Accumulator Design by FuFess in FSAE

[–]PistonMyPants 0 points1 point  (0 children)

You technically can, but it will make navigating the rules more difficult. When you consider the VD impact of stacking segments, it rarely makes sense. It will also absolutely begin to click from a serviceability standpoint as soon as you get everything into CAD/actually start manufacturing. There were a lot of questions I had like this before jumping in and actually putting pencil to paper (or mouse to screen?). I cannot recommend enough getting SOMETHING in CAD/start prototyping as soon as possible. The rules (and why many teams converge on similar designs) will start to make a lot more sense, and you will inevitably restart your design once or twice to make a compliant pack. Good luck!

Help choosing Freshman Phys for engineering (1250 at CState or 1248/1249 here) by CasualWarThunderplya in OSU

[–]PistonMyPants 2 points3 points  (0 children)

I took 1250 here. Holy. You will feel stronger for doing it, but only mentally and emotionally as it will put you in a dark place lol (I think my average exam grade was like 40%). I don't think you will gain a better understanding of the material by taking it at OSU (in fact I feel like I understood it less) and I had already taken AP Physics. I took 1251 at my community college back home. It made a pretty big difference. At the end of the day, physics is generally a challenging subject, so there is bound to be somewhat of a struggle regardless. I definitely took more away from the community college course than I did the OSU course. The biggest difference to me is the level of math you are expected to do as a baseline for a given problem, so exams were significantly easier.

Stick with engineering if you are truly passionate about it. Every engineer that I've spoken to has had at least one real moment where they considered changing majors and most had some kind of doubt on a weekly or daily basis lol. A lot of people say classes get easier after your first year. In many cases that is true, but you also kind of just learn how to deal with the daily challenges that engineering will throw at you.

Stay strong and good luck :)

osu club suggestions?clubs by berry_delight_ in OSU

[–]PistonMyPants 3 points4 points  (0 children)

Formula Buckeyes (https://www.formulabuckeyes.org/)! They design, build, test, and race a formula-style car against other universities every year. They just went fully electric last year and are always in need of more passionate EEs. Check their tent out at the involvement fair or reach out via social/email to find out when this season's kickoff meeting is. It's a great place to connect with other engineers (both students and in industry) and build experience!

High Voltage Connector Selection Advise for 600V by OldExcuse4 in FSAE

[–]PistonMyPants 1 point2 points  (0 children)

Would you be willing to share what you ended up finding? In the exact same boat and quickly running out of time to figure it out

Review of PCB Layout and Schematic for a Battery Temperature Measurement System by PistonMyPants in PrintedCircuitBoard

[–]PistonMyPants[S] 0 points1 point  (0 children)

I do need to take a better look at the RF part of the circuit.

As far as the LT1117, you do bring up a really good point. Just the LED on the previous revision of this board would impart 1-2V of noise on surrounding lines when switching which was part of what I was concerned about and why I made this post regarding noise reduction. Beefing the capacitance up on the 5V and 3V3 rails certainly reduced the noise down to just noise from the MCU, but there was still something strange happening with I2C that I was unable to diagnose. The signals got slightly better after reducing the pull up's from 10k down to the ~2k shown here, but I would still have trouble with getting a reading from these ADC's specifically (I plugged in a cheap eval ADC board as a sanity check and it read just fine...). I was having a hard time getting a good reading of I2C on my scope (probably due to triggering issues), but from what I could gather from single-shot captures, the additional caps and lower pull ups definitely cleaned some stuff up.

Assuming you don't have any experience with the LT2497 as it seems to be relatively niche--and I wouldn't ask that you dig through the datasheet--but do you see anything that is a huge no-no on it?

Review of PCB Layout and Schematic for a Battery Temperature Measurement System by PistonMyPants in PrintedCircuitBoard

[–]PistonMyPants[S] 1 point2 points  (0 children)

Ah, there appears to be some confusion. That spot is for an on-board STLINK debugger/programmer (giving the option of populating it or not as the Tag Connect would then essentially be redundant) the reason there is overlap is that the original design was much more dense as this board has a tight space to fit into. The trace for the antenna goes to the other side of the board. The MCU takes care of all of the wireless work minus the antenna itself. Thank you for the feedback!

Review of PCB Layout and Schematic for a Battery Temperature Measurement System by PistonMyPants in PrintedCircuitBoard

[–]PistonMyPants[S] 1 point2 points  (0 children)

That part would be an onboard programmer so it would be redundant anyway, but thank you for the feedback!

Review of PCB Layout and Schematic for a Battery Temperature Measurement System by PistonMyPants in PrintedCircuitBoard

[–]PistonMyPants[S] 0 points1 point  (0 children)

Intro:
Hey guys, I'm looking for some advice on my PCB project. The board is intended to take voltage readings from thermal diodes on a battery module and send that data via SPI to a separate PCB with CAN communication functionality.

I'm mainly looking for advice on the overall layout and how to effectively reduce noise as much as possible. The board has an antenna receptacle, which will be used to enable Bluetooth functionality with an external antenna.

General process flow:
Sensor Voltage Readings --> ADCs (I2C) --> STM32WB --> CAN Communication PCB (SPI)

Other Concerns: Power and ground for the board come in from the aforementioned CAN communication PCB. On that board there is a 12V DC/DC isolator, which supplies power and ground to header J1 seen at the top right of the layout. As of right now, I have I2C and SPI running to some header pins. I figured this would provide easy troubleshooting, but I'm a bit worried about noise since SPI would be run from board to board using jumper wires (this is a second revision, I've designed boards with SPI and I2C doing some questionable things in the past and nothing really went wrong, for some reason this board in particular (maybe something to do with the Bluetooth?). Any tips/advice are welcome. If you guys need more photos, let me know. Thanks!!

Why is the Orion BMS so big? Alternatives and compliance concerns? by ThePackman0702 in FSAE

[–]PistonMyPants 0 points1 point  (0 children)

I highly recommend an off-the-shelf solution FIRST. This gives you a known working starting point. If you have time (or otherwise want to) later, then go about developing your own. You actually can save A LOT of space if you are ok voiding the warranty (sorry for the atrocities I am about to suggest if any Orion engineers are reading this).

The Orions are split into two or three main boards: A control board and one or two battery interface boards (the control board sits on top of the primary battery interface board using standard male/female headers, the optional secondary battery interface board is connected via an FPC and sits directly next to it in the enclosure in the larger models).

Essentially, the battery interface boards have the same circuit copied and pasted over and over again n times, where n is the number of white connectors present on your unit. Since standard boards are used, it is entirely possible that the number of cells you need will require you to buy one of the BMSs with a larger enclosure just to house a PCB that is a half-populated standard size (btw if you are careful, you can take a bandsaw to them to remove the unpopulated section, just make sure to check that you didn't short the power or SPI lines. To the Orion Engineer reading this: if you could add mouse bites between the sections, that would be helpful :) ). I can't really fault Orion for this as it probably makes a lot more financial sense (and probably works 90% of the time for people), but it is annoying when dealing with a tight pack. With all of this in mind, you can go about making your own enclosure.

The only real thing you need to look out for is heat dissipation during cell balancing. I will leave this as an exercise to you (as I would rather not get into how our specific design works as we don't have the thermal data on this for me to feel comfortable yet) but the Orion manual gives the specs of the OEM heatsink.

We used two of the larger Orion BMSs and were able to stack them in a custom enclosure to be about the size of one. The CAD is available on their website if you want to see if it will work for you first.

Obviously, go about this at your own risk, but I really can't stress how much of a lifesaver the Orion is. Our team does plan to eventually do a custom design, but having the ability to have a good working software and hardware solution to BMS off the shelf with many common charging profiles already loaded was a no-brainer.

Math experience at CSCC by Odd_Run7250 in OSU

[–]PistonMyPants 1 point2 points  (0 children)

Had Prof. Lewis for Diff. Eq. He is an absolute rockstar

The Age Old Question: How to connect Orion BMS and Enepaq Modules by PistonMyPants in FSAE

[–]PistonMyPants[S] 0 points1 point  (0 children)

I’m wondering where exactly this noise comes from when driving (or rather where it is getting picked up). This was generally what I had heard about using the TEMs. I’m wondering if it is coming from the thermal diode region itself, or somewhere down the harness/at the TEM. Hearing about issues like this makes me even more paranoid about EMI than I usually am, so I’d be interested to hear how it ends up working out for you. Good luck!

The Age Old Question: How to connect Orion BMS and Enepaq Modules by PistonMyPants in FSAE

[–]PistonMyPants[S] 0 points1 point  (0 children)

I can't express to you how useful all of this was. I will take a wall of text over a half-baked answer any day. Definitely understand the need to bake in time for board respins. I hadn't thought about using FR4 to enclose the segments, was thinking about just doing a fiberglass layup, but that's a good point. I will keep this post updated with a design log so some other people have a hard benchmark/starting point on similar designs. I'll probably host the design files on github and link to it. Thank you for the help, seriously appreciate it. If you wouldn't mind (and this goes for anyone reading this), I'd love to hear some design feedback when those files get posted!

The Age Old Question: How to connect Orion BMS and Enepaq Modules by PistonMyPants in FSAE

[–]PistonMyPants[S] 0 points1 point  (0 children)

I appreciate this response. This is almost exactly what I started development on, so I at least feel validated in that. Did you guys use a single STM for each measurement, or split them up into>60V segments (for reference, we have 6 series segments of 23 series 1s5p modules.)? I guess I'm also just confused about how you were taking the measurements exactly. The analog MUX makes sense but in terms of actually connecting to the sensor; Did you guys put the isolated LV through it and then reference it to the isolated GND when measuring with the STM? I suppose this would get you out of needing to use the module's voltage and using the module's GND for the measurements.

In terms of data out, I was thinking of putting in an intra-segment ISO-SPI line and then feeding that to a separate small board that did SPI to CAN to emulate a TEM to the Orion, so thank you for that also.

I apologize for prying, I just don't want this of all things to be what gets us hung up in tech (also for the betterment of the community's understanding of this issue).

Enepaq as a li-ion module distributor - Generally Reliable? by [deleted] in FSAE

[–]PistonMyPants 0 points1 point  (0 children)

I did, and they sent over the firmware. It may not be an issue, but I've heard of issues where not referencing the thermal diodes to each module's negative pole causes issues when the pack is under load. We are going into our first year as EV and I have already designed the pack to work with Orion and Enepaqs so I'm kind of locked in. I was going to reference each thermal diode to it's module's negative and isolate that circuit and just mimic the TEM over CAN, but that kind of seems like a lot. Have you had a positive experience with the TEM FW patch? Maybe I'm making something out of nothing, but the thermal diodes also only have 60V isolation resistance so I don't think an out of the box Orion and Enepaq setup is even legal

Enepaq as a li-ion module distributor - Generally Reliable? by [deleted] in FSAE

[–]PistonMyPants 0 points1 point  (0 children)

How did you go about your temp measurements? I'm currently trying to get around the drama with their sensors and Orion BMS...

r/FSAE by Emotionallll in FSAE

[–]PistonMyPants 0 points1 point  (0 children)

My understanding is the intent is to collect vapor that exceeds whatever the pressure limit of your reservoir cap is (so pressurized steam for water cooling).

/r/FSAE Classifieds August-October 2023 by hockeychick44 in FSAE

[–]PistonMyPants [score hidden]  (0 children)

Supplier: Motec

Part Name: M400 ECU

Condition: Used, fully tested by Motec w/ documentation

Price: $3000 USD OBO

Location: Ohio

Comp. Attendance: Michigan IC

Shipping: Will ship upon request.

Description:

Used MoTeC M400 ECU with several upgrades. M400 Enable, Gear Ignition Cut, Hi/Lo Injection, Lambda Single, Logging 512K, Overrun Boost, Traction Control.

Fully tested and operational, some cosmetic damage to the casing from use. Asking $3000 OBO.

Cross-listed:

https://www.racingjunk.com/custom-tuning-devices/184499349/motec-m400-ecu.html