ENGS 89/90 Reports

Year of Graduation

2025

Project Advisor

Jason Stauth

Instructor

Solomon Diamond

Document Type

Report

Publication Date

2025

Abstract

Dartmouth Formula Racing (DFR) is a student-run group that designs, builds, and competes with a custom, formula-style race car in two annual SAE events: the Formula Hybrid + Electric (FH+E) competition in New Hampshire and Formula SAE in Michigan. Although these competitions have distinct rules, many technical requirements overlap—particularly regarding battery performance and safety. This project addresses DFR’s need for a standard, robust method to assess the performance of its car’s battery pack under simulated racing conditions. We iterated upon a battery discharge apparatus (BDA) to create a validated testing protocol, a functional BDA and 50V battery segment with integrated cooling features to safely test and log critical metrics (e.g., cell health, temperature, voltage, current), and a dedicated testing segment enclosure. This validated testing protocol measures capacity, discharge cycles, and thermal performance under load, yielding insights into the team’s overall powertrain strategy. This new setup lets the team test multiple battery packs and battery segments, as well as the accumulator, without removing it from the car, saving time and improving resource efficiency. Designed with cost-effectiveness in mind, it leverages spare parts, readily available materials and user-friendly documentation to create a full solution to characterize the batteries they use. Built-in fault detection and established procedures enhance safety and reduce the risk of mishandling. The battery discharge apparatus, segment and testing protocol provide student engineers hands-on exposure to real-world battery management principles, creating a lasting educational benefit. Looking ahead, plans include refining the battery discharge apparatus PCB design, exploring alternative sensors for greater accuracy, and adapting the enclosure for Tesla‐sponsored battery modules, ensuring a durable, reusable platform for subsequent Dartmouth Formula Racing teams.

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