current protection
Key Challenges & Solutions
- Thermal Management: Strategic thermistor placement and monitoring code for early thermal runaway detection
- Mechanical Integrity: Internal bracing system to prevent cell damage from drops and impacts
- Electrical Safety: Multiple layers of protection including fuses and BMS for comprehensive safety
- Custom BMS: Designing a BMS that balances protection with performance requirements
Results & Impact
The battery pack provides reliable 14.4V power with enhanced safety features. The rugged design withstands real-world conditions while the monitoring systems provide early warning of potential issues.
This project demonstrates expertise in battery pack design, safety systems, and power electronics integration.
Altium DesignerBattery SafetyEmbedded CThermal ManagementPower Electronics