Gryphon Racing

Who is Gryphon Racing?

Founded in 2003, the Gryphon Racing FSAE Team is composed of passionate students from various disciplines, including engineering, physics, and computer science, all united by their goal to design and build a high-performance electric Formula SAE vehicle. The team focuses on pushing the boundaries of electric vehicle technology and competing in international Formula SAE competitions.

One of the team's current projects involves the development of an advanced electric race car for this year's Formula SAE competition.

Gryphon Racing consistently performed at multiple competitions last year and received 2nd place for the innovation award at Formula Student Electric in Michigan.

Looking ahead, Gryphon Racing is committed to advancing its designs, improving vehicle performance, and fostering a culture of collaboration and learning. The team aims to inspire the next generation of engineers and innovators while remaining at the forefront of electric vehicle development in the FSAE community.

One part of the car that requires PCBs extensively is the Accumulator. The accumulator is the vehicle’s electric energy storage system and is responsible for delivering power to the electric motor. This system is composed of multiple elements, including the Segment Board and Flex PCBs, which work together to ensure safe and efficient operation of the battery cells.

Gryphon Racing team at the Michigan FSAE competition.

1. Segment Board

The accumulator is composed of 5 segments in series each containing multiple Molicel 18650 P28A Li-ion cells, arranged in a series-parallel configuration (28s5p) to provide the maximum voltage and sufficient capacity for the vehicle. These cells offer excellent power density and high discharge rates, making them ideal for the demanding environment of Formula SAE competitions.

The Accumulator segment PCB monitors the temperature and voltage of individual cells within the battery pack. The Segment Board collects temperature data from the battery pack to prevent overheating and ensure safe operation. Along with the temperature, the voltage data of the cells are also collected. This data is sent to the Orion Battery Management System (BMS), an intermediate system that processes the voltage and temperature data received from the Accumulator PCB. The Orion BMS translates this information into actionable data, allowing for real-time diagnostics of the battery pack. It manages individual cell balancing, thermal protection, and fault prevention, ensuring the battery pack operates optimally in different modes—idle, charging, and discharging.

Segment PCB

2. Flex PCBs

The Flex PCBs are an integral part of the Accumulator system, connecting directly to the Segment Board via FPC connectors. These flexible printed circuit boards are designed for precise temperature monitoring of the battery cells and are placed on the segment busbars. The busbars are spot-welded to the cells.

Each Flex PCB is equipped with thermistors that sit against the busbar to measure the temperature of the cells. A thermal pad is placed between the busbar and the thermistor to ensure accurate temperature readings by enhancing heat transfer from the busbar to the thermistor. This configuration allows for real-time monitoring of the battery’s temperature during high-stress conditions, preventing overheating and protecting the cells from thermal damage.

The Flex PCBs are also designed with four connection points that are soldered onto the busbar, ensuring a solid and reliable electrical connection. These connection points facilitate the communication of temperature data from the thermistors to the Segment Board. This data is crucial for the BMS to balance the battery cells effectively and manage thermal performance throughout the vehicle's operation.

Flex PCB

Collaboration with PCBWay

As a team dedicated to pushing the limits of electric vehicle technology, Gryphon Racing faces challenges in sourcing and manufacturing parts within our budget and timeline. Quick prototyping and reliable PCB production are essential for our success. The support of PCBWay would greatly benefit us by enabling rapid prototyping, allowing team members to expand their skills in PCB design and manufacturing across multiple projects.

For more information, please visit one of our socials or reach out to us directly via email!

Website: https://gryphonracing.org/

Instagram: https://www.instagram.com/gryphonracing/

Youtube: https://www.youtube.com/@GryphonRacingSAE

Email: ugracing@uoguelph.ca