Reference no: EM133616420

Engineering Study of Swappable Battery Trays

Your task for Scenario 3 will be to design the structure which the battery packs are carried in, we will call these trays.

You will be expected to investigate the design space, you will be given a number of constraints, but it is up to you to interrogate them and decide the limits of your investigation.

This scenario will give you the opportunity to apply what you have learned about manufacturing, materials and design to a realistic problem. Only a limited amount of information will be provided via Moodle as it will be expected from you to investigate the design space.

Some important objectives of this design are the minimisation of mass and cost, the use of an appropriate material and manufacturing method. Critical constraints are:

- The tray must be safe, i.e. not fail under the action of loads generated on the components of the tray from the weight of heaviest of battery packs and typical road conditions (e.g. riding over potholes, road barriers or other similar obstacles).

- The tray must be durable, i.e. it must not fail from fatigue loading or environmental degradation (corrosion) for a minimum of 5 years of daily use.

- The tray must be commercially viable

You will not be supplied with detailed instructions on how to design the tray. Therefore it is important that you research any issues associated with the requirements and constraints identified in this instruction pack in order to design a tray that meets the user's needs.
- Carry out a material selection and design sustainability analysis for the components of the frame, using CES Edupack, Granta.
- Create a CAD model of your team's tray using Fusion 360.
- Demonstrate the structural integrity and performance of the tray under static/dynamic loading conditions using Fusion 360 Finite Element Analysis (FEA) functions.

DELIVERABLES
You are required to complete a report and a presentation detailing the work you have conducted. The information will be the same in both and it is important you include the necessary details below:
- Specification of design requirements (e.g. Functions Objectives Constraints)
- Material selection
- Analytical Solution
- Computational tests including boundary conditions
- Results and justification for meeting the design requirements

Presentation
You will present your work via a video presentation submitted by Friday 08:00 am as an mp4 file. Your presentation should address the following points:
- How you gathered information and completed the FOCs.
- Material selection (CES EduPack)
- Analytical solutions
- Computational tests (e.g. FEA, Topological Optimisation, Generative Design)
- Conclusion of which design is the best option.
Other aspects can also be discussed and supporting data should be used (facts, calculations, drawings...).

The pre-recorded presentation should be max. 10 minutes. All team members are required to participate. They should contain at least a video of the speaker, but can contain other things. e.g. the speaker narrating beside a site or object of interest, or with another screen containing powerpoints or animation. Feel free to be creative. You can use any software you want to create the presentation (MS Streams, Powerpoint, Loom. iMovies etc are popular screen-capture softwares). Keep in mind that the maximum file size that can be uploaded on Moodle is 160 MB.

The presentation video is due for submission via UCL Media Central by 08:OOam on Friday.
Videos will be displayed to a panel in an allotted slot on Friday - please see Moodle for group timings and zoom links - you are expected to be present for the duration of your session.
Videos will be followed by maximum 10 minutes of Questions. panel feedback and summing up.

Report
You are required to submit a structural report consisting of 5 sides of A4. This industry type report merely set out the analytical and computational solutions to the project brief. Very little in the way of discussion, more statement of the facts. A good way to lay this out is:
- Introduction of FOCs
- Material selection
Analytical Solution
Computational tests including boundary conditions Result(s)
Concluding on design
Remember, as engineers you must provide evidence (think about pictures. and use calculations) to support any statements.
N.B take time to reflect on the lectures you have been taught this academic year - most are relevant to this Scenario.

Peer Assessment
The peer assessment system will be in place again - remember to take your time to complete it correctly, providing feedback on yourself and your peers, be fair and honest in the review.