Challenge

Project 1 Mechanical design of battery pack

BBalu Prasanna J5 May 2022

Battery pack capacity: 18 kWh

Cell: ANR26650M1-B

Aim:

Prepare a detailed battery pack drawing along with its enclosure. State your assumptions and Battery pack capacity: 18 kWh Cell: ANR26650M1-B

Cylindrical Cell Insulation

The outside case of the ANR26650 and AHR32113 is electrically connected to the positive end (cathode) of the cell.

The outside case of the APR18650 cell is electrically connected to the negative end (anode) of the cell. Take care

to keep this surface electrically isolated from any electrical bus bar or mechanical support that may be of different

voltage potential. Insulation, such as tapes, shrink wraps, or sleeves, must have at least a 150 °C melting point. This

helps ensure that the cells do not short circuit to each other in a high-temperature fault condition, which could

cause even more widespread damage

Battery Calculation:

Battery pack capacity: 18 kWh:

Find the Voltage(V) and Capacity(AH)

Total Voltage(V) is 400V assumption value

Total Capacity(AH) = Total Energy/total Battery Voltage = 18000/400 = 45AH

Numbers of Series cell (NS) = Total voltage of battery pack/Individual cell voltage = 400/3.3 = 121NS

Numbers of Parallel cell (NP) = Total Capacity of battery pack/Individual cell Capacity = 45/2.5 = 18NP

Number of cells(N) = Numbers of Series cell (NS)/ Numbers of Parallel cell (NP) = 122/18 = 2178N

Cell architecture = 121series and 18 parallel = 121S18P

Cell Weight = 76g

Number of cells = 2178

Battery pack Weight (W) = Cell Weight (W) * Number of cells + Weight of accessories = 76 * 2178 + 4.5 = 165Kg

ANR26650M1-B TECHNICAL DATA

Cell Dimensions = 26 x 65 mm

Cell Weight = 76g

Cell Capacity (nominal/minimum) (0.5C Rate) = 2.5/2.4 Ah

Voltage (nominal) = 3.3V

Internal Impedance (1kHz AC typical) = 6mΩ

Power* = 2600 W/kg

Recommended Standard Charge Method = 2.5A to 3.6V CCCV, 60 min

Recommended Fast Charge Method to 80% SOC = 10A to 3.6V CC, 12 min

Maximum Continuous Discharge = 50A

Maximum Pulse Discharge (10 seconds) = 120A

Cycle Life at 20A Discharge, 100% DOD = >1,000 cycles

Operating Temperature = -30°C to 55°C

Storage Temperature = -40°C to 60°C

Nanophosphate High Power LithiumIon Cell (ANR26650M1-B)

A123’s high-performance Nanophosphate®lithium iron phosphate (LiFePO4) battery technology delivers high power and energy density combined with excellent safety performance and extensive life cycling in a lighter weight, more compact package. Our cells have a low capacity loss and impedance growth over time as well as high usable energy over a wide state of charge (SOC) range, allowing our systems to meet end-of-life power and energy requirements with minimal pack oversizing.

ANR26650M1-B Specifications:

Nominal Ratings
Voltage: 3.3 Volts
Capacity: 2.5 Ah
Energy: 8.25 Wh
Specific Power: 2600 W/kg
Impedance (1KHz AC Typical) 6 mΩ
Cycle Life at 1C/1C, 100% DOD: > 4000 cycles
Cell Type: 26650 Lithium Ion Power Cylindrical Cell

Discharging
Max Continuous Discharage: 50 A
Max Pulse Discharge Current >50% SOC (10s): 120 A
Minimum Voltage: 2 Volts
Temperature: -30ºC to 55ºC

Charging
Recommended Standard Charge: 2.5 Amps
Max Charge Rate: 10 Amps
Max Pulse Charge Current <50% SOC (10s): 25 A
Float Voltage: 3.45 Volts
Recommended charge V & Cut-off Current: 3.6 Volts, taper to 125mA
Temperature
(reduce charging current to 250mA when under 0ºC): 0ºC to 55ºC

Mechanical
Diameter: Ø25.96 +/- 0.5 mm (1.0")
Length: 65.15 +/- 0.5 mm (2.6")
Mass: 76 g

Applications:

COMMERCIAL SOLUTIONS

Advanced lead-acid replacement batteries for:
+ Datacenter UPS
+Telecom backup
+IT backup
+Autonomously guided vehicles (AGVs)
+ Industrial robotics and material handling equipment

GOVERNMENT SOLUTIONS

+ Military vehicles
+ Military power grids
+Soldier power
+ Directed energy

GRID SOLUTIONS

+ Frequency regulation
+ Renewables integration
+ Reserve capacity
+ Transmission and distribution

TRANSPORTATION SOLUTIONS

Hybrid, plug-in hybrid, and electric vehicle battery systems for:

+Commercial vehicles

+ Off-highway vehicles

+Passenger vehicles

Prepare a detailed battery pack drawing along with its enclosure

Project 1 Mechanical design of battery pack

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Ship work like this
in your own course.