Written by Conner Neeley
The Ohio State University and Columbus State Community College Battery Workforce Challenge Team made great strides in development this year through the stewardship of industry leaders Vibration Research and Dana Inc. Through direct access to professional testing equipment, advanced software tools and continuous mentorship, our team is gaining hands-on exposure to the same technology and process used across the automotive industry. Sponsors like these are shaping the careers of tomorrow’s engineers.
Throughout the competition, our team has encountered numerous engineering challenges in designing the battery pack for the RAM ProMaster. With support from Vibration Research’s technology and Dana Inc.’s guidance, we’ve overcome design challenges and are building a stronger product.
Vibration Research provided us with access to OBSERVR1000, an advanced data acquisition system which can capture and analyze dynamic vibration signals. The logging system was integrated with accelerometers mounted at multiple locations along the vehicle chassis to measure vibration response under various operating conditions.
This setup was tested at the Transportation Research Center (TRC) in East Liberty, Ohio, where the team collected vibration data across the oval track, skid pad and gravel roads.
Vocational Deputy Joe Borgerson from Columbus State Community College worked closely with Vibration Research accelerometers to gather essential data about the vibration patterns. Borgerson installed the gift at the bottom of the van and drove it around the campus area. The sensors worked to track spikes of disturbances throughout the trip. The data collected enabled our team to identify vibration hotspots and refine mounting strategies for critical battery components.
“Working with Vibration Research” was a great experience for our team. They provided us with extremely useful equipment and software that allowed us to collect vibration data from our van that we would never have access to otherwise,” Borgerson said. “This also gave us the opportunity to compare our simulations to real-time data, which is what a real manufacturer would do. They have been very supportive and helpful throughout the entire process.”
In parallel with Vibration Research, Dana Inc. has also played a pivotal role in guiding the design and manufacturability of our thermal management system.
Vehicle Systems Integration Lead Tahmina Fatima from Ohio State University, and Joe Borgerson collaborated with four other Battery Workforce Challenge teams to develop a shared bottom liquid cooling plate design which is adaptable across different battery module architectures. Dana Inc also supported this initiative by sponsoring the manufacturing of cold plates.
“We had scheduled weekly meetings to brainstorm design ideas, present design progress and make decisions,” Fatima said. “DANA Inc representative Ben Kenney also attended these weekly meetings and gave suggestions on which design would work in terms of manufacturability and durability. With a 20-week lead time for manufacturing, Ben’s feedback was essential to deliver a viable design on schedule. “
As the team drives into the final stage of the competition, we take a step back to acknowledge our incredible partners and everything they’ve given us. Through their hardware and mentorship, our team has grown its knowledge and experience in industry standards. We intend to use sponsorship from Vibration Research and Dana Inc. to shape the future.
Educators, industry leaders, and students are encouraged to continue supporting such endeavors, paving the way for a more innovative and sustainable future. To keep up with the team’s journey, latest events and updates, follow us on Instagram and LinkedIn (@BattChallengeOSU)!
