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For my Spartan Racing FSAE team, I redesigned the battery accumulator cold-plate mounting system to improve battery cooling. The redesigned mount reduced peak battery cell temperature from 58°C to 56°C, helping keep the cells within their optimal operating range for improved performance and reliability. The design was developed in SolidWorks while meeting the accumulator's packaging and structural constraints.
Overall system using a cooler, aluminum cold platem, and 12V battery pack
Inital drawing of the mouting system
During manufacturing, tool clearance was not taken into consideration. This issue was quickly resolved by machining custom spacers that did not compromise the cold plate’s performance.
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