Lesson 3: Powering the Vehicle—The High-Current Loop
Duration of Days: 5
Lesson Objective
SWBAT:
Wire a 24V or 48V battery bank in series to achieve the required race voltage.
Install a high-amperage shunt and power analyzer to monitor Watt-hour consumption.
Why do we use thick 4-gauge wire for the motor but thin 18-gauge wire for the horn?
How does an "Amp-Hour" rating tell us how long we can race before the battery dies?
Watt-hour, Amp-hour, Shunt, Battery Bank, Gauge (AWG), Solenoid, Master Disconnect, Insulated Tools.
CT-CTE.TRANS.E.25: Identify and describe the operation of electric vehicle drive systems
DOK Level: 3 (Strategic Thinking/Hands-on)
Students move to the vehicle's "Heart." The purpose is to wire the high-current loop that connects the batteries to the motor controller.
Misconception: "Two batteries always give you more power."
Correction: Explain the difference between wiring in Series (adds Voltage) vs. Parallel (adds Capacity/Runtime).
Support: Provide a 1:1 scale wiring diagram "map" that students can lay their wires on for physical routing.
Extension: Students calculate the "Watt-hour per mile" efficiency based on a 1-hour race simulation.
The vehicle's high-current loop is inspected for secure crimps, proper insulation, and correct polarity before the "First Power-Up."