Innovation Workshop Wiki

Last Updated: 6/6/23 Jason
This SOP provides a guide to safely manufacture and assemble battery segments of the GR23 electrical vehicle. Some of the information is compiled from the following sources.

• Electrical Insulating PPE Guide
• NFPA 70E PPE

Battery assembly should take place on one of the workbenches in the Innovation Workshop in Elings 2442.

• Safety considerations, how they can occur, and how to avoid electrical accidents
• Battery segment design
• Necessary materials, tools, and equipment
• Machining of insulation panels
• Assembly of Enepaq modules within insulation

• Electrical shock & arc flash
  • There are two primary ways that direct current electrical injury can occur:
    1. Body completing the loop in a high voltage circuit (touching positive and negative terminals of a high potential battery segment)
    2. Non-insulated tool or a conductive material completes the circuit in a medium to high voltage circuit, generating an explosive arc that can produce intense heat
• Electrical Insulating PPE
  • Referencing this Electrical Insulating PPE Guide and NFPA 70E PPE, working with electric potentials between 50-750VDC (GR23 battery segment is 110V max voltage, entire battery pack is 546V max voltage) requires:
    • electrically insulating class 00 gloves
    • nonconductive safety glasses
    • insulated tools
    • long sleeve shirt & pants
    • closed toed shoes
    • electrically insulating mat
    • arc-flash face shield
• Workspace
  • As mentioned above, ensure that no non-insulated tools can fall across battery terminals or be accidentally used (remove all non-insulated tools that are magnetically attached above the workbench)
  • Workspace and ground should be covered with electrically insulating mats
  • No machining of metals should occur while battery segment terminals are exposed
• Machining Fiberglass
  • Machining fiberglass can produce fine resin and glass particles that can be harmful if inhaled
    • Keep particles contained in CNC router enclosure
      • Use vacuum attachment
    • Wear masks
    • Wipe up particles often

26s5p li-ion cells per segment comprised of Enepaq 1x5p Sony VTC6 modules