Project 1 Mechanical design of battery pack

The general terminology for battery unit hierarchy used in this document are as follows:

 Cell - The Simplest and Smallest Battery Unit, No Control Or Monitoring

 Module - A Collection of Cells Contained Within Factory Packaging and Including A Voltage and Temperature Measurement Board

 Battery Pack - A Complete System Containing Multiple Modules, an Overall Supervisory Management System, and a Thermal Management System

 Vehicle System - A Complete System That Consists of Multiple Battery Packs To Meet the Overall Vehicle Power Needs. This Includes a Master Controller.

If the cell is cylindrical cell

Data sheet of single cell

Calculations:

cell voltage is 3.2V

cell current rating is 80 Ah

Design battery pack power 18kwh

if the 10 cells are in series then

voltage of series string is 3.2* 50=160V

so current = 18000/160V= 112.5

number of cells connected in parallel= 112.5/80=1.4 apporimtely 2

so total battery pack power with the above calculations are

Electric circuit:

If the cells are prismatic cells then the mechanical structure as follows

Mechanical pack.

Fig complete battery pack

References:

1. https://www.boldvaluable.tech/technologies/custom-battery-pack-design-lithium-cells/
2. https://kb.osu.edu/bitstream/handle/1811/51863/1/david_cooke_thesis.pdf
3. K. King, B. Schwemmin, and D. Zhu. Full Hybrid Electrical Vehicle Battery Pack System Design, CFD Simulation and Testing. SAE Paper, 2010-01-1080, 2010. C. Merkle and L. Kennedy. High Voltage Safety for the Service Technician. SAE Paper, 2010-01-2014, 2010.
4. 
   K. Miyatake, T. Abe, Y. Hisamitsu, T. Kinoshita, Y. Shimoida, and H. Horie. Research of Large Capacity, High Power Lithium-ion Batteries. SAE Paper, 2009-01-1389, 2009.
5. 
   J. Belt. Battery Test Manual For Plug-In Hybrid Electric Vehicles. U.S. Department of Energy Vehicle Technologies Program, 2008.
6. D. Doughty and C Crafts. FreedomCAR Electrical Energy Storage System Abuse Test Manual for Electric and Hybrid Electric Vehicle Applications. Sandia National Laboratories, 2006.
7. 
   C. Motloch, J. Christophersen, J. Belt, R. Wright, G. Hunt, R. Sutula, T. Duong, T. Tartamella, H. Haskins, and T. Miller. High-Power Battery Testing Procedure and Analytical Methodologies for HEV's. SAE Paper, 2002-01-1950, 2002.
8. 
   M. Origuchi, T. Miyamoto, H. Horie, and K. Katayama. Development of a Li-ion Battery system for EVs. SAE Paper, 970238, 1997.