Objective: Re-design connector to increase compliance in 2-Dimensions. 

Skills Used:

• Working and designing for High Voltage/High Current

• Designing for adjustability

• Data Analysis - Python

• Designing for assembly

• Thermal calculations

Design Constraints:

• Ability to comply for ±2.5 cm in 2-Dimensions

• Cannot have High Voltage exposures [safety]

• Maintain low maintenance requirements (especially, for degradations due to thermal effects)

Design Process:

• Designed a junction box to isolate heavy cables from busbars.

• Sized and designed flexible busbars to handle high current (500 A) without sacrificing compliance or ability to handle thermal loads.

• Wrote a Python script to collect and analyze data/failures, used to quantify improvements.

• Performed thermal and stress analysis on new connector.

Final Solution: Completed prototype, pending testing.