Charging Forward: Design and Build of a High Voltage Formula Electric Vehicle Charger

Abstract

The urgency to combat climate change is propelling a swift transition to electric vehicles (EVs). Student motorsport competitions, in the wake of this trend, are transitioning from internal combustion engines to EVs. However, these charging systems are often an afterthought in the design, leading to cumbersome and unsafe charging systems that hinder mass adoption. Easy-to-use high-voltage chargers emerge as a pivotal solution, blending safety, efficiency, and simplicity.

This thesis presents the high voltage charger for the Princeton Racing Electric’s upcoming generations of high voltage vehicles comprised of a direct charging system, a power distribution network for low voltage components, a safety loop, and a communications relay system. The first part defines the design requirements and conducts a market review of primary charger components, which defines the scope of the thesis. Next is the electrical PCB design of the electrical board that serves as a power distribution network, safety circuit, and network relay. Then is the mechanical design of the high voltage distribution and the enclosure system. Finally, I conduct an evaluation of the charger in functionality and performance, while outlining future work to integrate charging with the motorsport EV.