A new electric power train design to power an open-wheel, single seat electric race car to compete in the 2014 SAE Formula Electric competition is presented. This research project is part of the clean technology initiative for sustainable energy sources for automotive application proposed by the Santa Clara University Formula Electric (SCUFE) team. In this paper, a new battery pack design and integration is evaluated. This includes analysis of battery cell connectivity, cell enclosure, safety system, and battery control system. The cell connectivity proposed will maximize electrical conduction through surface area contact of the cell tabs while allowing for quick removal of individual cells in the case of cell failure. The structure of the pack enclosure will consist of polycarbonate panels. The connection panels will be mounted between the wall enclosure lid and wall in order to prevent the pack from being opened when the contactors are engaged, preventing the risk of exposure to high voltage. The proposed design allows the pack to be completely removed from the vehicle for easier disassembly and transportation. The exterior connections will consist of one large plug for the power cables as well as a smaller plug assembly for the battery management system (BMS) and other necessary sensors and connections. Cell voltage states will be monitored through the BMS. In addition, maximum voltage capacity and cell storage capacity will be analyzed and discussed. Recommendations on future designs will also be presented in light of preliminary results on the efficiency versus performance.

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