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Who am I?
Who am I?
Hi! I'm a physics student at the University of Toronto with a passion for building tangible, high-impact technology.
Right now, I'm working with the University of Toronto Electric Vehicle (UTEV) Research Centre, where I'm helping to develop and upgrade several key battery projects. My hands-on work includes building the test platform for a new Multi-Chemistry Battery (MCB) system, bringing up and upgrading the lab's DC Fast-Charging (DCFC) setup, and expanding our Electrochemical Impedance Spectroscopy (EIS) rig to optimize fast-charging profiles.
This hands-on drive is what led me to my previous role at Blue Sky Solar Racing. I was part of the team that built a solar car entirely from scratch, from designing the battery management system and custom battery pack to wiring the entire vehicle. The ultimate test was driving it across a 3000+ km trail in the Australian desert, relying on nothing but solar energy.
Academically, my physics degree has given me an invaluable perspective. It has trained me to find the right "level of abstraction" for any given problem. It’s taught me how to simplify complex systems—knowing when to dive deep into the fundamental physics or when a higher-level perspective is the better tool for the job. This skill of reframing a problem is, I've found, the key to solving tough engineering challenges.
When I'm not in the lab, my focus shifts from circuits to scenery. I'm an avid photographer and love getting out of the city for some stargazing. There's something special about both, whether it's capturing an exciting, fleeting moment with my camera or just appreciating the physics of the universe on a grand scale.
Always down for 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!!
UTEV Research Centre
UTEV Research Centre
(Sept 2024 - Present)
(Sept 2024 - Present)
As an undergraduate researcher at the University of Toronto Electric Vehicle (UTEV) Research Centre, I get to work on next-generation battery technology. My main role involves designing and assembling a complete Multi-Chemistry Battery (MCB) test platform from the ground up, including high-voltage wiring and liquid cooling, as well as developing a Python control GUI that runs the entire system. I'm also working on our lab's DC Fast-Charging (DCFC) and Electrochemical Impedance Spectroscopy (EIS) rigs , and I help supervising a capstone team working on Vehicle-to-Grid (V2G) technology.
I've also co-authored a paper on power-mix control algorithms for EV mix-chemistry battery packs, which was accepted to the 2025 IEEE ECCE Europe conference. More to come.
Earlier Experiences...
Earlier Experiences...
Blue Sky Solar Racing Team
Blue Sky Solar Racing Team
(May 2021 - Nov 2023)
(May 2021 - Nov 2023)
At Blue Sky Solar Racing, our mission was as audacious as it gets: design, build, and race a car 3000+km across the Australian desert powered only by sunlight.
As the GEN XI Borealis Electromechanical Lead, I was responsible for the 'big picture' of the car's hardware, ensuring that our separate systems integrated into a single, reliable race car. I led a team of over 20 student engineers, and my main responsibility was ensuring that all six of our critical electrical subsystems integrated seamlessly into a single, reliable machine. This meant constant cross-functional collaboration with the structural, strategy, and solar array teams to ensure everything fit, functioned, and could withstand the 3000+km endurance race.
This was a deeply hands-on role. I designed our new Battery Management System (BMS) and led the assembly of our team's custom-built battery pack. My team and I wired the entire vehicle end-to-end , tested every sensor, and brought up all our custom PCBs. I also contributed to R&D on a new centralized electrical architecture, a crucial upgrade that simplifies the car, makes it more robust, and better aligns it with modern EV design.
Beyond the engineering, I also represented our team in the industry. I pitched our mission to companies and successfully secured a $6,000+ battery cell sponsorship from Molicel, their first sponsored student design team.
The entire journey, from our first designs to the race itself, was one of the most challenging and rewarding experiences of my life. In that one moment, seeing our car roll up to the starting line in the outback... all the all-nighters and long hours in the lab were instantly worth it.
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/
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.
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...
(Alex) Xi Zeng CV v10.1.pdfPage updated
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