Embedded Files
HT08 Telemetry Control Unit (TCU) Waterproof Case
One of my first projects with Hytech Racing involved designing a waterproof case to protect key data acquisition components, including a Raspberry PI 4, RKT SMA GPS card, and Antenna.
The case was designed in CATIA 3DX, with the orange lid featuring a reinforced "X" rib to reduce flex and improve sealing.
The 3D-printed case securely holds three boards, mounted using heat-set inserts and M3 bolts.
The boards were oriented and packaged using standoffs. The initial design featured resin standoffs, while the final design used plastic M3 standoffs for improved durability and ease of assembly.
HT09 Inverter Redesign
I was in charge of redesigning the HT09's Inverter casing and assembly. The casing holds the HV and LV Motor Controllers and AMK Inverter boards.
The case was ordered to be 3D printed in ABS for maximum strength to weight ratio.
The casing will be sealed with compression resistant bolt sleeves, rubber/aluminum gaskets, and covered by a Carbon Fiber molded lid.
HT09 Penthouse Redesign
Communicated with the electrical sub team to redesign HT09's penthouse- an enclosure housing HV and GLV components that act as a breaker between the accumulator pack and the inverter.
The penthouse was made through CATIA's Sheet Metal Design.
<-----HT08's Penthouse was packed tightly. Common issues included bad sealing, poor serviceability, and difficult to manufacture
New redesigned HT09's Penthouse takes a triangular form, making sealing efficient and massively increasing serviceability. ------>
Ansys Steady State Thermal FEA - Heat Fin Heat Flux Study
I utilized ANSYS, to run a study on heat flux and its range of motion across a preforated heat fin with a given heat generation boundary condition.
This study helped optimized a heat flux to weight ratio for cooling and minimizing the weight on the Accumulator.
Ansys Fluent CFD - AlSi10Mg Cold Plate
I took advantage of nTopology in conjunction with ANSYS Fluent to CAD a gyroid infill Cold Plate for high heat transfer and superior cooling under heavy loads of heat.
The gyroid infill was created via nTopology and the heat sim was validated through Ansys Fluent.
ANSYS Fluent CFD - Cooling Jacket Turbulence Study
ANSYS Fluent CFD - Cooling Jacket Turbulence Study
This year's emphasis was to integrate an infill to create water turbulence in the cooling jacket - greater maximizing turbulent fluid flow and thus decreasing motor temperatures.
The CAD Design uses cylindrical patterned infill and I performed an ANSYS Fluent CFD study to monitor the turbulent intensity behind this design.
CATIA Structural FEA
CATIA Structural FEA
A support Aluminum (6061) plate I designed to hold the Inverter's LV boards.
I minimize the thickness by half saving over 400 grams of weight and lowering the inverter's subsystem mass by a ton.
Anti-Arc Flash Busbar Sleeves
Inspired by Tesla's battery packaging, I created CAD models of busbar sleeves in CATIA 3DX. These sleeves secure the busbars within the vehicle's accumulator, minimizing the risk of high-voltage electrical contact.
The sleeves were resin-printed on Form 3 Formlabs using Preform software.
I chose Elastic 50A for its flexibility and high electrical resistance, which allows the sleeves to slide easily over 90-degree bend busbars while minimizing electrical contact.
Torque Sensor Clamp Mount
With the team's inspiration to add a torque sensor for data acquisition, I created a CAD model in CATIA 3DX to securely mount the sensor onto the car's steering column.
The clamp features a keylock mechanism and was 3D printed on Bambu X1E.
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