Written by: Zack Rome, Team Member
The PackMules are racing toward the finish line of the Battery Workforce Challenge. We have come a long way from the day our RAM ProMaster EV first rolled into the bay. What started as a blank canvas is now the testing ground for our custom-designed Battery Disconnect Unit (BDU), Battery Management System (BMS), and high-voltage battery packs. As we approach the final stretch, we’re reflecting on the journey through the eyes of the team leading the charge.
Herding… Packs?
At the helm are Project Manager Viviana Nelson and Engineering Manager Parker Hewett, who have grown with this project for the last three years. Managing this project taught them that engineering and people have very different needs; they had to balance technical progress with team stress levels. Hewett, the former Electrical Hardware Lead, ensures that every system is compatible. He notes that despite the need for multiple redesigns, “We’re still able to show up and compete well, said Hewett.” Our managers learned this year that setbacks don’t equate to failure, and they’ve shown us not just how to push forward as a team, but also how to take these setbacks and learn from them.
The Process
Physical implementation has taught us that engineering is more than a clean CAD drawing. Thermal Systems Manager Brian Durland notes that implementing an advanced battery pack is a lesson in persistence: “Engineering is just as much about solving problems as it is sorting through the problems and solutions that have been found and cobble it all together into something useful, This mindset is shared by Software Lead Jeremy Utt, who stepped up to learn new coding languages and how to lead his own team on the fly. Recently, Jeremy has spent time using his skills to collect data from the van as part of the deliverables. By collecting data from the van vehicle system to ensure the pack integrates correctly, the team learned exactly what it takes to make custom hardware speak the same language as an OEM platform.
Real World Growth
Working on a professional-grade vehicle has pushed us to industry standards. Electrical Hardware Lead Dylan Mullally has seen this firsthand while leading the BDU through the last stages of CAD tweaks and prototyping. Stepping into this role in January, Dylan has grown by working side-by-side with the team to fit components within the van’s rigorous physical constraints.
Our vocational team members at Arapahoe Community College have also seen their roles expand. Vocational Lead Ethan Fall note , “Our real-world experience allows us to fill in the gaps that might be overlooked, whether it be in the assembly of a wiring harness or how to safely work in a garage environment. For both Mines and ACC students, this sponsorship has transformed our workflow from a “homemade” garage project into a small-scale company producing a service-ready product, where safety has been paramount throughout the project.
Team PackMules is excited to finish strong in the final year of the Battery Workforce Challenge! Keep an eye out for updates from our team.
