Microfluidics Lab and Innovation Workshop Wiki

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=====CNSI Innovation Workshop and Microfluidics Lab Battery Segment Manufacturing & Assembly Safe Operating Procedures===== 

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.
  * [[https://drive.google.com/file/d/1WaE5zUF_ONd5w97KBsFAAIgpMukKw4gw/view?usp=sharing|Electrical Insulating PPE Guide]]
  * [[https://drive.google.com/file/d/10a0mtayN_YjYS8mw8pcqEAQBuuY6iT1I/view?usp=sharing|NFPA 70E PPE]]

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

====Overview====
  * 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

====Safety Considerations====
  *Electrical shock & arc flash
    *There are two primary ways that direct current electrical injury can occur:
      -Body completing the loop in a high voltage circuit (touching positive and negative terminals of a high potential battery segment)
      -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 [[https://drive.google.com/file/d/1WaE5zUF_ONd5w97KBsFAAIgpMukKw4gw/view?usp=sharing|Electrical Insulating PPE Guide]] and [[https://drive.google.com/file/d/10a0mtayN_YjYS8mw8pcqEAQBuuY6iT1I/view?usp=sharing|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 {{wiki:fsae:arcflashgloves.png?150}}
      * nonconductive safety glasses
      * [[https://www.mcmaster.com/7315A71/|insulated tools]]
      * long sleeve shirt & pants
      * closed toed shoes 
      * [[https://www.mcmaster.com/6893T13/|electrically insulating mat]]
      * arc-flash face shield {{:wiki:fsae:arcflashfaceshield.png?200}}
  *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

====Battery Segment Design====
{{:wiki:fsae:batterysegmentdraeing.png}}
26s5p li-ion cells  per segment comprised of Enepaq 1x5p Sony VTC6 modules

====Necessary Materials, Tools, and Equipment====
  *Electrical Insulating PPE
    *Referencing this [[https://drive.google.com/file/d/1WaE5zUF_ONd5w97KBsFAAIgpMukKw4gw/view?usp=sharing|Electrical Insulating PPE Guide]] and [[https://drive.google.com/file/d/10a0mtayN_YjYS8mw8pcqEAQBuuY6iT1I/view?usp=sharing|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
  *Drill bits & end mills for insulation panel machining
  *Epoxy for assembling panels
  *Wires & solder

====Machining of insulation panels====
  - Fixture panels, program cam, and set up tools on ShopBot Router referencing [[http://microfluidics.cnsi.ucsb.edu/wiki/doku.php?id=shopbotdesktoptrainingsop|ShopBot SOP]] 
{{:wiki:fsae:insulationcnc.jpg?400}}
    *Set up vacuum attachment and wear masks to minimize inhalation of fine fiberglass particles
  - File edges of panels to remove sharp glass fibers

====Assembly of Enepaq modules within insulation====
  - Insert modules with correct polarities and use epoxy to bond base and side panels of segment 
{{:wiki:fsae:batterysegmentclamp.png}}
  - **Wear proper PPE (listed in safety considerations section); those without PPE should remain five feet away** and connect modules together using bolts and busbars
    * **Cover work surface and ground with electrically insulating mat and use insulated tools**
    * Attach voltage taps under bolt heads using solder if necessary (onto copper washers)
    * Attach temperature sensing wires to module xr connector
  - Route wires through holes in top panel
  - Connect voltage taps carefully and avoid short circuiting any modules 
{{:wiki:fsae:batterybusbarconnection.png}}
  - Bond top panels to enclose segment  
{{:wiki:fsae:batterysegmentclamp2.png}}