World’s Fastest Electric Vehicle Team Battery Power Electric Motorcycle 5/31/2019

Overall Project Description Made 35 battery modules from used cells that are expected to perform as client desired Communication with manufactures and lack of information caused difficulties in project completion. Also, delay in project planning led to little or no progress in early stages. Rely more on phone communication rather than email and ensure that a clearer knowledge of expectations is known by all members. Also, create a project plan earlier to assign and focus tasks. Working with professionals and learning about batteries and vehicle systems made the project informative and interesting 5/31/2019 Electric Motorcycle

Overall Project Description Cont. Microsoft Projects helped organize the tasks and improve progress as well as our assembly line preparing and manufacturing of the packs The analysis tool, PSAT was difficult to use due to lack of information, and the LabView program was a borrowed program that we had to learn in order to use. If anything could be changed in this project, it would be better access to information that would have helped in making more confident and timely decisions All of the stakeholders, managers, customers, and sponsors all participated effectively in the project 5/31/2019 Electric Motorcycle

Need and Feasibility In the beginning, more project deliverables were identified than were needed. Battery monitoring systems in the battery pack were unnecessary as well as cooling systems and housing. Items such as posters and presentations were not thought of at the first stages of planning. More critical information concerning the systems used would have helped aid in the determining what is needed and feasible. 5/31/2019 Electric Motorcycle

Create Project Plan We over estimated the duties that would need to be performed by our team and the time and resources that would have been needed in completing them. Incorporating more knowledgeable people about our specific questions, and creating more buffer time in the later portion of the project would have improved our efforts 5/31/2019 Electric Motorcycle

Create Project Plan Cont. Within the team, those who had certain skills were placed in the appropriate tasks. Other tasks were assigned based on time availability and member interest. Not being able to get in touch with those who had needed information was a warning sign that the design would not be specified early enough in the project. There was a lack of information at the beginning, so all parties did not get the constraints needed in a timely manner. 5/31/2019 Electric Motorcycle

Create Project Plan Cont. The people from Boundless should have been incorporated earlier in the process to expedite the welding process and information needed to buy resources. More persistent communication would have helped this problem. A more formal written specification of responsibilities of details would have helped cement tasks in members minds Milestones and deliverables specifications were as clearly defined as possible 5/31/2019 Electric Motorcycle

Create Specifications and Deliverables The details and CAD drawings were very detailed and showed the design intent for the project There was too much creative involvement, which caused confusion in the beginning of designing the problem Final battery specifications were approved quickly by professors Having a customer with more rigid constraints and a more defined date for the completion of design specifications would help to expedite process 5/31/2019 Electric Motorcycle

Create Deliverables We are very proud of our deliverables but think that a battery management system in the vehicle would have improved the design All team members had creative input as to how the battery packs would be assembled All of the project documentation were reviewed in a timely manner. Improving the time that the tested batteries and their information were received would have helped the process of creating the battery packs and purchasing the rest of the materials go more smoothly 5/31/2019 Electric Motorcycle

Test and Implement Deliverables The testing that was provided did not give very accurate results pertaining to how the battery packs would function in the “real world”. Testing the assembled modules and using them in a vehicle would give better results. The implementation process strategy for making the modules was effective and fairly accurate In the end, the modules are left at the school for the client to come take. Also, documentation of the entire process is left in a locker for future students to use. 5/31/2019 Electric Motorcycle

Manufacturing Process Tabs on batteries taken off and then batteries sorted into groups of similar voltages Edges are smoothed down using a dremmel and groups of 32 batteries are placed into Ziploc bags 5/31/2019 Electric Motorcycle

Manufacturing Process Cont. At Boundless in Boulder, Colorado the batteries are welded using a Miyachi Ez-Air Model 80 and 88 welder and a model HF25 DC resistance welding system On positive end of terminal, small bubbles left from tab removal are pushed down using a screw driver 5/31/2019 Electric Motorcycle

Manufacturing Process Cont. Metal plates and battery terminal ends are cleaned using Methanol and Kimwipes Batteries are placed in the jig in four rows alternating positive and negative ends facing upward Strapping tape is placed around batteries to hold them together 5/31/2019 Electric Motorcycle

Manufacturing Process Cont. Two metal plates are welded on to the positive and negative ends of the batteries The battery module is taken out of the jig and flipped over and a flat metal plate is welded on to the two middle rows. Two bent plates are welded onto the battery module 5/31/2019 Electric Motorcycle

Manufacturing Process Cont. Plastic wrap is wrapped twice along the length of the module Modules are placed in cardboard boxes with cardboard separators between them, and peanuts and bubble wrap surrounding them to prevent movement 5/31/2019 Electric Motorcycle

Deliverables Three different Power Point presentations Project Plan Proposed vehicle and system performance List of technical features and configuration Bill of Materials Poster Readiness and Completeness Assessment Enclosure Final Design Buy-in Agreement Fabricated Modules CAD drawings of battery Modules 5/31/2019 Electric Motorcycle