Problem Statement & Constraints
The electric formula-style vehicle required a robust accumulator housing to protect the battery cells while maintaining critical weight limits. The design needed to account for dynamic structural loads, heat dissipation during peak output, and strict formula rules regarding mechanical tolerances.
Design & Simulation
Using SolidWorks, the enclosure components were designed with structural rigidity in mind. Detailed GD&T was applied to the drawings to ensure all parts would mate seamlessly. [Insert details about FEA or thermal simulations here if applicable].
Fabrication & Machining
I machined the custom 6061 aluminum components using a manual knee mill. The most challenging aspect was maintaining the ±0.002" critical interface tolerances required for the mounting plates to ensure the structural integrity of the pack under race conditions.
Result & Impact
The final components were delivered on schedule and met all dimension checks. The completed assembly minimized overall pack weight without compromising the safety factor, ensuring reliable integration into the vehicle chassis.