High Voltage
Purpose
The High Voltage team works on all parts of the car which run at over 12V: the Accumulator (60kg high voltage battery), the BMS (Battery Monitoring System), motor controllers, MUR charge cart (for charging the car), and their accompanying safety systems/connections. The High Voltage team will work closely with the Low Voltage and Software teams to create a cohesive electrical framework for the car. The High Voltage team will also work alongside the Powertrain team when designing, manufacturing, and testing.
Goals
| Primary Goals |
|---|
| Design and build the accumulator |
| Integrate and manage battery management system |
| Secondary Goals |
|---|
| Optimise and enhance motor controllers and inverters |
| Upgrade charge cart |
| Research alternative accumulator housing materials |
Key Components
Accumulator
The largest role of the High Voltage team is to design and build the car’s 80kW battery that can supply our motors with continuous power to drive the car forward. This battery is called our ‘Accumulator’ to help distinguish it from our LV battery (which supplies 12V), as opposed to the Accumulator (which supplies 400V). Aside from its battery cells, the Accumulator also includes many safety systems (relays, fuses, cell-taps etc.) as well as the BMS.
Battery Management System (BMS)
The BMS is included in the circuitry of the accumulator and is responsible for constantly monitoring cell health, voltage and temperature. It also balances the cell voltages within the Accumulator whilst the car is running or being charged.
The BMS is currently purchased as a commercial unit. The High Voltage team’s main role is to implement it into the safety circuit and use its GUI to allow it to communicate with the LV safety systems.
Motor Controllers/Inverters
As the name suggests, these control our motors’ operation. In doing so, the Motor Controllers also serve as Inverters (turning the DC voltage out from the Accumulator into the 3-phase AC for our motors).
Like all other parts of the High Voltage family, there are some accompanying safety circuits. However, when working on the Motor Controllers, the crucial roles are: creating a circuit to implement the controllers, to use the RMS GUI to perform calibration and performance-enhancement, as well as providing communication capabilities with the LV system.
This is also where the HV system collaborates a lot with the Powertrain, LV and Software teams to ensure safety and increase motor performance (with the use of programs such as MoTeC).
Charge Cart
As per competition rules, the Accumulator must be charged on an external cart (off the car). This is called the ‘Charge Cart’. The accumulator must be bolted onto it. To allow safe charging, the Charge Cart includes many safety systems and communication circuits to allow for real-time monitoring of the charge state.
The charge cart will be getting a substantial make-over in 2024, including a complete re-design (in both its structure and electronics) to make it more user-friendly.
Future Research Projects
Future research projects for the High Voltage team in MUR Motorsports could focus on advancing battery technology, safety, and performance optimization. Some key areas include:
Improving Energy Density: Research into new battery chemistries or configurations to increase the energy density of the accumulator, allowing for more power in a lighter or more compact package, which could enhance performance and extend run times.
Thermal Management Systems: Developing advanced cooling and thermal management solutions for the accumulator and high-voltage components to ensure optimal performance under extreme conditions and prevent overheating or thermal runaway.
Battery Longevity and Efficiency: Investigating ways to extend the life cycle of battery cells and improve efficiency, possibly through regenerative energy recovery systems, which would allow the car to recharge during braking.
Fast Charging Solutions: Exploring fast charging technologies to reduce downtime between runs, making charging quicker and more efficient without compromising battery safety.
Industry and Work Opportunities
The High Voltage subsystem in MUR Motorsports provides valuable skills that translate into various industry and career opportunities, especially in the fast-growing electric vehicle (EV) and renewable energy sectors. Engineers with experience in high-voltage systems are in demand for roles in EV battery development, focusing on areas such as energy storage, battery management, and power delivery. Companies like Tesla, Rivian, and Lucid Motors seek engineers with expertise in designing and optimizing high-voltage batteries and systems.
In addition to automotive, there are opportunities in renewable energy fields, such as solar and wind energy, where high-voltage systems are used to store and transfer power. Engineers can also find roles in power electronics and energy grid management, working on advanced power distribution and high-voltage safety solutions. The growing fields of autonomous vehicles and electric aviation are also exploring new applications of high-voltage systems, opening up cutting-edge research and development roles.
Specific career paths include Battery Engineer, High-Voltage Systems Engineer, Power Electronics Engineer, and Energy Storage Specialist.
Design and Manufacturing Exposure
| Design |
|---|
| Safety Circuit/Battery Management |
| Charging Circuits and Configurations |
| EV Battery Cells |
| Electric Motor Control |
| High Voltage Operational Safety |
| Manufacturing |
|---|
| PCB Creation |
| CNC Machining |
| Laser Cutting |
| Water Jet Cutting |
| 3D Printing |