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Who am I?
Who am I?
I am a physics student from the University of Toronto passionate about solving real-world problems. I hope to leverage the knowledge I have gained from my physics degree and the electrical engineering experience I have gained from various design teams and personal projects to make an impact in this world.
This journey has led me to become the electromechanical lead of the Blue Sky Solar Racing team, where we build a solar car and race across a 3000 km trail in Australia, relying purely on solar energy. With my time in UofT design teams like this, I’ve developed strong technical skill sets and strengthened my communication, collaboration, project managing and critical thinking skills. I have working knowledge in STM32, ASIC design & validation, and power electronics, with industrial experience in Altium Designer, CATIA, embedded programming, Python and MATLAB. All these skills were later further enhanced after working at Litens Automotive Group as part of the BMS hardware team for a 15-month internship.
Academically, I am a fourth-year University of Toronto student in the Physics Specialist program, specializing in the Modern Optics, Quantum Information, and Quantum Computing stream. I am taking many theory-based courses, such as Quantum Mechanics, Optics and Electromagnetism, alongside practical courses, such as Computational physics and Time Series Analysis, that focus on solving real-world problems with skills such as mathematical modelling and numerical simulations using Python and Jupyter Notebook.
Always interested in an interesting project.
You can reach me at: alex.zeng@mail.utoronto.ca
Below is a collection of my most interesting work
OR, you can check out the more creative side of Alex here at my art portfolio!!
Blue Sky Solar Racing Team
Blue Sky Solar Racing Team
(May 2021 - Present)
(May 2021 - Present)
I am the GEN XI Electromechanical Lead Engineer from the Blue Sky Solar Racing Team. Our team is dedicated to the challenging mission of designing and racing solar-powered vehicles across an arduous 3000+km course spanning the Australian Outback, a journey that relies exclusively on solar energy for power.
As the Electromechanical Lead Engineer, my responsibilities encompass fostering close collaboration with the structural-fabrication, strategy, and solar array sub-teams. My primary goal is to ensure seamless integration across all facets of our project. This includes overseeing the integration and stress testing for all six of our critical electrical subsystems, an integral part of ensuring our vehicle's optimal performance and unwavering reliability. My dedication to making our system not only perform at its best but also stand as a paragon of dependability is a cornerstone of my role.
I've had the privilege of managing a dynamic team of over 20+ electrical members, guiding their efforts across various tasks. This includes tasks such as sensor testing and integration for simulation validation, rigorous radio antenna evaluations, and comprehensive PCB bring-up testing. Furthermore, my role extends to designing and assembling the next-generation battery pack, complete with an enhanced battery protection system, a vital component of our ongoing innovation.
Additionally, I am deeply involved in multiple research and development (R&D) projects. This includes contributions to the centralized electrical system, an exploration of dyno design, and the potential implementation of CAN bus technology into our system. I am passionate about applying my skills to innovate and drive progress within our team's endeavours.
I have also been organizing and presenting compelling sponsorship pitches to secure valuable in-kind and financial sponsorships from prominent electrical and automotive companies. Notably, I established a partnership with Molicel Energy, securing over $6,000+ worth of battery cells and becoming their first sponsored student design team.
BMS Evolution
BMS Evolution
BMS v1 (2021)
BMS v1 (2021)
The v1 version, created by a student back in the GEN X cycle in 2020, hadn't gone through any validation testing because the original designer graduated before getting to it. So, my partner and I rolled up our sleeves and took it upon ourselves to dive into the PCB, figure it out, and run the necessary tests, all without any help from the original designer.
BMS v2 (2022)
BMS v2 (2022)
After identifying certain issues with the original design, we decided to develop the v2 version. This new iteration addressed hardware bugs and repositioned all components onto a single side for improved integration with the original battery pack design. The board was divided into three main sections: the left side primarily served for passive balancing using the LTC6810 chip, the middle section handled active balancing, and the right side housed the power supplies, STM32 chip, and RS485 communication section.
BMS v3 + BMS Bridge (2023)
BMS v3 + BMS Bridge (2023)
This version was deployed in the GEN XI car for the race, and it featured several significant changes. Notably, we adopted ADI's isoSPI protocol to connect all BMS modules to increase reliability and also eliminated the active balancing section due to redundancy and cost considerations. We also designed the BMS Bridge to convert the communication from isoSPI between BMS modules to RS485 for the rest of the system using an STM32 chip.
System Integration & Stress Testing
System Integration & Stress Testing
The World Solar Challenge is like a long-haul race, so we run constant stress tests to spot and fix any issues early on, ensuring we don't break down during the race.
Battery Pack Redesign
Battery Pack Redesign
Originally, the battery box was situated behind the driver. However, during the later stages of the project cycle, we observed that the car's center of gravity had shifted to approximately 35% front and 65% rear. This compelled us to undertake a comprehensive battery pack redesign, relocating it to the front of the vehicle.
This redesign effort involved a cross-functional subteam, with active participation from the structural, fabrication, and mechanical subteams. Ultimately, we successfully reconfigured the battery box to resemble the design displayed on the right. It now features one side housing all 420 cells and the other side accommodating the entire Battery Protection System.
The initial design concept, depicted on the left, aimed to enhance the modularity of the entire battery pack for ease of cell replacement. However, this idea encountered several challenges, including mechanical constraints for individual cells, issues related to vibration, and volume considerations. It was ultimately abandoned when we learned of the necessity to relocate the battery box to the front of the car, necessitating a design that would fit 420 of 18650 cells with our BMS system within a tiny 11'x11'x17' box.
Litens Automotive Group
Litens Automotive Group
(May 2023 - Aug 2024)
(May 2023 - Aug 2024)
I worked as an Electronics Engineering Student with the BMS Hardware Team at Litens Automotive Group for a 15-month internship, focusing on developing the next-generation modular and high-power battery pack.
Part 1:
My primary responsibility was to design a comprehensive benchtop test setup for our electronics team. This setup enabled the testing of hardware, firmware, and control algorithms, while also allowing for the safe and easy injection of various fault cases to verify system functionality. I started by gathering requirements from different subteams to identify desired features, validating test feasibility, and ensuring that my plans aligned with their expectations. Once the designs were finalized, I manufactured and assembled the setup, which included over 300 electrical connections, 20+ electronic sensors, and 40+ PCBs—half of which I designed to enhance system integration and simplify fault/test case injections.
Another major part of my role was collaborating with this cross-functional team to help debug and isolate problems during integration. To do this, I had to have a deep and comprehensive understanding of both the high level and every detail of the battery pack and the test setup that I built. This expertise allowed me to effectively identify whether issues originated from the hardware, firmware, or algorithms, demonstrating my ability to troubleshoot and resolve complex problems efficiently.
I also created detailed design documents for knowledge transfer and conducted multiple workshops to help my team of over 30 members understand and use the setup. My work was highly regarded, leading to my involvement in other projects with similar benchtop test setups.
Part 2:
I contributed to a prototype project by integrating an in-house prototype battery pack with our BMS for an in-house electric vehicle platform intended to serve as a range extender and data collection tool. I designed two PCBs for better system integration and conducted extensive tests to ensure system functionality. Additionally, I had to debug various issues that arose during testing, including hardware malfunctions and software integration problems. This required a systematic approach to identify root causes and implement effective solutions, ensuring the reliability and performance of the prototype system.
Part 3:
Additionally, I designed and executed over three comprehensive hardware bring-up test plans for prototype PCBs within the BMS and benchtop setup, successfully identifying and resolving errors to ensure optimal system performance. I also collaborated with Analog Devices and external design partners for design reviews and troubleshooting unforeseen issues.
https://www.litens.com/ev-technologies/
Earlier Experiences...
Earlier Experiences...
Xtract One Technologies
Xtract One Technologies
(April 2022 - Aug 2022)
(April 2022 - Aug 2022)
During my summer internship at Xtract One Technologies (previously known as Patriot One Technologies) in the Toronto office, I served as a lab coordinator. Xtract One Technologies specializes in developing advanced threat detection solutions for crowded venues, utilizing AI and multi-wave sensors. In this role, I collaborated with different subteams to oversee the transition of the existing AI-and-electromagnetism-based threat detection system into production. Concurrently, I was engaged in prototyping the next-generation system, incorporating feedback from previous designs and conducting validation using electronics test instruments and proprietary software.
Furthermore, I worked collaboratively with cross-functional teams, including hardware, firmware, data science, sales, and logistics. This collaboration was instrumental in defining product requirements and validating new testing procedures to ensure the seamless operation of our 20+ prototype demonstration units, each tailored to meet the unique needs of various customers. Additionally, I played a pivotal role in structuring and creating manufacturing Build of Materials (BOM) and developing more than 5 assembly guides for mass production, contributing to the efficient scaling of our solutions to meet market demand.
University of Toronto Hyperloop Team
University of Toronto Hyperloop Team
(Sept 2020 - Aug 2022)
(Sept 2020 - Aug 2022)
We were building our first-generation high-speed bullet train that runs in a vacuum tube. I was part of the electronics team, where we prototyped and tested every safety monitoring sensor and electrical system across the pod and designed PCBs accordingly. I also worked on prototyping and installing a cooling system for our motor and inverter.
Computational Physics & Time Series Analysis Courses
Computational Physics & Time Series Analysis Courses
In these classes, we tackled physics questions involving mathematical models, computational simulations, experimental measurements, data, and uncertainty analysis. I utilized Python with Jupyter Notebook and PyCharm to analyze telemetry data from advanced physics sensors and laboratory equipment. Additionally, I developed computational modelling algorithms, including the use of techniques like the Fast Fourier Transform and Monte Carlo methods. Over the course, I authored more than 10 lab reports in LaTeX, systematically comparing and analyzing expected results against experimental outcomes.
Our coursework encompassed a variety of fundamental computational modelling techniques, including the computation of integrals and derivatives, root and extrema finding, addressing linear and non-linear equations, solving eigenvalue problems, implementing Fast Fourier Transform (FFT) analysis, handling ordinary and partial differential equations (ODEs and PDEs), and employing Monte Carlo techniques.
Hackathon Project: Fedoract
Hackathon Project: Fedoract
(Feb 19th, 2022 - Feb 20th, 2022)
(Feb 19th, 2022 - Feb 20th, 2022)
This project was successfully completed during a 24-hour hackathon by our team of four. Our creation, Fedoract, offers an engaging and interactive approach to controlling music. It wirelessly interprets hand gestures, enabling users to manage their Spotify playlist using intuitive motions. On the hardware side, our setup includes a camera module, a wifi module, and a custom-made power supply capable of delivering a stable 5V DC. The software backend is built on the foundations of OpenCV and the MediaPipe library. I played a central role in designing, testing, and seamlessly integrating all hardware components into the software backend, contributing to the project's overall success.
FIRST Robotics Competition
FIRST Robotics Competition
(Sept 2018 - May 2020)
(Sept 2018 - May 2020)
As the project manager of the Newmarket High School's FIRST Robotics Team for two cycles, I was leading 58+ people rookie team to design, prototype, and manufacture an advanced robot within six weeks. These robots compete against others on a basketball-sized field to complete objectives autonomously and under drivers’ control. We have won multiple district-level awards and ranked top among the competition.
and more to come...
and more to come...
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