Project Overview
As one of my first larger tasks on the FSAE team, this project marked the team's transition to electric vehicles. For the UT22 car, I was responsible for the mechanical design and manufacturing of the high voltage (HV) box - the critical electrical enclosure that houses safety critical power electronics. My focus was on creating a robust, manufacturable, and waterproof mechanical enclosure.
Mechanical Design Challenge
The HV box needed to be completely waterproof while being lightweight and easily manufacturable. As a mechanical engineer, I designed the enclosure to meet FSAE's safety requirements while optimizing for manufacturability. The design had to accommodate electrical components, provide access for maintenance, and integrate seamlessly with the vehicle's chassis.
Design & Manufacturing Approach
I developed a sheet metal enclosure design using aluminum that could be efficiently manufactured:
- Waterjet cutting for precise part dimensions and complex geometries
- Bendable aluminum construction allowing for compound curves and tight radii
- Mechanical fastening systems with gaskets for waterproof integrity
- Access panels and service ports designed for maintenance efficiency
- Chassis integration features for secure vehicle mounting
Key Achievements
Manufacturable Design
Created a sheet metal enclosure that could be efficiently produced using available shop Equipment
Waterproof Integrity
Designed mechanical sealing system that would pass a rain test
Integration Excellence
Developed mounting interfaces that seamlessly integrated with the vehicle's chassis while providing access for electrical maintenance
Technologies Used
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