- The Factory Co-Pilot Battery Pack v2 was developed as a critical subsystem to support the continuous operation of the Factory Co-Pilot wearable device, an AI-enabled system designed for automotive assembly supervision. The objective of this iteration was to engineer a compact, thermally stable, and reliable power source capable of sustaining extended operational cycles under industrial conditions.
- The project involved complete hardware development, including cell selection, electrical configuration, enclosure design, and integration with the main wearable system. A lithium-ion cell architecture was selected for its high energy density and consistent discharge performance, ensuring reliable operation during long production shifts. The design prioritized compactness, safety, and effective thermal management within the constraints of the wearable form factor.
- Thermal regulation was a key focus area in this version. Through optimized internal layout, passive heat dissipation features, and careful material selection, the system maintained safe temperature ranges during prolonged use. Finite Element Analysis (FEA) was conducted to evaluate enclosure strength and vibration resistance, ensuring structural integrity under real-world factory conditions.
- A Battery Management System (BMS) was integrated to monitor voltage, current, and temperature parameters, providing protection against overcharge, over-discharge, and overheating. These safety protocols improved operational stability and prolonged the service life of the battery pack.
- The final iteration delivered a deployment-ready power module that ensured stable energy output for continuous AI inference and sensor operation. The design improved reliability, reduced thermal stress on critical components, and enhanced overall system endurance during industrial deployment.
- This project represented a complete hardware development cycle from concept and design to validation and system integration, strengthening the reliability and scalability of the Factory Co-Pilot platform.
HOME
Factory Co-Pilot Power Module (Iteration 2)
Project Timeline
Jun 2025 - Aug-2025
OVERVIEW
The project involved the design, assembly, and optimization of a compact lithium-ion battery pack engineered to power the Factory Co-Pilot device. The focus of Iteration 2 was on improving energy density, thermal management, and structural integration within the device’s limited enclosure. Key enhancements included refined cell configuration, current load balancing, and incorporation of a BMS (Battery Management System) for improved safety and performance consistency. The resulting design provided longer operational uptime, faster charging capability, and stable power delivery under factory operating conditions.
HighlightS
- Designed and developed a compact lithium-ion battery pack optimized for the Factory Co-Pilot’s industrial power demands.
- Led hardware design from configuration to integration, ensuring structural rigidity and efficient space utilization within the wearable system.
- Improved thermal performance by optimizing heat dissipation and temperature distribution across the cell array.
- Implemented a Battery Management System (BMS) for voltage regulation, protection, and operational safety.
- Conducted FEA to evaluate enclosure strength and vibration resistance under factory conditions.
- Delivered a stable and deployment-ready power module, contributing to improved reliability and continuous operation of the Factory Co-Pilot.
SKILLS
Mechanical Design & CADFinite Element Analysis (FEA)Embedded Hardware IntegrationRapid PrototypingCross-Functional Collaboration
Additional Details
lowinertia
Portfolio Builder for Engineers