Mechanical Design of a Battery Pack by Solidworks

OBJECTIVE:

To prepare a detailed report on Battery pack, along with the enclosures.

ASSUMPTIONS:

Battery pack Capacity : 18 KWh

Cell Used : ANR26650M1-B

CALCULATIONS:

As, Our objective is to prepare a battery pack of 18kwh capacity.

Taking that into consideration,

We know that,

Energy or Capacity (E">EE) = Power (P">PP) `*Time(T">TT) KWh">KWhKWh

Again,

We know that,

Power(P">PP) = Voltage (V">VV)*Current(I">II) KW">KWKW

Again, In this project we are taking ANR26650M1-B Cell into action. So, following are the parameters of the cell:

Parameters

So,

As per the values, each cell can produce

3.3*2.5 = 8.25 KW power

So, to attain, 18KWh of Energy

We are considering 48S 48P ie., 48*48 = 2304 Number of cells

Connections in series gives us 48 * 3.3 = 158.4 V

and,

For those parallel connections,we are getting

48 * 2.5 =120 A of Current

So, with that we can get,

158.4 * 120 = 19.008 KWh Capacity of Energy

DESIGN PERSPECTIVE:

As, Discussed in the calculation we are taking 2304 number of cells to build a whole battery pack. Where, there will be of 48 number of cells in series for each module of 48 numbers in parallel connections.

Let us Start with cells, first,

Here we are taking dimensions as,

26mm. Diameters, 65mm. Height, 31mm. Space between each cells from center

Model 1: Set of 48 numbers of cells in series

Let us, Now give it a cover or base so that it may, not fall off

Here, the dimension of the cover is as

(253 x 191)mm

And, 3mm edges are given. So, that the cells are not fall off.

Model 2: set of cells with cover or base

Now, we are going to povide connectors. So, as to make it 159 V.

Here, the dimensions are as per the required distances ie.,

32.5 mm height of connector and 5mm and 2.5 mm a hollow circular excruded shape of 1mm.

Model 3: set of cells with cover and connector

Let us Now provide some support to the cover So, that it may get some strength.

Support dimension is 65mm.

Model 4: The Battery Module

As, we had made 159 V and 2.5 A of battery module. So, to attain 120 A we have to connect 48 modules in parallel.

The whole Battery pack is now 19.008KWh of capacity as per our objective. Here, Each module have a sapacing of 10mm horizontally and 0.5mm vertically for a proper coolant setup for thermal management.

With that it attains a Dimension which can easily be assembled in 2.5 x 1.3 metres length and width of a vehicle.

In this project, we are assuming a Sub Compact Electric Vehicle (TOYOTA).

Model 5: BATTERY PACK