Power Distribution Assembly

Subteam: ElectricalSubsystem: Custom ElectronicsAssembly: Power Distribution AssemblyCars: CR21, CR22, CR25, CR26I, CR26E

Purpose

Assembly line covering the power distribution modules and their wiring.

Function

Groups the PDM15, the PDM-4C and the busbar arrangement. Design Philosophies and Processes: Inherited from the Custom Electronics subsystem design process: 1. Collect the sensor list from every subteam, agree location and type with the designer who needs the data. 2. Split sensors between ECU and dash based on which parameters are engine-critical. 3. Size the charging system and validate it. A custom current measurement board (50 A bidirectional sensing chip, inline on the rectifier-to-PDM wire) measured what the rectifier actually puts back. 4. Build the datalogging parameter list with rates, then check CAN bus load. 5. Validate on a mock endurance: average battery voltage 13.4 V, minimum 12.1 V excluding cranking on CR26I.

Reoccuring issues

None recorded. This part has no entry in Knowledge_Transfer/Issue Logging/Fault Vault.xlsx, in either Issue Log.xlsx, in CR22/Issue Tracking/Shakedown 7-15-23.xlsx, or in any design review issue list found in CrimsonStorage or Box.

Still to document

Nothing in CrimsonStorage covers these yet.

Design Process — How it is designed and deemed effective at its purpose and function
Design Constraints — What held back the design whether it be location, time, materials etc
Analysis — How you get quantitative, predictive information on the part
Manufacturing Process — How it is assembled in detail from start to finish
Full Material List — Everything used to build this part (Best if actual numbers are used to show how it evolves year to year)
Improvements — Improvements for this generation
Properties — Size, weight, mass, charge, thermal properties, anything else relevant