MRacing · Formula SAE Electric · 2026
MRacing TSSI assembly & integration
An assembly that communicates high-voltage presence and monitored electrical faults. I worked on assembling, debugging, and packaging the electronics.
Assembly, connection repair, bench testing, and protective packaging
Complete
Building one board, repairing another
I assembled and soldered a new indicator board, then repaired a separate board with a damaged PCB connection. The repair used a 30 AWG jumper wire to restore the connection.
These were two different boards: one new assembly and one repair. The repaired board then went through a functional bench check.
One board assembled · One separate board repaired
Checking the indicator channels
After the repair, I powered the board and applied the control inputs separately. Both the green and red LED channels illuminated in response to their respective inputs, confirming that the repaired board passed this functional check.
Both indicator channels responded to their corresponding inputs.
How the bench-test signal works
The board is powered through 12 V and ground. A high input at FAULT_SIG_G enables the green LED channel, while a high input at FAULT_SIG_R enables the red channel. Each input turns on a MOSFET to complete the LED current path to ground. These are direct voltage inputs.
What the lights communicate
The green TSSI indication represents low-voltage power with no BMS or IMD fault indicated. Red represents a BMS or IMD fault. The separately controlled amber Ready to Move Light indicates high voltage outside the accumulator. BMS monitors the battery; IMD monitors electrical isolation. Vehicle indications follow the applicable Formula SAE rules; the photos here document LED illumination during bench checks.
Protecting the assembly during epoxy curing
After checking the electronics, I fitted the assembly into a 3D-printed enclosure, filing the housing as needed. I applied epoxy and rubber coating to help protect the electronics from water exposure.
The components shifted before the epoxy cured. I used clamps to hold the assembly in position while the epoxy set, keeping the parts aligned during this manufacturing step.
Clamping kept the components aligned while the epoxy cured.
Bringing the assembly onto the car
The completed assembly was installed near the vehicle roll hoop.