Global Formula Racing puts its trust in eurolaser

Laser technology provides for more efficient battery solution

Global Formula Racing is an international collaboration between the former BA Racing Team from the Duale Hochschule Baden-Württemberg-Ravensburg (DHBW-R), Germany, and the Beaver Racing Team from Oregon State University (OSU), USA. The starting pistol for this innovative global collaboration, which is the first and, to date, only one of its kind in the history of both American and European Formula Student racing, was fired in 2009.

Global Formula Racing Team
Global Formula Racing Team

 

Combined experience, shared resources and collective German and American expertise should result in a vehicle that will earn an international reputation - with success. The design, manufacture and testing will take place at both universities, separated by nine time zones and more than 8,700 kn. The unique supply chain management of Formula Student plays a very important role in this. Likewise the English language, which has been set as the team language to ensure a comprehensive flow of information across national borders.

Electric vehicle
Electric vehicle

 

In the first joint season in 2010, an identical combustion engine vehicle was built at each university, and this laid the foundation stone for the designs in the following years, as well as the future collaboration. This common basis has been used since the 2011 season to design and build two cars - a combustion engine variant at the OSU campus in Corvallis, Oregon, USA and an electric vehicle at the DHVW-R campus in Friedrichshafen, Baden-Württemberg, Germany. For the current season, too, the DHBW-R team is building an electric vehicle. An essential component, to which particular attention is paid, is, of course, the battery (or accumulator).

Battery container
Battery container

The battery system is based on a 450 volt concept and is built into a battery container comprising a base body and a lid. The battery container holds eight battery packs connected in series, each of which accommodates 12 serial and 2 parallel cells in an L-shaped, sintered protective case.

The cells are connected to the cell contacts on the top of the protective case by circuit boards made of silver-coated aluminium. In order to protect the individual battery packs in the event of an accident, protective film made from the flame retardant material Lexan FR60 is used.

Lexan foil cut by laser
Lexan foil cut by laser

 

For this, three different films were designed in the CAD: one which is folded and bonded then clipped over holes in the protective casing; one which is stuck to the inside of the protective case; and one which is likewise stuck to the sintered lid of the battery packs. Their task is to delay the spread of fire to other battery packs in the event that the battery catches fire, and the film should also protect the lid against any short circuits which might be caused by tools falling into the battery container.

Global Formula Racing Team
Global Formula Racing Team

The company eurolaser enabled us to assemble this precisely thanks to high precision laser cutting of the Lexan film.

"The laser cutting enabled us to reduce working time to a minimum, and to build the battery system productively and within the timetable." Andreas Ott GFR - Battery Mechanical Team

The Global Formula Racing Team would like to thank the company eurolaser most sincerely for its support and hopes to enjoy continued collaboration in the future.

We at eurolaser also wish the team from DHBW-Ravensburg all the very best and success in the head-to-head race!

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