Challenge

Project 1 Mechanical design of battery pack

SSrikanth Nallabothu22 Mar 2022

Battery pack capacity: 18 kWh

Cell: ANR26650M1-B

Prepare a detailed battery pack drawing along with its enclosure. State your assumptions.

soluction:

from above all parameters we will calculate further parameters which are used for battery pack constrruction cycle life performance 100% dod,various and discharge rates of cell.

caluctions:

battery pack caluction

now we calculated parallel and series combinations so we can now caluclate total no of cells requried

total no of cells:series cells*parallel cells

:50*44

:2200

total no of cells reqiried are 2200

series and parallel combination we can caluculate the voltage of battery pack and the current of the battery pack

voltage=no of celll in series*nominal voltage

=50*3.3

=165v

THE total value of voltage is 165v.

current =no of parallel cells*cell capacity

=44*2.5

=110AH

the total value of current is 110AH

ENERGY=VOLTAGE*CURRENT

=165*110

=18150wah

THE TOTAL VALUE OF ENERGY IS 18150WAH

we have total noof cells and volume of single cell so we can caluclate the total volume requried for battery pack

total volume=no of cells*volume of single cell

=2200*0.0000344929

=0.0788438m^3

TOTAL VOLUME REQUIRED FOR BATTERY PACK IS 0.0788438m^3

WEIGHT=NO OF CELLS*WEIGHT OF SINGLE CELL

=2200*0.076

=167.2KG

WEIGHT OF BATTERY PACK IS 167.2KG

ENERGY DENSITY=volume*battery pack energy

=0.0788438*18150

=1,3377,301497kwh/m^3

ENERGY DENSITY is 1,3377,301497kwh/m^3

volume of the cell formula is

frome datasheet of cell we have r and v values

r=0.013m and h=0.065m=volume of the cell

=3.14*0.013^2>0.065

=o.oooo344929m^3

THE VOLUME OF THE CELL IS 0.0000344929M^3

THE valume of the cell is used to find out the total volume of the battery pack

cell energy =cell capacity(AH)*cell voltage

=2.5*3.3

=8.35wh

cell energy is 8.25 wh

the value of a single cell is used to calculate the total energy of the battery pack

valumetric energy(wh/m^3)=single cell energy/volume each cell

=8.25wh/0.0000344929m^3

=2,39,179.6572/m^3

single energy density is 2,39,179.6572/m^3

battery pack is 8.25 wh

there are 50 cell are in series and 44 cells parallel and as above maintioned to use cell:

ANR26650MI-B this cell

THE ARRAGEMENT DESIGN OF SINGLE CELL IS SHOWN BELOW:

THE suitability of joining methods to build battery packs using cylindrical cell is shown in figer:

NICKEL STRIPS:

Pure Nickel strips are used in battery tabs since Holes can be made into them to create extra bus bars by drilling into multiple strips at once or punching a hole at a time. The width of these strips determines their capacity to let varying currents pass through without corrosion.

pure nickel strip are the material you whant but many vendirs swap out it for nickel-plated steel strips which are poorper and have greater resistance-not suitable for most battery projects. nickel strip verify all of our strips to assure that you are getting the high quality pure nickel.it also solder incredibly quicklu,so you can weld them onto your existing busbar connctions to rise the supply of current you can pull through the busbars.

BATTERY ENCLOUSER:

A battery enclosure is.they can be designed for indoor or outdoor use, and may include room for electronics. Specific designs allow for pole, wall, or ground mounted systems.

DESIGN BENEFITS:

Accoummodates all battery cell types and id design particulariy for battery electric vehicles withalrger power packs such as pick-up trucks sport utility vehicles and crossovers.

most cost effective aluminum soluction for mass production electric vehicles when compared to aluminum extrusion and casting intense degigns.

low price premium $/kg saved compared to equvalent steel designs at aubstantially lower weiqht.