- The first iteration of the Factory Co-Pilot Battery Pack marked the foundation of the system’s power architecture. The primary objective was to establish a reliable energy source capable of supporting the early hardware and AI integration phases of the Factory Co-Pilot wearable device. This phase served as a proof of concept, focusing on validating electrical feasibility, basic safety, and mechanical compatibility within the device housing.
- The design utilized off-the-shelf lithium-ion cells configured to meet the voltage and current requirements of the embedded computing system. The pack was manually assembled with protective insulation and basic balancing to ensure stable operation during short-duration tests. The initial enclosure was fabricated using ABS to assess internal component arrangement, wiring clearance, and weight distribution relative to the wearable’s ergonomics.
- During testing, the system successfully delivered consistent power to the Raspberry Pi Zero and camera module, enabling real-time AI inference and data acquisition. However, extended runtime testing revealed minor heat accumulation and uneven temperature distribution across the cells. These observations emphasized the need for enhanced thermal management and improved cell layout in future iterations.
- Despite these challenges, Iteration 1 effectively demonstrated the viability of an integrated onboard battery solution for industrial wearable systems. The lessons learned regarding electrical load handling, enclosure design, and thermal characteristics directly informed the design priorities for subsequent versions.
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Factory Co-Pilot Battery Pack (Iteration 1)
Project Timeline
Jun 2025 - Jul-2025
OVERVIEW
The first iteration focused on developing a baseline power system to support the initial Factory Co-Pilot wearable prototype. A modular lithium-ion battery pack was designed using readily available cells to deliver consistent power for early AI integration and testing. The enclosure was 3D printed to assess component placement, weight distribution, and wiring layout within the compact wearable form.
While the system achieved stable power delivery, it showed thermal buildup during extended operation. These findings highlighted the need for improved heat dissipation, cell balancing, and structural reinforcement, forming the foundation for subsequent design refinements in later iterations.
HighlightS
- Designed and assembled the first functional lithium-ion battery pack for the Factory Co-Pilot prototype.
- Established core electrical parameters including voltage, current, and discharge requirements for system integration.
- Developed the initial enclosure concept ensuring compatibility with the wearable’s form factor.
- Enabled continuous power supply for prototype testing and early AI model deployment.
- Identified key thermal and structural limitations that guided subsequent design iterations.
- Validated proof of concept for an onboard power system within an industrial-grade wearable platform.
SKILLS
Mechanical Design & CADFinite Element Analysis (FEA)Embedded Hardware IntegrationRapid PrototypingCross-Functional Collaboration
Additional Details
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